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FOREWORD
DET NORSKE VERITAS (DNV) is an autonomous and independent foundation with the objectives of safeguarding life, prop-
erty and the environment, at sea and onshore. DNV undertakes classification, certification, and other verification and consultancy
services relating to quality of ships, offshore units and installations, and onshore industries worldwide, and carries out research
in relation to these functions.
DNV Offshore Codes consist of a three level hierarchy of documents:
~ Ofshore Service S'eciJications. Provide principles and procedures of DNV classification, certification, verification and con-
sultancy services.
~ Ofshore Standards. Provide technical provisions and acceptance criteria for general use by the offshore industry as well as
the technical basis for DNV offshore services.
~ Recommended Practices. Provide proven technology and sound engineering practice as well as guidance for the higher level
Offshore Service Specifications and Offshore Standards.
DNV Offshore Codes are offered within the following areas:
A) Qualification, Quality and Safety Methodology
B) Materials Technology
C) Structures
D) Systems
E) Special Facilities
F) Pipelines and Risers
G) Asset Operation
O Det Norske Veritas. All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means, including
photocopying and recording, without the prior written consent of Det Norske Veritas.
If any penon suffers loss or damage which is proved to have been caused by any negligent act or omission of Det Norske Veritas, then Det Nonke Veritas shall pay compensation to such person
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sation shall never exceed USD 2 million
In this provision "Det Nonke Veritas" shall mean the Foundation Det Nonke Veritas as well as all its subsidiaries, directors, officers, employees, agents and any other acting on behalf of Det
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DNV is grateful for the valuable Co-operations and discussions with the individual personnel of these companies.
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Offshore Standard DNV-OS-FI 01, January 2000
Contents - Page 5
CONTENTS
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Offshore Standard DNV-OS-FI 01. January 2000
Page 6 . Contents
D 700 . .............................................................................
Fatigue . 40 G . Documentation. Records and Certification ........................... 64
D 800 Ovalisation ...................................................................... 40 G 100 General ............................................................................ 64
D 900 Ratcheting ....................................................................... 41
D 1O00 Accumulated plastic strain Sec 7 . Components and Assemblies ............................. 65
D 1100 Fracture .............................
D 1200 Accidental limit state ...................................................... 42 A . General 65
A 1 0 0 Scope ............................................................................... 65
E. Special Considerations ......................................................... 42 A 200 Quality assurance ............................................................ 65
E 1O0 General ............................................................................ 42
E 200 Pipe soil interaction......................................................... 42 B. General requirements for Design of Pipeline Components ..65
E 300 Spanning riserdpipelines ................................................ 42 B 1O0 General ............................................................................ 65
E 400 On bottom stability B 200 Material selection............................................................ 65
E 500 Trawling interferen B 300 Flanged and mechanical connections.............................. 66
E 600 Third party loads, dropped objects.................................. 44 B
E 700 Insulation......................................................................... 44 B
E 800 Pipe-in-pipe and bundles................................................. 44 B 600 Pressure vessels .............................................................. 66
B 700 Components fabricated by welding 66
F . Pipeline Components and Accessories ................................. 44 B 800 Insulatingjoints ............................................................... 66
F 1O0 General ............................................................................ 44 B 900 Pipeline fittings ............................................................... 67
B 1000 Anchor flanges ................................................................ 67
G. Supporting Structure ............................................................. 44 B 1100 Other components 67
G 1O0 General ............................................................................ 44 B 1200 Structural items ............................................................... 67
G 200 Riser supports.................................................................. 44
G 300 J-tubes ............................................................................. 44 C . Material and Manufacturing Specifications for
G 400 Stability of gravel ............................................................ 44 Components .......................................................................... 67
C 100 Material and manufacturing specifications..................... 67
H. Installation and Repair .......................................................... 44
H 1O0 General ............................................................................ 44 D . Material for Hot Formed, Forged and Cast Components ..... 68
H 200 Pipe straightness 45 D 100 General ............................................................................ 68
H 300 Coating ............................................................................ 45 D 200 Components made of low alloy C-Mn steel.................... 68
.
Sec 6 Linepipe ............................................................... 46
D 300 Components made of ferritic-austenitic(duplex) steel.
other stainless steel and nickel based corrosion resistant
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alloy (CRA) ..................................................................... 69
A . General 46 D 400 Delivery condition 69
A 100 Scope ............................................................................... 46
A 200 Material specification...................................................... 46 E. Hot Forming. Forging. Casting and Heat Treatment ............69
A 300 Pre-qualification of materials and manufacturers 46 E 100 Hot forming..................................................................... 69
A 400 Process of manufacture ................................................... 46 E 200 Forging 69
..
. Linepipe Designations .......................................................... 46 E 300 Casting ............................................................................ 69
E 400 Heat treatment ................................................................. 69
B 100 Lineuiue NDT levels .......................................................
I I
46
B 200 Supplementary requirements........................................... 46 F. Manufacturing of c ~~~~i~~~~~ and ~ structural~ ~
B 300 Designations.................................................................... 47 Items ..................................................................................... 70
C. Mateiia1 Properties 47 F 1O0 General ............................................................................ 70
c 100 General ........................................ ....................... 47 F 200 Manufacture of flanges ................................................... 70
c 200 Carbon Manganese (C-Mn) steel 47 F 300 Manufacture of valves 70
C 300 Ferritic-austenitic (duplex) steel 50 F 400 Manufacture of pressu
components fabricated by welding 71
C 400 Other stainless steel and nickel b t
alloy (CRA) linepipe 51 F 500 Manufacture of other equipment and components..........71
F 600 Fabrication of structural items ........................................ 71
C 500 Cladílined . . steel linepipe .................................................. 51
F 700 Mechanical testing of hot formed, cast and forged
C 600 Weldability...................................................................... 52
components ..................................................................... 71
D . Supplementary Requirements ............................................... 52
D 100 Supplementary requirement. sour service (S) .................52 G . Manufacture of Bends 71
D 200 Supplementary requirement. fracture arrest G 100 General ............................................................................ 71
properties (F) ................................................................... 53 G 200 Mother pipe for seawater service.................................... 73
D 300 Supplementary requirement. linepipe for plastic G 300 Supplementary requirements to mother pipe ..................73
deformation @)' ............................................................... 54 G 400 Requirements to pipe other than dedicated mother pipe.73
D 400 Supplementary requirement. dimensions @) .................55 G 500 Required post bending heat treatment ............................. 73
D 500 Supplementary requirement. high utilisation (u) ...........55 G 600 Bending procedure qualification..................................... 74
G 700 Bending and post bend heat treatment ............................ 75
E. Manufacture .......................................................................... 55 G 800 Non-destructive testing and visual inspection ................75
E 100 General ............................................................................ 55 G 900 Production testing of bends ............................................. 75
E 200 Quality Assurance ........................................................... 55 G 1000 Dimensions, tolerances and marking .............................. 76
E 300 Manufacturing Procedure Specification and G 1100 Repair 76
Qualification 55
E 400 Steel making .................................................................... 56 H . Fabrication of Risers, Expansion Loops, Pipe Strings for
E 500 Manufacture of plate and strip ........................................ 56 Reeling and Towing .............................................................. 76
E 600 Linepipe manufacture 57 H 100 General ............................................................................ 76
E 700 Chemical analysis ........................................................... 58 H 200 Quality Assurance
E 800 Mechanical and corrosion tests 58 H 300 Materials for ri
E 900 Non-destructive testing ................................................... 59 reeling and towing
E 1000 Visual inspection. workmanship and correction of H 400 Fabrication pro
defects ............................................................................. 60 H 500 Material receipt. identification and tracking ................... 77
E 1100 Mill pressure test ............................................................. 61 H 600 Cutting. forming. assembly. welding and heat treatment77
E 1200 Dimensions. weight and lengths 61 H 700 Hydrostatic testing .......................................................... 77
H 800 Non-destructive testing and visual examination .............78
F . Marking and 64 H 900 Dimensional verifica ' 78
F 100 Genera 64 H 1000 Corrosion protection 78
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Contents - Page 7
. .
I. Documentation, Records, Certification and Marking.. .........78 D. Pipeline Installation .............................................................. 88
I 100 Documentation, records, certification and marking........ 78 D 100 General 88
D 200 Installat ......................................................... 89
Sec. 8 Corrosion Protection and Weight coating ........79 D 300 Review and qualification of the installation manual,
essential variables and validity ....................................... 89
A. Gener 79 D 400 Operating limit conditions .............................................. 90
A 100 79 D 500 Installation procedures.................................................... 90
A 200 ...................................................................... 79 D 600 Contingency procedures ................................................. 90
A 300 Definitions ...................................................................... 79 D 700 Layvessel arrangement, laying equipment and
instrumentation............................................................... 90
B. General Principles for Corrosion Control During Design ....79 D 800 Requirements for installation 91
B 100 General
E. Additional Requirements for Pipeline Installation Methods
Introducing Plastic Deformations
C. Pipeline External Coatings ................................................... 80 E 100 General...................
C 100 General............................................................................ 80 E 200 Installation Manual
C 200 Coating materials, surface preparation and application.. 80 E 300 Qualification of the Installation Manual ......................... 92
E 400 Installation procedures.................................................... 92
D. Special Riser Coatings .......................................................... 80 E 500 Requirements for installation.......................................... 92
D 100 General............................................................................ 80
D 200 Coating materials, surface preparation and application.. 81 F. Pipeline Installation by Towing ............................................ 93
F 100 General 93
E. Field Joint Coatings .............................................................. 8 1 F 200 Installat ......................................................... 93
E 100 General............................................................................ 81 F 300 Qualification of Installation Manual............................... 93
E 200 Coating materials, surface preparation and application.. 81 F 400 Operating limit conditions .............................................. 93
F 500 Installation procedures.................................................... 93
F. Concrete Weight Coating ..................................................... 8 1 F 600 Contingency procedures ................................................. 93
F 100 General............................................................................ 81 F 700 Arrangement, equipment and instrumentation ............... 93
F 200 Concrete materials and coating manufacturing .............. 81 F 800 Pipestring tow and installation 93
F 300 Inspection and testing ..................................................... 82 G. Other Installation Methods ................................................... 93
G 100 General............................................................................ 93
G. Cathodic Protection Design .................................................. 82
G 100 General............................................................................ 82 H. Shore Pull .............................................................................. 94
G 200 Design parameters and calculations................................ 82 H 100 General............................................................................ 94
H 200 Installation Manual
H. Manufacturing and Installat H 300 Qualification of Ins
H 1O0 Anode manufacturing H 400 Operating limit CO
H 200 Anode installation...... H 500 Installation procedures.................................................... 94
H 600 Contingency procedures ................................................. 94
I. Design and Manufacturing/Fabrication of Internal Corrosion H 700 Arrangement, equipment and instrumentation 94
H 800 Requirements for Installation ......................................... 94
. .
I. Tie-in Operations .................................................................. 94
I 100 General............................................................................ 94
I 200 Installation Manual ......................................................... 94
I 300 Qualification of Installation Manual 94
I 400 Operating limit conditions .............................................. 94
I 500 Tie-in procedures 94
I 600 Contingency procedures ................................................. 95
Sec. 9 Installation ........................................................... 85 I 700 Tie-in operations above water ........................................ 95
I 800 Tie-in operations below water ........................................ 95
A. General .................................................................................. 85
A 100 Objective......................................................................... 85 J. As-Laid Survey ..................................................................... 95
A 200 Application...................................................................... 85 J 100 General 95
A 300 Failure Mode Effect Analysis @MEA) and Hazard and J 200 Specification of as-laid survey........................................ 95
Operability WAZOP) studies .........................................85 J 300 As-laid survey ................................................................. 95
A 400 Installation and test J 400 As-laid survey of corrosion protection systems..............95
A 500 Installation Manual
A 600 Quality Assurance.
A 700 Welding........................................................................... 85 K 100 Genera
A 800 Non-destructive testing and visual examination.............86
A 900 Production tests 86 K 300 Span rectification
K 400 Trenching............
B. Pipeline Route, Survey and Preparation ............................... 86 K 500 Post-installation gravel dumping .................................... 96
B 100 Pre-installation route survey ........................................... K 600 Grout bags and concrete mattresses................................ 96
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86
B 200 Seabed preparation.......................................................... 87
B 300 Pipeline and cable crossings L 100 General
B 400 Preparations for shore appro
M. Installation of Risers
C. Marine Operations ................................................................ 87 M 100 General............
C 100 General............................................................................ 87 M 200 Installation Manual
C 200 Vessels 87 M 300 Qualification of the Installation Manual ......................... 97
C 300 Anchoring systems, anchor patterns and anchor M 400 Operating limit conditions
87 M 500 Contingency procedures ...
C 400 Positioning systems ........................................................ 88 M 600 Requirements for Installation ......................................... 97
C 500 Dynamic positioning....................................................... 88
C 600 Cranes and lifting equipment .......................................... 88 N. As-Built Survey 97
C 700 Anchor handling and tug 88 N 100 General.... 97
C 800 Contingency procedures 88 N 200 Specification of as-built survey 97
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Page 8 - Contents
B. Pipeline Configuration Survey ........................................... 101 I. Components and assemblies ............................................... 113
B 100 General ..................................................... 101 I 100 Bends.........................................
..................................................... 101
I 300 J-tubes ...... .................................... 114
C. Inspection and Monitoring of External Corrosion.............. 102
C 100 General ..................... .................... 102 J. Material and Design Links ................................. 114
C 200 Risers in the Splash zone an
C 300 Pipelines and Risers in the Submerged Zone ................102
J 300 Links based on accumulated
D. Inspection and Monitoring J 400 Material data sheet ........................................................ 115
- of Internal Corrosion 103
D 1Oô General ......................................................................... ,103
D 200 Corrosion inspection ..................................................... 103 K. Installation .......................................................................... 116
D 300 Corrosion monitoring .................................................... 103 K 1O0 Safety class definition ................................................... 116
K 200 Coating .......................................................................... 116
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Contents .Page 9
B. Corrosion Testing ............................................................... 123 B . Manual Non-destructive Testing and Visual Examination of
B 100 General.......................................................................... 123 Welds .................................................................................. 143
B 200 Pitting corrosion test ..................................................... 123 B 100 General 143
B 300 Hydrogen Pressure Induced Cracking test ................... 123 B 200 Radiogr ..................................................... 143
B 400 Sulphide Stress Cracking test ....................................... 123 B 300 Manual ultrasonic testing .............................................. 143
B 400 Manual magnetic particle testing .................................. 144
App C Welding . .............................................................. 128 B 500 Manual liquid penetrant testing .................................... 145
B 600 Manual eddy current testing ......................................... 145
B 700 Visual examination ....................................................... 146
A 200 Welding processes ........................................................ 128 C . Manual Non-destructive testing of Base Materials and Weld
A 300 Quality Assurance ......................................................... 128 Overlay ............................................................................... 146
C 100 General
B . Welding Equipment. Tools and Personnel ......................... 128
B 100 Welding equipment and tools ....................................... 128 C 300 Forgings
B 200 Personnel 128
C 500 Weld overlay................................................................. 146
C . Welding Consumables ........................................................ 129
C 100 General D . Automated Non-Destructive Testing .................................. 146
D 100 General
C 500 Handling and storage of welding consumables E . Non-Destructive Testing Acceptance Criteria .................... 147
E 100 General.......................................................................... 147
D . Welding Procedures ............................................................ 130 E 200 Acceptance cntena based on Engineering Critical
D 100 General Assessment (ECA)........................................................ 148
D 300 Welding procedure qualification record F . Non-Destructive Testing of Plate and Strip at Mill ............ 148
D 400 Welding procedure specification .................................. 130 F 100 General.......................................................................... 148
D 500 Welding procedure specification for repair welding .... 131 F 200 Ultrasonic testing of C-Mn and duplex steel plate
D 600 Essential variables for welding procedures .................. 131 and strip ........................................................................ 148
F 300 Ultrasonic testing of clad plate and strip ...................... 149
E. Qualification of Welding Procedures ................................. 131 F 400 Visual examination of plate and strip ........................... 149
E 100 General.......................................................................... 131
E 200 Qualification of repair welding procedures 132 G . Non-Destructive Testing of Linepipe at Pipe Mills ............ 149
E 300 Qualification of longitudinal and spiral we1 Pe G 100 General
and linepipe components .............................................. 132
E 400 Qualification of girth welds in risers. expansion loops and G 300 Suspect pipe .................................................................. 149
pipe strings for towing .................................................. 132 G 400 Non-destructive testing applicable to all pipe .............. 149
E 500 Qualification of girth welds for installation and tie-in . 133 G 500 Non-destructive testing of seamless pipe ..................... 150
E 600 Qualification of girth welds exposed to accumulated G 600 Non-destructive testing of HFW, LBW and EBW pipe150
plastic strain .................................................................. 134 G 700 Non-destructive testing of SAW pipe ........................... 152
E 700 Qualification of underwater welding for tie-in ............. 134 G 800 Manual NDT ................................................................. 154
E 800 Qualification of overlay welding .................................. 135 G 900 Non-destructive testing of weld repairs in pipe ............ 155
E 900 Qualification of welding procedures for structures ...... 135 G 1000 Visual examination of welds in linepipe ...................... 155
G 400 ............................................... 138 I 300 Acceptance cntena for forgings ................................... 158
G 500 Welding of linepipe and linepipe components ............. 139 I 400 Acceptance cntena for castings 158
G 600 Fabrication of risers. expansion loops. pipe strings for I 500 Acceptance cntena for weld overlay ............................ 158
.
App E Automated Ultrasonic Girth Weld Testing .... 159
H . Material and Process Specific Requirements ..................... 139 A . General ................................................................................ 159
H 1O0 Internally cladlined carbon steel .................................. 139 A 100 Scope............................................................................. 159
H 200 Duplex stainless steel A 200 References..................................................................... 159
H 300 Martensitic (13% Cr)
B. Basic Requirements 159
App D Non-Destructive Testing (NDT) . ............ 141 B 100 General.......................................................................... 159
B 200 Documentation
. . .............................................................. 159
A . General ................................................................................ 141 B 300 Qualification ................................................................. 159
A 100 Scope............................................................................. 141 B 400 Ultrasonic system equipment and components............. 159
A 200 Codes and standards...................................................... 141 B 500 Recorder set-up ............................................................. 161
A 300 Quality Assurance ......................................................... 142 B 600
A 400 Non-destructive testing methods 142 B 700
A 500 Non-destructive testing procedur 142 B 800
A 600 Personnel qualifications. 142 B 900
A 700 Reporting ......... 142 B 1000 Software........
A 800 Timing ofNDT 142 B 1100 System Log Book
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Page 10 . Contents
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Offshore Standard DNV-OS-FI 01, January 2000
Sec.1 - Page 11
SECTION 1
GENERAL
A. General 402 Where reference is made to codes other than DNV doc-
uments, the valid revision shall be taken as the revision which
A 100 Introduction was current at the date of issue of this standard, unless other-
wise noted.
101 This standard gives criteria and guidance on design, ma-
terials, fabrication, installation, testing, commissioning, oper- 403 This standard is intended to comply with the IS0 stand-
ation, maintenance, re-qualification, and abandonment of ard 13623: Petroleum and natural gas industries - Piyeline
pipeline systems. transportation systems, specifiing functional requirements for
offshore pipelines and risers.
A 200 Objectives Guidance note:
201 The objectives of this standard are to:
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The following major deviations to the IS0 standard are known:
~ provide an internationally acceptable standard of safety ~ applying the supplementary requirements U, for increased
for submarine pipeline systems by defining minimum re- utilisation, this standard allows higher pressure containment
quirements for the design, materials, fabrication, installa- utilisation than the IS0 standard;
tion, testing, commissioning, operation, repair, re- ~ the equivalent stress criterion in the IS0 standard sometimes
qualification, and abandonment; allows higher utilisation than this standard;
requirements to system pressure test (pressure test); and
serve as a technical reference document in contractual
~
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Offshore Standard DNV-OS-FI 01, January 2000
Page 12 - Sec.1
ed, this means agreed in writing between Manufacturer/ Con- 217 Design: All related engineering to design the pipeline in-
tractor and Purchaser. cluding both structural as well as material and corrosion.
218 Design temperature, maximum: The highest possible
C 200 Definitions temperature to which the equipment or system may be exposed
201 As-built survey: Survey of the installed and completed to during installation and operation. Environmental as well as
pipeline system, that is performed to ver@ that the completed operational temperatures shall be considered.
installation work meets the specified requirements, and to doc- 219 Design temperature, minimum: The lowest possible
ument deviations from the original design, if any. temperature to which the equipment or system may be exposed
202 As-laid survey: Survey performed either by continuous to during installation and operation, irrespective of the pres-
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Offshore Standard DNV-OS-FI 01, January 2000
Sec.1 - Page 13
sure. Environmental as well as operational temperatures shall 239 Load combination: The local bucking limit state criteri-
be considered. on for combined loading shall be checked for two load combi-
220 Engineering Criticality Assessment (ECA): Fracture me- nations, a and b. Load combination a is a system check and
chanic assessment of defects. shall only be applied when system effects are present.
221 Erosion: Material loss due to repeated impact of sand 240 Load effect: Effect of a single load or combination of
particles or liquid droplets. loads on the equipment or system, such as stress, strain, defor-
mation, displacement, motion, etc.
222 Fabrication: Activities related to the assembly of ob-
jects with a defined purpose. In relation to pipelines, fabrica- 241 Load effect factor: The partial safety factor by which the
tion refers to e.g. risers, expansion loops, bundles, reels, etc. characteristic load effect is multiplied to obtain the design load
effect.
223 Fabricationfactor: Factor on the material strength in or-
der to compensate for material strength reduction from cold 242 Location class: A geographic area of pipeline system
forming during manufacturing of linepipe. classified according to human activity.
224 Fabricator: The party performing the fabrication. 243 Lot: A number of pipes from the same heat, the same
225 Failure: An event affecting a component or system and heat treatment batch and with the same diameter and wall
causing one or both of the following effects: thickness.
244 Manufacture: Making of articles or materials, often in
~ loss of component or system function; or large volumes. In relation to pipelines, refers to activities for
~ deterioration of functional capability to such an extent that the production of linepipe, anodes and other components and
the safety of the installation, personnel or environment is application of coating, performed under contracts from one or
significantly reduced more Contractors.
226 Fatigue: Cyclic loading causing degradation of the ma- 245 Manufacturer: The party who is contracted to be respon-
terial. sible for planning, execution and documentation of manufac-
221 Fluid categorisation: Categorisation of the transported turing.
fluid according to hazard potential as defined in Section 2. 246 Manufacturing Procedure Specijication (MPS): A man-
228 Fractile: The p-fractile (or percentile) and the corre- ual prepared by the Manufacturer to demonstrate how the spec-
sponding fractile value xp is defined as: ified properties may be achieved and verified through the
proposed manufacturing route.
F(Xp) = Y 241 Material resistance factor: Partial safety factor trans-
forming a characteristic resistance to a lower fractile resist-
F is the distribution function for xp ance.
229 Hydrogen Pressure Induced Cracking (HPIC): Internal 248 Material strengthfactor: Factor for determination of the
cracking of wrought materials due to a build-up of hydrogen characteristic material strength reflecting the confidence in the
pressure in micro-voids (Related terms: hydrogen induced yield stress.
cracking, stepwise cracking)
249 Mill pressure test: The hydrostatic strength test per-
230 Hydro-test or Hydrostatic test: See Mill pressure test formed at the mill, see Section 5B 200.
231 Inspection: Activities such as measuring, examination,
testing, gauging one or more characteristics of a product or 250 NDT level: The extent and acceptance criteria for the
service and comparing the results with specified requirements NDT of the linepipe are given for two levels. Level one, which
to determine conformity. is more stringent, is required for displacement controlled de-
sign criteria.
232 Installation (activity): The operations related to install-
ing the equipment, pipeline or structure, e.g. pipeline laying, 251 Nominal outside diameter: The specified outside diame-
tie-in, piling of structure etc., including final testing and prep- ter. This shall mean the actual outside diameter, e.g. 12.75" for
aration for operation. a 12" pipe (clarification).
233 Installation (object): See Offshore installation. 252 Nominal p@e wall thickness: The specified non-corrod-
ed pipe wall thickness of a pipe, which is equal to the minimum
234 Installation Manual (7M): A document prepared by the steel wall thickness plus the manufacturing tolerance.
Contractor to describe and demonstrate that the installation
method and equipment used by the Contractor will meet the 253 Offshore installation (object): General term for mobile
specified requirements and that the results can be verified. and fixed structures, including facilities, which are intended
for exploration, drilling, production, processing or storage of
235 J-tube: A J-shaped tube installed on a platform, through hydrocarbons or other related activities/fluids. The term in-
which a pipe can be pulled to form a riser. The J-tube extends cludes installations intended for accommodation of personnel
from the platform deck to and inclusive of the bottom bend at engaged in these activities. Offshore installation covers subsea
the sea floor. The J-tube supports connect the J-tube to the sup- installations and pipelines. The term does not cover traditional
porting structure. shuttle tankers, supply boats and other support vessels which
236 Limit state: A state beyond which the structure no longer are not directly engaged in the activities described above.
satisfies the requirements. The following categories of limit
states are of relevance for pipeline systems: 254 Operation, Incidental: Conditions which that are not
part of normal operation of the equipment or system. In rela-
SLS = Serviceability Limit State tion to pipeline systems, incidental conditions may lead to in-
ULS= Ultimate Limit State cidental pressures, e.g. pressure surges due to sudden closing
FLS = Fatigue Limit State of valves, or failure of the pressure regulation system and acti-
ALS = Accidental Limit State. vation of the pressure safety system.
255 Operation, Normal: Conditions that arise from the in-
231 Linedpipe (z): Pipe with internal liner where the bond tended use and application of equipment or system, including
between (linepipe) base and cladding material is mechanical. associated condition and integrity monitoring, maintenance,
238 Load: Any action causing stress, strain, deformation, repairs etc. In relation to pipelines, this should include steady
displacement, motion, etc. to the equipment or system. flow conditions over the full range of flow rates, as well as pos-
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joints and pipe components upon completion of manufacture 297 Specijied Minimum Tensile Strength (SMTS): The mini-
and fabrication, see Section 5 B200. mum tensile strength prescribed by the specification or stand-
ard under which the material is purchased.
279 Pressure, Propagating: The lowest pressure required for
a propagating buckle to continue to propagate. 298 Specijied Minimum Yield Stress (SMYS): The minimum
yield stress prescribed by the specification or standard under
279b Pressure, shut-in: The maximum pressure that can be at- which the material is purchased.
tained at the wellhead during closure of valves closest to the
wellhead (wellhead isolation). This implies that pressure tran- 299 Splash zone: External surfaces of a structure or pipeline
sients due to valve closing shall be included. that are periodically in and out of the water by the influence of
waves and tides.
280 Pressure, System test: In relation to pipelines, this is the
internal pressure applied to the pipeline or pipeline section dur- C 300 Definitions (continued)
ing testing on completion of installation work to test the pipe-
line system for tightness (normally performed as hydrostatic 300 Splash Zone Height: The vertical distance between
testing). splash zone upper limit and splash zone lower limit.
281 Pressure, Test: See Pressure, System test. 301 Splash Zone Lower Limit (LSZ) is determined by:
282 Purchaser: The owner or another party acting on his be- LSZ = IL11 - IL21 - IL31
half, who is responsible for procuring materials, components
or services intended for the design, construction or modifica- L1 = lowest astronomic tide level (LAT)
tion of a installation or a pipeline. L2 = 30% of the Splash zone wave-related height defined in
303.
283 Quality Assurance (QA): Planned and systematic actions L3 = upward motion of the riser, if applicable.
necessary to provide adequate confidence that a product or
service will satissl given requirements for quality. 302 Splash Zone Upper Limit(USZ) is determined by:
284 Quality Plan (QP): The document setting out the specif- usz = lu11 + lu21 + lu31
ic quality practices, resources and sequence of activities rele-
vant to a particular product, project or contract. A quality plan U1 = highest astronomic tide level (HAT)
usually makes reference to the part of the quality manual appli- U2 = 70% of the splash zone wave-related height defiied in
cable to the specific case. 303.
285 Ratcheting: Accumulated deformation during cyclic U3 = settlement or downward motion of the riser, if applica-
loading, especially for diameter increase. ble.
286 Reliability: The probability that a component or system 303 Splash zone wave-related height: The wave height with
will perform its required function without failure, under stated a probability of being exceeded equal to as determined
conditions of operation and maintenance and during a speci- from the long term distribution of individual waves. If this val-
fied time interval. ue is not available, an approximate value of the splash zone
287 Re-qualification: The re-assessment of a design due to height may be taken as:
modified design premises and/or sustained damage. 0.46 HSloo
288 Resistance: The capability of a structure, or part of a where
structure, to resist load effects.
HSloo=significant wave height with a 100 year return period
289 Riser: A riser is defined as the connecting piping or flex-
ible pipe between a submarine pipeline on the sea bottom and 304 Submarine pipeline: See definition for pipeline.
installations above water. The riser extends to the above sea
emergency isolation point between the import/export line and 305 Submerged zone: The part of the pipeline system or in-
the installation facilities, i.e. riser ESD valve. stallation below the splash zone, including buried parts.
290 Riser support/clamp: A structure which is intended to 306 Supplementary requirements: Requirements for material
keep the riser in place. properties of linepipe that are additional to the basic require-
ments, and that are intended to apply to pipe used for specific
291 Riser system: A riser system is considered to comprise applications.
riser, its supports, all integrated pipelining components, and
corrosion protection system. 307 System effects: System effects are relevant in cases
where many pipe sections are subjected to an invariant loading
292 Risk: The qualitative or quantitative likelihood of an ac- condition, and potential structural failure may occur in connec-
cidental or unplanned event occurring, considered in conjunc- tion with the lowest structural resistance among the pipe sec-
tion with the potential consequences of such a failure. In tions.
quantitative terms, risk is the quantified probability of a de-
fiied failure mode times its quantified consequence. 308 System pressure test: Final test of the complete pipeline
system, see Section 5B 200.
293 Safety Class (SC): In relation to pipelines; a concept
adopted to classisl the significance of the pipeline system with 309 Target safety level: A nominal acceptable probability of
respect to the consequences of failure. structural failure. Gross errors are not included.
294 Safety class resistancefactor: Partial safety factor which 310 Ultimate Tensile Strength (UTS): The measured ulti-
transforms the lower fractile resistance to a design resistance mate tensile strength.
reflecting the safety class. 311 Verification: An examination to c o n f i i that an activity,
295 Slamming: Impact load on an approximately horizontal a product or a service is in accordance with specified require-
member from a rising water surface as a wave passes. The di- ments.
rection is mainly vertical. 312 Work:All activities to be performed within relevant con-
296 Slapping: Impact load on an approximately vertical sur- tract(s) issued by Owner, Operator, Contractor or Manufactur-
face due to a breaking wave. The direction is mainly horizon- er.
tal. 313 Yield Stress (Ys):The measured yield tensile stress.
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Tmax = Maximum design temperature Load effect factor for environmental load
T min = Minimum design temperature Resistance factor, strain resistance
TO = Testing temperature I$ Load effect factor for functional load
tl, t2 = Pipe wall thickness, see Section 5C 300 Yinc Incidental to design pressure ratio
tcorr = Corrosion allowance Ym Material resistance factor
tfab = Fabrication thickness tolerance Pressure load effect factor
tmin = Minimum thickness Safety class resistance factor
tmmin = Measured minimum thickness, see Table 6-14, Curvature
Table 6-15 Usage factor
tnom = Nominal wall thickness of pipe (un-corroded) Friction coefficient
W = Section modulus Standard deviation of a variable (e.g. thickness)
Z = Height from the pipeline part considered to the Equivalent stress, von Mises
pipeline reference point for design pressure Hoop stress
D 300 Greek characters Longitudinal/axial stress
Tangential shear stress
301 Greek Characters
Subscripts
a = Thermal expansion coefficient
= Anisotropy factor A = Accidental load
a C = Flow stress parameter, ref. Section 5D 300 C = characteristic resistance
%ab = Fabrication factor, ref. Section 5D 300, Section d = Design value
5B 600 E = Environmental load
qat = Allowable damage ratio for fatigue e = External
= Girth weld factor (strain resistance) el = Elastic
agw I vo\
-
Minimum strain hardening F = Functional load
ah h = Circumferential direction (hoop direction)
aT T ~
= Material strength
- factor i = Internal
E = Strain 1 = axial (longitudinal) direction
EM = Characteristic bending strain resistance M = Moment
Ef = Accumulated plastic strain resistance P = Plastic
Ep = Plastic strain S = Steel
YA = Load effect factor for accidental load S = SLS
Y
c = Condition load effect factor U = ULS
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Page 18 - Sec.2
SECTION 2
DESIGN PHILOSOPHY
A. General
A 100 Objective
101 The purpose of this section is to present the safety phi-
losophy and corresponding design format applied in this stand-
ard.
A 200 Application
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B. Safety Philosophy
B 100 General
101 The integrity of a pipeline system constructed to this
standard is ensured through a safety philosophy integrating Figure 2-1 Safety Philosophy structure
different parts as illustrated in Figure 2- 1. B 300 Systematic review
B 200 Safety objective 301 As far as practical, all work associated with the design,
construction and operation of the pipeline system shall be such
201 An overall safety objective shall be established, planned as to ensure that no single failure will lead to life-threatening
and implemented, covering all phases from conceptual devel- situations for any person, or to unacceptable damage to the fa-
opment until abandonment. cilities or the environment.
Guidance note: 302 A systematic review or analysis shall be carried out at all
All companies have some sort of policy regarding human as- phases in order to identiSl and evaluate the consequences of
pects, environmentand financial issues. These are typically on an single failures and series of failures in the pipeline system,
overall level, but they may be followed by more detailed objec- such that necessary remedial measures can be taken. The ex-
tives and requirements in specific areas. These policies should be tent of the review or analysis shall reflect the criticality of the
used as a basis for defining the Safety Objective for a specific pipeline system, the criticality of a planned operation, and pre-
pipeline system. Typical statements can be: vious experience with similar systems or operations.
- The impact on the environment shall be reduced to as far as Guidance note:
reasonably possible; A methodology for such a systematic review is quantitative risk
- No releases will be accepted during operation of the pipeline analysis (QRA). This may provide an estimation of the overall
risk to human health and safety, environment and assets and
system; comprises:
- There shall be no serious accidents or loss of life during the
construction period; - hazard identification,
- assessment of probabilities of failure events,
- The pipeline installation shall not, under any circumstances
- accident developments, and
impose any threat to fishing gear;
- consequence and risk assessment.
- Diverless installation and maintenance; etc.
It should be noted that legislation in some countries requires risk
Statements such as those above may have implications for all or analysis to be performed, at least at an overall level to identie
individual phases only. They are typically more relevant for the critical scenarios that might jeopardise the safety and reliability
work execution (i.e. how the Contractor executes his job) and of a pipeline system. Other methodologies for identification of
specific design solutions (e.g. burial or no burial). Having de- potential hazards are Failure Mode and Effect Analysis @MEA)
fined the Safety Objective, it can be a point of discussion as to and Hazard and Operability studies WAZOP).
whether this is being accomplished in the actual project. It is
therefore recommended that the overall Safety Objective be fol-
lowed up by more specific, measurable requirements. 303 Special attention shall be given to sections close to in-
If no policy is available, or if it is difficult to define the safety ob- stallations or shore approaches where there is frequent human
jective, one could also start with a risk assessment. The risk as- activity and thus a greater likelihood and consequence of dam-
sessment could identify all hazards and their consequences, and age to the pipeline. This also includes areas where pipelines are
then enable back-extrapolation to define acceptance criteria and installed parallel to existing pipelines and pipeline crossings.
areas that need to be followed up more closely.
B 400 Safety class methodology
In this standard, the structural failure probability is reflected in
the choice of three safety classes (see B 400). The choice of safe- 401 In this standard, structural safety of the pipeline system
ty class should also include consideration of the expressed safety is ensured by use of a safety class methodology. The pipeline
objective. system is classified into one or more safety classes based on
failure consequences, normally given by the content and loca-
tion. For each safety class, a set of partial safety factors is as-
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101 The design format within this standard is based upon a The partial safety factors related to the safety class are given in
limit state and partial safety factor methodology, also called Section 5D 200.
Load and Resistance Factor Design format (LRFD).
402 For normal use, the safety classes in Table 2-4 apply:
C 200 Categorisation of fluids
201 Fluids to be transported by the pipeline system shall be
categorised according to their hazard potential as given by Ta- Fluid Categoy Fluid Categoy
ble 2- l . Phase A, C B, D and E
Location Class Location Class
Table 2-1 Classification of fluids
Categoy I
Description Temporary1,2 I Low I Low I Low I Low
A I Tvuical non-flammablewater-based fluids. Operational I Low I Normal3 I Normal I Hieh
B Flammable andor toxic substances which are liq- Note:
uids at ambient temperature and atmospheric pres-
sure conditions. Typical examples would be oil 1) Installation until pre-commissioning (temporary phase) will normally
petroleum products. Methanol is an example of a be classified as safety class Low.
flammable and toxic fluid. 2) For safety classification of temporary phases after commissioning, spe-
C Non-flammable substanceswhich are non-toxic gas- cial consideration shall be made to the consequences of failure, i.e. giv-
ing a higher safety class than Low.
es at ambient temperature and atmosphericpressure
conditions. Typical examples would be nitrogen, 3) Risers during normal operation will normally be classified as safety
carbon dioxide, argon and air. class High.
D Non-toxic, single-phasenatural gas. * Other classifications may exist depending on the conditions and criti-
Flammable andor toxic fluids which are eases at cality of failure the pipeline. For pipelines where some consequences
ambient temperature and atmospheric pr&sure con- are more severe than normal, i.e. when the table above does not apply,
the selection of a higher safety class shall also consider the implication,
ditions and which are conveyed as gases andor liq-
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on the total gained safety. If the total safety increase is marginal, the se-
uids. Typical examples would be hydrogen, natural lection of a higher safety class may not be justified.
gas (not otherwise covered under category D),
ethane, ethylene, liquefied petroleum gas (such as C 500 Partial Safety Factor methodology
propane and butane), natural gas liquids, ammonia,
I and chlorine. 501 The fundamental principle of the partial safety factor de-
sign methodology is to ver@ that factored design loads do not
202 Gases or liquids not specifically identified in Table 2-1 exceed factored design resistance for any of the considered
shall be classified in the category containing substances most failure modes. A factored design load effect is obtained by
similar in hazard potential to those quoted. If the fluid category multiplying a characteristic load effect by a load effect factor.
is not clear, the most hazardous category shall be assumed. A factored resistance is obtained by dividing the characteristic
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resistance by a resistance factor. ~ it is used for calibration of explicit limit states outside the
502 The level of safety is considered to be satisfactory if the scope of this standard;
design load effect (Ld) does not exceed the design resistance ~ the method complies with DNV Classification Note no.
30.6 "Structural reliability analysis of marine structures";
(%I : and
the approach is demonstrated to provide adequate safety
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SECTION 3
DESIGN PREMISES AND DOCUMENTATION
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Guidance note: ble 3- l, the given pressures shall be used as the incidental pres-
As a minimum the monitonngíinspection frequency should be sure.
such that the pipeline system will not be endangered due to any
realistic degradationídeterioration that may occur between two
consecutive inspection intervals. I Table 3-1 Selection of incidental pressures for specific condi-
tions
Condition Pli
When design pressure is equal to full shut-in pressure Pld
202 Instrumentation of the pipeline system may be required Svstem pressure test Uit
when visual inspection or simple measurements are not con-
sidered practical or reliable, and available design methods and 307 The pipeline system may be divided into sections with
previous experience are not sufficient for a reliable prediction different design pressures provided that the pressure control
of the performance of the system. system ensures that, for each section, the local design pressure
cannot be exceeded during normal operations and that the
203 The pressure in a pipeline system shall not exceed the maximum incidental pressure cannot be exceeded during inci-
design pressure during normal steady-state operation. dental operation.
308 When the pipeline system is connected to another sys-
B 300 Pressure Control System tem with different pressure definition, the conversion between
301 A pressure control system may be used to prevent the in- the two system definitions shall be made based on the maxi-
ternal pressure at any point in the pipeline system rising to an mum incidental pressure.
excessive level. The pressure control system comprises the
pressure regulating system, pressure safety system and associ-
ated instrumentation and alarm systems.
C. Pipeline Route
302 The purpose of the pressure regulating system is to
maintain the operating pressure within acceptable limits during C 100 Location
normal operation. The set pressure of the pressure regulating 101 The pipeline route shall be selected with due regard to
system shall be such that the local design pressure is not ex- safety of the public and personnel, protection of the environ-
ceeded at any point in the pipeline system. Due account shall ment, and the probability of damage to the pipe or other facil-
be given to the tolerances of the pressure regulating system and ities. Factors to take into consideration shall, at minimum,
its associated instrumentation, see Figure 1- 1. include the following:
303 The purpose of the pressure safety system is to protect ship traffic;
the downstream system during incidental operation, i.e. in the fishing activity;
event of failure of the pressure regulating system. The pressure offshore installations;
safety system shall operate automatically and with a set pres- existing pipelines and cables;
sure such that there is a low probability for the internal pres-
sure at any point in the pipeline system to exceed the local unstable seabed;
subsidence;
incidental pressure.
uneven seabed;
Guidance note: turbidity flows;
An annual probability for the pressure to exceed the maximum seismic activity;
pressure of less than is usually appropriate. obstructions;
dumping areas for waste, ammunition etc.;
mining activities;
military exercise areas;
304 The set pressure of the pressure safety system, the max- archaeological sites;
imum allowable incidental pressure, shall be such that the local exposure to environmental damage; and
incidental pressure is not exceeded at any point in the pipeline oyster beds.
system. Due account shall be given to the tolerances of the
pressure safety system. Hence, the maximum allowable inci- 102 Expected future marine operations and anticipated de-
dental pressure is equal to the incidental pressure minus the velopments in the vicinity of the pipeline shall be considered
pressure safety system operating tolerance. when selecting the pipeline route.
305 The ratio between the incidental pressure and the design C 200 Route survey
pressure, xnc,
is normally 1.10 which also is the maximum al-
201 A survey shall be carried out along the planned pipeline
lowed ratio. The local incidental pressure can be expressed as:
route to provide sufficient data for design and installation re-
lated activities.
202 The survey corridor shall have sufficient width to define
a pipeline corridor which will ensure safe installation and op-
where eration of the pipeline.
203 The required survey accuracy may vary along the pro-
h is the height difference between the point and the ref- posed route. Obstructions, highly varied seabed topography, or
erence point special sub-surface conditions may dictate more detailed in-
pcont is the density of the content of the pipeline vestigations.
204 An investigation to identiSl possible conflicts with exist-
Provided that the requirements to the pressure safety system ing and planned installations and possible wrecks and obstruc-
are satisfied, the incidental pressure to design pressure ratio, tions shall be performed. Examples of such installations
xnc,may be taken as less than 1.10, but minimum 1.O5 include other submarine pipelines, and power and communica-
306 A pressure safety system is not necessary if the pressure tion cables.
source to the pipeline cannot deliver a pressure in excess of the 205 The results of the survey shall be presented on accurate
maximum incidental pressure. For the conditions given in Ta- route maps, showing the location of the pipeline and related fa-
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cilities together with seabed properties and anomalies. ~ problems with respect to pipeline crossing,
206 Special route surveys may be required at landfalls to de- ~ problems with the settlement of pipeline system andor the
termine: protection structure at the valve/tee locations,
~ possibilities of mud slides or liquefaction as the result of
~ environmental conditions caused by adjacent coastal fea- repeated loading, and
tures; ~ implications for external corrosion.
~ location of the landfall to facilitate installation; and
~ location to minimise environmental impact. 307 Pipeline components (e.g. valves, tees) in particular
should not be located on the curved route sections of the pipe-
207 All topographical features which may influence the sta- line.
bility and installation of the pipeline shall be covered by the
route survey, including but not limited to:
~ obstructions in the form of rock outcrops, large boulders, D. Environmental Conditions
pock marks, etc., that could necessitate levelling or remov-
al operations to be carried out prior to pipeline installation; D 100 General
and 101 Effects of environmental phenomena relevant for the
~ topographical features that contain potentially unstable particular location and operation in question shall be taken into
slopes, sand waves, deep valleys and erosion in the form account. The principles and methods described in Classifica-
of scour patterns or material deposits. tion Note No. 30.5 "Environmental Conditions and Environ-
mental Loads" may be used as a basis for establishing the
C 300 Seabed properties environmental conditions.
301 Geotechnical properties necessary for evaluating the ef- 102 Environmental phenomena that might impair proper
fects of relevant loading conditions shall be determined for the functioning of the system or cause a reduction of the reliability
sea-bed deposits, including possible unstable deposits in the and safety of the system shall be considered, including:
vicinity of the pipeline. For guidance on soil investigation for
pipelines, reference is made to Classification Note No. 30.4 ~ wind,
"Foundations". ~ tide,
302 Geotechnical properties may be obtained from generally ~ waves,
available geological information, results from seismic surveys, ~ internal waves and other effects due to differences in water
sea bottom topographical surveys, and in-situ and laboratory density,
tests. Supplementary information may be obtained from visual ~ current,
surveys or special tests, as e.g. pipe penetration tests. ~ ice,
earthquake,
303 Soil parameters of main importance for the pipeline re-
~
soil conditions,
sponse are:
~
~ temperature, and
~ shear strength parameters (intact and remoulded und- ~ marine growth (fouling).
rained shear strength for clay, and angle of friction for D 200 Collection of environmental data
sands); and
~ relevant deformation moduli. 201 The environmental data shall be representative for the
geographical areas in which the pipeline system is to be in-
These parameters should preferably be determined from ade- stalled. If sufficient data are not available for the geographical
quate laboratory tests or from interpretation of in-situ tests. In location in question, conservative estimates based on data from
addition, classification and index tests should be considered, other relevant locations may be used.
such as 202 For the assessment of environmental conditions along
~ unit weight, the pipeline route, the pipeline may be divided into a number
~ water content, of sections, each of which is characterised by a given water
~ liquid and plastic limit, depth, bottom topography and other factors affecting the envi-
~ grain size distribution, ronmental conditions.
~ carbonate content, and 203 Environmental parameters shall be described using
~ other relevant tests. characteristic values based on statistical data or long-term ob-
servations.
304 It is primarily the characteristics of the upper few centi-
metres of soil that determine the response of the pipeline rest- 204 Statistical data shall be utilised to describe environmen-
ing on the seabed. The determination of soil parameters for tal parameters of a random nature (e.g. wind, waves). The pa-
these very shallow soils may be relatively more uncertain than rameters shall be derived in a statistically valid manner using
for deeper soils. Also the variations of the top soil between soil recognised methods.
testing locations may add to the uncertainty. Therefore, soil pa- 205 The effect of statistical uncertainty due to the amount
rameters used in the design shall be defiied with upper and and accuracy of data shall be assessed and, if significant, shall
lower limits. The characteristic value of a soil parameter used be included in the evaluation of the characteristic load effect.
in the design shall be taken as the upper or lower value depend-
ing on which is more critical for the limit state in question. D 300 Wind
305 In areas where the sea-bed material is subject to erosion, 301 Wind effects shall be considered in the design of risers,
special studies of the current and wave conditions near the bot- including the possibility of wind induced vibrations of exposed
tom including boundary layer effects may be required for the free spans. Consideration shall be given to wind actions occur-
on-bottom stability calculations of pipelines and the assess- ring in the construction phase
ment of pipeline spans. 302 For a riser adjacent to other structural parts, possible ef-
306 Special investigation of the sea-bed material may be re- fects due to disturbance of the flow field shall be considered
quired to evaluate specific problems, as for example: when determining the wind actions. Such effects may cause an
increased or reduced wind speed, or a dynamic excitation by
~ problems with respect to excavation and burial operations; vortices being shed from adjacent structural parts.
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records;
design to start-up of the pipeline system.
~
pipeline route drawings including information on, e.g. sea- F 400 Corrosion control system and weight coating
bed properties and topology, existing and future platforms, manufacturing
pipelines/cables, subsea well heads, ship lanes, etc.; 401 The documentation to be submitted for review prior to
detailed pipeline crossing drawings; start of manufacturing shall include:
platform layout drawings with risers, riser protection sys-
tems, loading zones, boat landing areas, rescue areas, etc. ~ manufacturing procedures, including inspectionhest re-
as applicable; quirements and acceptance criteria, repairs, documenta-
spool fabrication drawing; tion, etc.;
pipeline protection drawings; and ~ documentation of materials and concrete mix design;
riser and riser clamp fabrication drawings. ~ Manufacturing Procedure Qualification Tests results;
~ quality plan with referenced procedures for inspection,
Linepiye and piyeline components testing and calibrations; and
204 The following documentation shall be prepared: ~ outline drawing of anodes.
~ material manufacturing specifications, and 402 The as built documentation to be submitted after manu-
~ material take off/data sheets. facturing shall include, but not be limited to:
Corrosion control systems and weight coating manufacturing procedures, including test requirements
205 The following documentation shall be prepared, as ap- and acceptance criteria, repairs, personnel qualification
plicable: records, etc.;
material certificates;
~ cathodic protection design report, production test records;
~ anode manufacturing and installation specifications, complete statistics of coating dimensions, weight and neg-
~ coating manufacturing specifications, ative buoyancy for the each joint delivered;
~ field joint coating specification(s), repair log; and
~ corrosion monitoring system specification, and electrical resistance test log.
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Page26 - Sec.3
start of installation shall include but not be limited to: installation history, reference to specifications, drawings
etc., discussion of problem areas, deviations from specifi-
installation procedures, including acceptance criteria, test cations and drawings, of importance for the operational
certificates for equipment, qualification records for per- phase;
sonnel (e.g. welding, coating), etc.; ~ as-installed route drawings;
trenching specification; ~ identification of waivers and deviations from the govern-
intervention procedure; ing technical requirements; and
commissioning pro cedure; ~ identification of areas deemed to require special attention
survey procedure; during normal operation and maintenance of the pipeline
procedure for installation of protective and anchoring system.
structures; and
procedure for installation of risers and spools. F 700 Operation
701 In order to carry out the periodical surveys, the mini-
502 The as built documentation to be submitted after instal- mum documentation shall include:
lation and commissioning shall include, but not be limited to:
personnel responsible for the operation of pipeline system;
~ records; history of pipeline system operation with reference to
~ survey reports; events which may have significance to design and safety;
~ intervention reports; and installation condition data as necessary for understanding
~ commissioning reports. pipeline system design and configuration, e.g. previous
survey reports, as-laid / as-built installation drawings and
F 600 DFI Résumé test reports;
601 A DFI Résumé shall be prepared to provide information physical and chemical characteristics of transported media
for operation of the pipeline system and for preparation of and sand detection facilities (if any);
plans for periodic inspection. The DFI Résumé shall contain inspection and maintenance schedules and their records;
all documentation required for normal operation, ROV surveys inspection procedure and results covering the inspection
and maintenance and provide references to the documentation aspects described in Section 10, including supporting
needed for any repair, modification or re-qualification of the records such as diver survey reports and video films.
pipeline system.
702 In case of mechanical damage or other abnormalities
602 Documentation referred to in the DFI Résumé shall be that might impair the safety, reliability, strength and stability
kept for the lifetime of the pipeline system and shall be easily of the pipeline system, the following documentation shall, as a
retrievable at any time. minimum, be prepared prior to start-up of the pipeline:
603 As a minimum, the DFI Résumé shall contain the fol-
lowing: ~ description of the damage to the pipeline, its systems or
components with due reference to location, type, extent of
brief description of the pipeline system; damage and temporary measures, if any;
design basis including design life, conditions along the ~ plans and full particulars of repairs, modifications and re-
pipeline route, environmental and geotechnical condi- placements, including contingency measures; and
tions, pressure, flow rate, design temperature, design pres- ~ further documentation with respect to particular repair,
sure, incidental pressure, corrosion allowance, fluid modification and replacement, as agreed upon in line with
composition, etc; those for the construction or installation phase.
relevant design assumptions and conditions including ap-
plicable limitations; F 800 Filing of documentation
any special requirements affecting safety or reliability 801 Maintenance of complete files of all relevant documen-
found during design, fabrication or installation phases; tation during the life of the pipeline system is the responsibility
design resume including reference to and description of of the owner.
analyses from the design phase, evaluation of critical or
problem areas, highly utilised and critical areas of the sys- 802 The engineering documentation shall be filed by the
tem and highlighting points that require special attention Owner or by the engineering Contractor for a minimum of 10
during subsequent phases; years. Design basis and key data for the pipeline system shall
reference to accepted calculations and other documents by filed for the lifetime of the system. This includes documen-
verif$ng compliance with governing technical require- tation from design to start-up and also documentation from
ments for all temporary and permanent phases; possible major repair or re-construction of the pipeline system.
fabrication resume giving a summary description of the 803 Files to be kept from the operational and maintenance
manufacturing/fabrication history, reference to specifica- phases of the pipeline system shall, as a minimum, include fi-
tions, drawings etc., discussion of problem areas, devia- nal in-service inspection reports from start-up, periodical and
tions from specifications and drawings, of importance for special inspections, condition monitoring records, and final re-
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the operational phase; ports of maintenance and repair, see Section 10.
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Offshore Standard DNV-OS-FI 01, January 2000
Sec.4 - Page27
SECTION 4
LOADS
environmental loads;
pressure at the considered location corresponding to low tide.
~
lines near fixed points (in-line valvedtees, fixed plants 102 Environmental loads are defined as those loads on a
etc.), caused by cooling of the contained gadliquid; and pipeline system which are caused by the surrounding environ-
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Page28 - Sec.4
ment, and that are not otherwise classified as functional or ac- Guidance note:
cidental loads. Maximum wave load effects may not always be experienced dur-
ing the passing of the design wave. The maximum wave loads
103 Trawl gear loads shall be classified in accordance with may be due to waves of a particular length, period or steepness.
the requirements in F below.
The initial response to impulsive wave slam or slap usually oc-
C 200 Wind loads curs before the exposed part of the pipeline system is significant-
ly immersed. Therefore, other fluid loading on the system need
201 Wind loads shall be determined based on available wind not normally be applied with the impulsive load. However, due
data using recognised theoretical principles. Alternatively, di- to structural continuity of the riser, global wave loading on other
rect application of data from adequate tests may be used. parts of the system must be considered in addition to the direct
wave loading.
202 The possibility of vibrations and instability due to wind Wave slam occurs when an approximately horizontal member is
induced cyclic loads shall be considered (e.g. vortex shed- engulfed by a rising water surface as a wave passes. The highest
ding). slamming forces occur for members at mean water level and the
slam force directions are close to the vertical.
C 300 Hydrodynamic loads Wave slap is associated with breaking waves and can affect
301 Hydrodynamic loads are defined as flow-induced loads members at any inclination, but in the plane perpendicular to the
wave direction. The highest forces occur on members above
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caused by the relative motion between the pipe and the sur-
rounding water. When determining the hydrodynamic loads, mean water level.
the relative liquid particle velocities and accelerations used in Both slam and slap loads are applied impulsively (over a short in-
the calculations shall be established, taking into account con- stant of time) and the dynamic response of the pipeline system
tributions from waves, current and pipe motions if significant. shall be considered.
account. N
408 The effect of possible wave and current loading on a ris- where:
er system in the air gap zone shall be included. F(LE) is the probability distribution function of LE
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Offshore Standard DNV-OS-FI 01, January 2000
Sec.4 - Page29
stacking of pipes;
not less than 3 hours. ~
604 For the on-bottom pipeline in temporary conditions the inertia loads on the riser supports/guides due to pile driv-
characteristic combined environmental load effect should be ing;
taken as follows: re-distribution of support forces when possible temporary
riser supports are removed and the riser turned into the fi-
~ for a time period less than 3 days, the characteristic load nal position;
effects may be based on reliable weather forecasts, and cold springing of the risers (elastic pre-deformations);
~ for the on-bottom pipe in temporary conditions, a 10 year tie-in forces generated when the riser is connected to the
return period value for the considered time period shall be tie-in spooYpipeline; and
applied. The relevant time period is not to be taken less dynamic loads from pre-commissioning activities, e.g.
than a season (3 months). If the joint distribution for envi- flooding and de-watering with pigs.
ronmental loads is unknown, the combined characteristic
load may be taken from a table similar to that for opera- 109 The load combinations to be considered shall be selected
tion. to reflect the most severe load combinations likely to be en-
countered during the construction phase under consideration.
Guidance note:
"Similarto that for operation" implies, e.g. '10 year wave + 1 year
current' or '1 year wave + 10 year current'.
E. Accidental Loads
E 100 General
101 Loads which are imposed on a pipeline system under ab-
normal and unplanned conditions shall be classified as acci-
D. Construction Loads dental loads.
D 100 General 102 The main criteria for classiSling a load as accidental is
the probability of occurrence in line with Section 5D 1200.
101 Loads which arise as a result of the construction of the 103 Typical accidental loads can be caused by:
pipeline system, comprising installation, pressure testing,
commissioning, maintenance and repair, shall be classified ~ vessel impact or other drifting items (collision, grounding,
into functional and environmental loads. sinking);
102 All significant loads acting on pipe joints or pipe sec- ~ dropped objects;
tions during transport, fabrication, installation, maintenance ~ mud slides;
and repair activities shall be considered. ~ explosion;
~ fire and heat flux;
103 Functional Loads shall consider forces generated due to operational malfunction; and
imposed tension during pipeline installation, maintenance and
~
~ dragging anchors.
rep air.
104 Environmental loads shall consider forces induced on 104 Size and frequency of accidental loads, for a specific
the pipeline due to wind, waves and current, including deflec- pipeline system, may be defiied through risk analyses.
tions and dynamic loads due to vessel movement.
105 Accidental loads shall consider inertia forces due to sud-
den waterfilling, excessive deformation in overbend and sag- F. Other loads
bend, and forces due to operation errors or failures in
equipment that could cause or aggravate critical conditions, F 100 Trawling loads
see Section 9A 300. 101 For calculation of characteristic trawling loads, refer-
106 Other loads to be considered are: ence is made to the principles given in the Guideline 13: "In-
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Page30 - Sec.4
terference between Trawl Gear and Pipelines". a) Trawl impact, i.e. the initial impact from the trawl board
102 The requirement for designing pipelines for trawling or beam which may cause local dents on the pipe or dam-
loads shall be determined based upon trawling frequency stud- age to the coating. This should be classified as an environ-
ies and assessment of the potential damage due to trawling, in mental load.
order to ensure that the integrity of the pipeline is not compro- b) Over-trawling, often referred to as pull-over, i.e. the sec-
mised. ond phase caused by the wire and trawl board or beam slid-
103 Trawling loads may be imposed either by trawl boards ing over the pipe. This will usually give a more global
or trawl beams depending on what is the preferred fishing tool response of the pipeline. This should be classified as an
in the area. environmental load.
104 Fishing gear and hence trawl loads may vary significant- c) Hooking, i.e. the trawl board is stuck under the pipe and in
ly, not only between pipeline systems, but also along a pipeline extreme cases, forces as large as the breaking strength of
system. Trawl loads will depend on the type, mass, velocity, the trawl wire are applied to the pipeline. This should be
warp line (line stifhess, catenary effects, and line length) and classified as an accidental load.
size of the trawl board or beam. Variations in pipeline support-
ing conditions along the pipeline route will also have varying 107 The impact energy shall be determined considering, as a
response to trawling gear. minimum:
105 The following trawling data shall be determined:
~ the trawl board or trawl beam mass and velocity, and
~ the maximum trawling equipment size normally used in ~ the effective added mass and velocity.
the area;
~ future trends (new types, (gear) mass, trawling velocity, F 200 Earthquake
shape); and
~ the frequency of the trawling activity in the area. 201 Load effects imposed by earth quake, either directly or
indirectly, shall be classified into accidental or environmental
106 The trawling load effects can be divided in accordance loads, depending on the probability of earthquake occurrence
with the three crossing phases: in line with accidental loads in Section 5D 1200.
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Offshore Standard DNV-OS-FI 01, January 2000
Sec.5 - Page31
SECTION 5
DESIGN CRITERIA
personnel,
tional reliability shall be evaluated.
~
~ traffic,
~ corrosion, and 106 A pipeline may be divided into sections having different
~ fracture arrest. design pressure. The pipeline system shall in such cases be
equipped with an adequate pressure control system, to ensure
This may require a higher safety level than reflected by the that the section or sections with a lower design pressure are not
safety classes. subjected to pressure above the allowable.
204 For spiral welded pipes, the following requirements ap- 107 Risers and J-tubes should be routed inside the structure
ply: to avoid vessel impact, and shall be protected against impact
~ when supplementary requirement F (fracture arrest prop- loads from vessels and other mechanical interaction. Risers
erties) is required, the possibility for a running fracture to should not be located inside the loading zones of platforms.
continue from a weld in one pipe joint to the weld of the 108 Riser and J-tube supports shall be designed to ensure a
next pipe joint shall be assessed; smooth transition of forces between riser and support.
~ external pressure resistance should be documented; and
~ the design shall be based on the load controlled condition 109 The routing of J-tubes shall be based on the following
unless the feasibility for use of displacement controlled considerations:
condition can be documented. platform configuration and topsides layout,
Guidance note: space requirements,
The limitations to fracture arrest and load controlled condition movements of the J-tube,
are due to limited experience with spiral welded pipes subjected cable/pipeline approach,
to running fracture or large strains. J-tube protection,
in-service inspection and maintenance, and
installation considerations.
B 200 Mill pressure test and system pressure test
B. Design Principles and Materials 201 The purposes of the mill test requirement are:
B 100 Pipeline layout ~ to constitute a pressure containment proof test, and
101 A pipeline should not be located close to other struc- ~ to ensure that all pipe sections have at least a minimum
tures, other pipeline systems, wrecks, boulders, etc. The mini- Yield stress.
mum distance should be determined based upon anticipated
deflections, hydrodynamic effects, and upon risk-based evalu- Therefore, the mill test pressure is defined in terms of stress
ations. Wherever a pipeline system is located close to other utilisation, rather than related to the design pressure.
structures, pipeline systems, wrecks, large boulders, etc., the 202 With exception of 203, the pipeline system shall be sys-
detailed routing shall take into account possible deflections, tem pressure tested after installation. The local test pressure
movements and other risks to ensure a sufficient separation (pit) during the system pressure test shall fulfil the following
and margin against interference. requirement:
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Normal and High Safety Class during normal operation: ~ safety class High, and
~ location class 2.
pit = 1.05~1, (5.1)
Guidance note:
Low Safety Class during normal operation: The minimum wall thickness requirement is based on failure sta-
tistics, which clearly indicate that impact loads are the most like-
pit = 1.03~1, (5.2) ly cause of failure and have the decisive effect on thickness
design (not D/t).
Guidance note:
Normally, i.e. with an incidental pressure of 10% above design
pressure, the above gives a system test pressure of approximately
1.15 times the design pressure, given that the design pressure is B 500 Materials selection
referenced to the highest point of the pipeline system.
501 Materials for pipeline systems shall be selected with due
consideration of the fluid to be transported, loads, temperature
and possible failure modes during installation and operation.
203 The system pressure test requirement provides a leakage The selection of materials shall ensure compatibility of all
test after completed construction and is a function of the local components of the pipeline system. The following material
incidental pressure. By agreement, the system pressure test characteristics shall be considered:
may be waived provided that:
~ mechanical properties,
welded linepipes are welded by the SAW method; ~ hardness,
the wall thickness design is governed by the external pres- ~ fracture toughness,
sure and less than 75% of the pressure containment design fatigue resistance,
resistance is utilised;
~
records show that the specified requirements have consist- ~ weldability, and
ently been obtained during manufacture, fabrication and ~ corrosion resistance.
installation;
the mill pressure test requirement of Section 6E 1100 has 502 Materials selection shall include identification of the fol-
been met; lowing supplementary requirements as required:
all components and risers are hydrostatically pressure test- ~ supplementary requirement S, sour service;
ed during manufacture; ~ supplementary requirement F, fracture arrest properties;
local leak testing is performed after installation and tie-in
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of safety as the system pressure test with respect to detect- ~ supplementary requirement D, more stringent dimensional
able defect sizes etc.; requirements.
automated ultrasonic testing (AUT) has been performed
after installation welding (see Section 9A.904); The supplementary requirements are given in Section 6D.
installation and intervention work is unlikely to have 503 Materials selection shall include the selection of linepipe
caused damage to the pipeline. Special attention shall here NDT Level, see B 600. Linepipe NDT Level I is required for
be given to ploughing, other trenching methods or third use of displacement controlled condition local buckling crite-
party damages e.g. anchor cables; and ria (strain based design).
the pipe has not been exposed to accumulated plastic 504 Under conditions when water, oxygen and chloride can
strains exceeding 2% after AUT. be present in the fluid, e.g. water injection, stainless steels can
be susceptible to both localised corrosion and environmentally
204 During system pressure test, all limit states for safety assisted cracking, and hence the corrosion resistance shall be
class low shall be satisfied (see D). considered for each specific application. For special applica-
B 300 In-service inspection tions, corrosion testing shall be performed to qual@ the mate-
rial for the intended application.
301 Requirements to inspections affecting safety and relia-
bility during operation of the pipeline system shall be identi- 505 Routing of well stimulation fluids through duplex or
fied during the design phase, and shall be documented in the martensitic stainless steel pipeline systems requires special
DFI Résumé. precautions.
506 Special precautions are required to avoid corrosion dam-
B 400 Minimum wall thickness age to CRA pipelines, during system pressure testing using
401 Unless equivalent protection against accidental loads, seawater.
dropped objects and other external loads is provided by other 507 Duplex and martensitic stainless steel linepipe, and C-
means, a minimum nominal pipe wall thickness of 12mm shall Mn steel linepipe with SMYS > 450 MPa require special con-
be used for all pipelines with: siderations of the susceptibility of environmentally assisted
cracking (including SSC and hydrogen induced cracking relat-
~ nominal diameter equal to 8" and above, ed to cathodic protection). In particular this applies to material
~ safety class High, and subjected to significant plastic straining during fabrication, in-
~ location class 2. stallation and operation.
Guidance note:
402 Special evaluation of accidental loads, dropped objects
and other external loads shall be included in the determination Linepipe NDT level I gives more stringent requirement to NDT
of minimum required wall thickness for pipelines with: than NDT level II.
The strength factor is 4% higher for supplementary requirement
nominal diameter less than 8", U, usually giving approximately 4% less material.
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S e c 5 - Page33
The relationship between the different material requirements and Table 5-2 Characteristic material strength, fy,fu
design is illustrated in the table below.
ProDer& I Value
Design resistance utilisation as function of NDT level and Characteristicyield stress If, = (SMTS -f,.ternJ.au
sumlementarv reauirement U
Linepipe NDT level
Characteristic tensile strength ,fI = (SMTS -f,ternu).au.aA
Supplementa y req. U Where:
Pressure containment is the derating value due to the tempera-
andf,,temp
Load controlled buckling ture of the yield stress and the tensile
NIA strength respectively
ling. au Material strength factor, ref. Table 5-1
Notes to table: Anisotropy factor,
High and Low in the above table refers to the allowable utilisa- = 0.95 for axial direction (i.e. a, of Eq.
1)
tion. (5.23))due to relaxed testing require-
2) Load controlled condition and displacement controlled condition ments in linepipe specification (ref. Ta-
are defined in C 1OO. ble 6-3, Note 4
= 1.O for other cases.
Guidance note:
If no other information on de-rating effects of the yield stress ex-
ists the recommendations for C-Mn steel, 22Cr Duplex or 25Cr
Duplex stainless steel in Figure 5-1 below may be used.
B 600 Characteristic material properties
601 Characteristic material properties shall be used in the re-
sistance calculations. The yield stress and tensile strength shall
be based on the engineering stress-strain curve.
602 Supplementary requirement U ensures increased confi-
dence in yield stress, which is reflected in a higher material
strength factor, given in Table 5-1. The design strength is a
function of this value and is given in 604.
I Table 5-1 Material Strength factor, a,
I Factor I Normal I SuDDlementaw reauirement U I
I I I I
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604 The characteristic material strength values to be used in 606 For fabrication processes which introduce cold deforma-
the limit state criteria are given in Table 5-2. tions giving different strength in tension and compression, a
fabrication factor, shall be determined. If no other infor-
mation exists, maximum fabrication factors for pipes manufac-
tured by the UOE or U 0 processes are given in Table 5-3.
These factors also apply to other fabrication processes which
introduce similar cold deformations such as three roll bending
(TRB).
The fabrication factor may be improved through heat treat-
ment, if documented.
Table 5-3 Maximum fabrication factor, af,b
PiDe I Seamless I UO&TRB I UOE
&"L 1.o0 0.93 0.85
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B 700 Corrosion allowance 102 A load-controlled condition is one in which the structur-
701 For C-Mn steel pipelines carrying potentially corrosive al response is primarily governed by the imposed loads.
fluids andor exposed to an external corrosive environment 103 A displacement-controlled condition is one in which the
without cathodic protection, the use of an extra wall thickness structural response is primarily governed by imposed geomet-
to compensate for any corrosive degradation during operation ric displacements.
("corrosion allowance") shall be duly considered, (see also 104 A load controlled design criterion can always be applied
Section 8). in place of a displacement controlled design criterion.
Guidance note:
Guidance note:
A corrosion allowance is primarily used to compensate for forms
of corrosion attack affecting the pipeline's pressure containment An example of a purely displacement-controlledcondition is a
resistance, i.e. uniform attack and, to a lesser extent, corrosion pipeline bent into conformity with a continuous curved structure,
damage as grooves or patches. However, a corrosion allowance such as a J-tube or a reel. In that case, the curvature of the pipe
may also enhance the operationalreliability and increase the use- axis is imposed but the circumferential bending that leads to
ful life if corrosion damage occurs as isolated pits; although such ovalisation is determined by the interaction between the curva-
damage is unlikely to affect the pipeline's resistance, it will cause ture of the axis and the internal forces induced by the curvature.
a pinhole leak when the full wall thickness is penetrated. Howev- A less clear-cut example is a pipeline in contact with the rollers
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er, the extra wall thickness will only delay leakage in proportion of a lay barge stinger. On a large scale, the configuration of the
to the increase in wall thickness. pipeline has to conform to the rollers, and in that sense is dis-
placement controlled. On a local scale however, bending of the
pipe between the rollers is determined by the interactionbetween
weight and tension and is load-controlled. The stinger tip will,
702 The needs for, and benefits of, a corrosion allowance however, always be load controlled.
shall be evaluated, taking into account the following factors as
a minimum: Another intermediate case is an expansion spool in contact with
the seabed. Pipeline expansion induced by temperature and pres-
design life and potential corrosivity of fluid andor exter- sure imposes a displacementat the end of the spool. The structur-
al response of the spool itself has little effect on the imposed
nal environment; expansion displacement, and the response is primarily displace-
expected form of corrosion damage (see Guidance note ment-controlled.However, the lateral resistance to movement of
above); the spool across the seabed also plays a significant part and in-
expected reliability of planned techniques and procedures duces a degree of load control.
for corrosion mitigation (e.g. chemical treatment of fluid, These examples show that in many cases a simple distinction be-
external coating, etc.); tween load control and displacement control is not seen. The
expected sensitivity and damage sizing capability of rele- choice should be based on an informed judgement about which
vant tools for integrity monitoring, time to fiist inspection components of the combined load are more important.
and planned frequency of inspection;
consequences of sudden leakage, requirements to safety
and reliability; and 105 Linepipe NDT level I is required for use of displacement
potential for down-rating (or up-rating) of operating pres- controlled local buckling criteria.
sure.
C 200 Load effect calculation
703 Unless a sudden leakage of fluid is acceptable (may ap-
ply for pipelines of safety class Low), the magnitude of a cor- 201 The design analyses shall be based on accepted princi-
rosion allowance shall be sufficient to accommodate any ples of statics, dynamics, strength of materials and soil me-
realistic corrosive degradation that may occur in the period be- chanics.
tween two consecutive inspections for integrity monitoring 202 Simplified methods or analyses may be used to calculate
(see Section 10) the load effects provided that they are conservative. Model
704 Pipelines of safety class Normal and High in C-Mn steel tests may be used in combination with, or instead of, theoreti-
carrying hydrocarbon fluids likely to contain liquid water dur- cal calculations. In cases where theoretical methods are inade-
ing operation shall have an internal corrosion allowance of quate, model or full-scale tests may be required.
minimum 3 mm. 203 All loads and forced displacements which may influence
705 Subject to agreement, the general requirements for a the pipeline integrity shall be taken into account. For each
minimum corrosion allowance of 3 mm may be waived if it is cross section or part of the system to be considered and for
demonstrated that the design andor procedures for corrosion each possible mode of failure to be analysed, all relevant com-
control exclude any critical damage by corrosion. binations of loads which may act simultaneously shall be con-
706 An external corrosion allowance of 3 mm shall be ap- sidered.
plied to C-Mn steel risers of safety class Normal and High in 204 When determining responses to dynamic loads, the dy-
the splash zone. For risers carrying hot fluids (more than 10°C namic effect shall be taken into account if deemed significant.
above normal ambient seawater temperature) of the same safe- 205 Load effect calculation shall be performed applying
ty classes the use of a corrosion allowance in excess of 3 mm nominal cross section values.
shall be considered. Any allowance for internal corrosion shall
be additional. 206 Load effect calculations shall be based on characteristic
values, ref. Section 4B 200 and C 600.
207 Possible beneficial strengthening effect of weight coat-
ing on a steel pipe shall not be taken into account in the design,
C. Load and Resistance Calculations unless the strengthening effect is documented. Coating which
C 100 Load conditions adds significant bending stiffness to the pipe may increase the
stresses/strains in the pipe at any discontinuity in the coating
101 Differentiation is made between: (e.g. at field joints). When appropriate, this effect shall be tak-
~ Load Controlled condition (LC condition), and en into account.
~ Displacement Controlled condition (DC condition). 208 Possible beneficial strengthening effect of cladding or
liner on a steel pipe shall not be taken into account in the de-
Different design checks apply to these two conditions. sign, unless the strengthening effect is documented.
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209 The effective axial force that determines the global re- 403 Strain concentrations shall be accounted for when con-
sponse of a pipeline is denoted S. Counting tensile force as sidering:
positive:
uneven deformation caused by variations in actual materi-
7T 2 2
S = N-piAi +p,A =N
- -@i(D 2 t ) -p,D ) (5.3)
- al yield stress and strain hardenability between pipe joints
4 and in the weld metal due to scatter in material properties;
210 In the as-laid condition, when the pipe temperature and variations in cross sectional area (actual diameter or wall
internal pressure are the same as when the pipe was laid, thickness) between pipe joints;
S=H stiffening effects of coating and variations in coating
thickness;
Where H i s the effective (residual) lay tension
--```,,`,`,,,`,,````,````,`,```-`-`,,`,,`,`,,`---
reduction of yield stress in field joints due to high temper-
211 Effective axial force of a totally restrained pipe in the ature imposed by field joint coating application during in-
linear elastic stress range is (if it can be idealised as thin- stallation; and
walled): undermatcldovermatch of actual weld metal yield stress,
relative to actual pipe material yield stress.
S = H- A u i . A i ( l -2v)-A,. E . a . AT (5.4)
404 Accumulated plastic strain is defiied as the sum of plas-
where : tic strain increments, irrespective of sign and direction. Strain
H = Effective (residual) lay tension increments shall be calculated from after the linepipe manufac-
turing.
4i = Internal pressure difference relative to as laid
AT = Temperature difference relative to as laid 405 Plastic strain increment shall be calculated from the
point where the material stress-strain curve deviates from a lin-
C 300 Characteristic wall thickness ear relationship, ref. Figure 5-2.
301 Pressure containment resistance shall be calculated
based on wall thickness as follows:
Mill pressure test and system pressure test condition
tl = t-tfab (5.5)
Operational condition
t2 = t (5.7)
Otherwise
Figure 5-2 Reference for plastic strain calculation
t2 = -tcorr (5.8) Guidance note:
303 Corrosion prior to start of operation shall be considered The yield stress is defined as the stress at which the total strain is
in the above calculation of thickness. 0.5%. As an example for a 41 5 grade C-Mn steel, a unidirectional
strain of 0.5% corresponds to an elastic strain of approximately
304 Minimum wall thickness requirement is given in B 400. 0.2% and a plastic strain of 0.3%.
C 400 Stress and strain calculations 406 The equivalent plastic strain is defined as:
401 Stress Concentration Factors (SCF) shall be included if E = J(2/3)(EpL 2 +EPH 2 +EpR-)
P (5.9)
relevant.
Guidance note: where
Distinction should be made between global and local stress con-
centrations. 5 is the equivalent plastic strain
Local stress concentrations (that may be caused by welded at- 5L is the plastic part of the principal longitudinal strain
tachments, the weld itself, or very local discontinuities) will af- ~p~ is the plastic part of the principal circumferential (hoop)
fect the pipe only locally and are typically accounted for in strain
fatigue and fracture evaluations. Global stress concentrations is the plastic part of the principal radial strain
(such as stress amplifications in field joints due to concrete coat- ~p~
ing, which typically extend one diameter) will affect the pipe glo-
bally, and shall be accounted for in the bending buckling
evaluations as well as fatigue and fracture evaluations.
D. Limit States
D 100 General
402 Strain Concentration Factors (SNCF) shall be deter-
mined and accounted for if plastic strain is experienced. The 101 All relevant failure modes formulated in terms of limit
SNCF shall be adjusted for the non-linear stress-strain rela- states shall be considered in design. The limit states shall be
tionship for the relevant load level. classified into one of the following four limit state categories:
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safety class may vary for different phases and different loca- safety class and given in Table 5-5.
tions.
I Table 5-5 Safetv class resistance factors. I
203 The level of safety is considered to be satisfactory if the
design load effect (Ld) does not exceed the design resistance
Safety class Low Normal High
(%I : Pressure containment2 1.0463, 1.138 1.308l
Ld 5 Rd (5.10) Other 1.O4 1.14 1.26
1) For parts of pipelines in location class 1, resistance safety class normal
204 The design load can generally be expressed in the fol- may be applied (1.13s).
lowing format: 2) The number of significant digits are given in order to comply with the
I S 0 usage factors.
(L,j = L F . YF. YC + L E . YE +LA . YA . YC) (5.11) 3) Safety class low will be governed by the system pressure test which is
required to be 3% above the incidental pressure. Hence, for operation
in safety class low, the resistance factor will effectively be 3% higher.
In specific forms, this corresponds to:
4) For system pressure test, au shall be equal to 1.00, which gives an al-
lowable hoop stress of 96% of S M Y S both for materials fulfilling sup-
plementary requirement U and those not.
The load effect factors, @ , &, yA, % and yc are given in Table
5-5 and Table 5-6. These factors apply to all safety classes.
Definition of characteristic functional and environmental load
effect values are given in Section 4B 200 and C 600.
di
Limit State /
Load com&
ULS
FLS
ALS
Functional Environ- Accidental
loads1) mental load
1.1
1.o
1.o
loads
1.o
1.o 1.o
Pressure
loads
1.O5
1.o
1.o
Guidance note: 1) If the functional load effect reduces the combined load effects, % shall
be takenas Ul.1.
The above load combinations are referred to explicitly in the de-
sign cntena, e.g. Eq. (5.23), and shall not be applied elsewhere, 302 Load combination a in Table 5-6 is required when sys-
e.g. not in Eq. (5.14) or in Eq. (5.22). tem effects are present. It is therefore not required for local de-
sign checks, which normally means for c p - O in combination
with other loads.
Guidance note: 303 The loads listed in Section 4 shall be considered for all
For the system pressure test condition, the local test pressure is design phases relevant to the pipeline system.
considered as incidental pressure. In order to calculate the corre- 304 The condition load effect factor applies to the conditions
sponding Pld, included in APd above, the local test pressure shall in Table 5-7. Condition load effect factors are in addition to the
be calculated as: load effect factors and are referred to explicitly in Eq. (5.12).
Table 5-7 Condition load effect factors, y c
Condition
Pipeline resting on uneven seabed or in a snaked con-
--```,,`,`,,,`,,````,````,`,```-`-`,,`,,`,`,,`---
dition
where h,,f is the vertical distance between the point in question Continuouslv stiff suuuorted 0.82
and the reference height and xncshould be 1.1. The same ap- I Svstem uressure test I 0.93 I
proach applies to when the shut-in pressure is used.
(5.13)
The characteristic material strength,fk, is given in B 600.
206 The material resistance factor, ym, is dependent on the
limit state category and is defiied in Table 5-4.
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402 The pressure containment shall fulfil the following cri- Guidance note:
teria: Ovalisation caused during the constructionphase shall be includ-
ed in the total ovality to be used in design. Ovalisation due to ex-
(5.14) ternal water pressure or bending moment shall not be included.
Guidance note:
Criterion for the incidental pressure is given in Section 3B 300 504 The external pressure at any point along the pipeline
The concept of local pressure is given in Section 12E 100 shall meet the following criterion (system collapse check):
(5.22)
403 The pressure containment resistance, Pb (x) is given by: Guidance note:
If the pipeline is laid fully or partially liquid-filledor is otherwise
= Minbb, pb,u(x)) (5.15) under internal pressure, then the internal pressure may be taken
into account provided that it can be continuously sustained.
Guidance note:
In the above formulas, x shall be replaced by t l or tz as appropn-
ate.
fU
a, = (1-ß)+ß-
where : fY
but maximum 1.20
(5.19) 0.4 + q, for D/t2 < 15
qh)(60 D/t2)/45 for 15 5 D/t2 5 60
-
Dmax Dmin
fo = (5.21)
D for P l d 5 Pe
not to be taken < 0.005 (0.5%) a, is not to be taken larger than 1.20.
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Guidance note: cient safety margin in compliance with this standard. Any in-
creased utilisation shall be supported by analytical design
methods.
506 Pipe members subjected to bending moment, effective fÖmed during laying; and
axial force and external overpressure shall be designed to sat- buckle arrestors are installed if the external pressure ex-
isfy the following equation: ceeds the initiation propagating pressure.
Relevant resistance factors may then be calibrated according to
the SLS requirements in Section 2.
Propagation buckling
D/t 5 45, pi < y , 510 Propagation buckling cannot be initiated unless local
buckling has occurred. In case the external pressure exceeds
Combined loading criteria - Displacement controlled condi- the criteria given below, buckle arrestors should be installed
tion and spacing determined based on consequences of failure. The
507 Pipe members subjected to longitudinal compressive propagating buckle criterion reads:
strain (bending moment and axial force) and internal over pres-
sure shall be designed to satisfy the following condition at all
cross sections:
Ec
Ed I- D A 145,pi 2p, (5.25)
YE
where :
Ed = Design compressive strain, Eq. (5.12)
t o
E, = 0 . 7 8 ( ~ - 0 . 0 1 ) ( 1 +5+)%p1'5agw
Guidance note:
ah = Maximum allowed yield% tensile ratio Collapse pressure, p c , is the pressure required to buckle a pipe-
a,= Girth weld factor line.
$'- Resistance strain factor, see Table 5-8
D-t Initiation pressure, pinit, is the pressure required to start a propa-
gating buckle from a given buckle. This pressure will depend on
oh= 'pd'($) the size of the initial buckle.
Guidance note: Propagating pressure, ppr,is the pressure required to continue a
The maximum yield to ultimate stress ration, a,, is found in Ta- propagating buckle. A propagating buckle will stop when the
ble 6-3 and Table 6-6. The increase of this factor with 0.02 in ac- pressure is less than the propagating pressure.
cordance with footnote 5 and 3 in these tables respectively does The relationship between the different pressures are:
not apply since it is already included in the factor 0.78.
Pc >Pinit >Pnr
ysc . y,
D/t 5 45,pi < y , (5.26) 602 The effect of internal and external pressures may be tak-
en into account using the concept of an effective axial force,
see C.209 above. The procedure is as for "ordinary" compres-
where : ye sion members in air.
&d = Design compressive strain, Eq. (5.12) 603 A negative effective force may cause a pipeline or a riser
E, = 0.78(6t2 0.01) %p'1'5)agw
- to buckle as a bar in compression. Distinction shall be made
between load-controlled and displacement-controlled buck-
Guidance note:
ling.
For d t < 20, the utilisation may be increased provided that full Load-controlled buckling involves total failure, and is not al-
scale testing, observation, or former experience indicate suffi- lowed.
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604 The following global buckling initiators shall be consid- tests, the following shall be considered:
ered:
determination of long-term distribution of stress range, see
~ trawl board impact, pullover and hooking, and 707;
~ out of straightness. ~ selection of appropriate S-N curve (characteristic resist-
ance), see 708;
605 For global buckling resistance for load-controlled condi- ~ determination of Stress Concentration Factor (SCF) not
tion, reference is made to DNV Offshore Standard OS-C101, included in the SN-curve; and
"Design of Steel Structures rr (not yet issued; until issue, refer ~ determination of accumulated damage, see 709.
to DNV Rules for ClassiJication of Fixed Ofshore Installa-
tions, Pt. 3, Ch. 1, Structural Design, General). 707 As most of the loads which contribute to fatigue are of a
606 Displacement-controlled buckling may be allowed, pro- random nature, statistical consideration is normally required in
vided it does not result in other failure modes as listed under determining the long-term distribution of fatigue loading ef-
102 above. This implies that global buckling may be allowed fects. Where appropriate, deterministic or spectral analysis
provided that: may be used.
708 The characteristic resistance is normally given as S-N
~ local buckling criteria are fulfilled in the post global buck- curves or e-N curves, i.e. stress amplitudes (or strain ampli-
ling configuration, tudes for the case of low-cycle fatigue), versus number of cy-
~ displacement of the pipeline is acceptable and cles to failure, N. The S-N curve shall be applicable for the
~ cyclic effects are acceptable. material, construction detail, and state of stress considered, as
well as to the surrounding environment. The S-N curve should
Guidance note:
be based on the mean curve of log(N) with the subtraction of
A condition that can give rise to excessive strain is when a short two standard deviations in log(N).
length of an otherwise fully restrained pipeline is less restrained
or unconstrained. A typical example is upheaval buckling of a 709 In the general case where stress fluctuations occur with
buried pipeline. varying amplitude of random order, the linear damage hypoth-
esis (Miner's Rule) may be used. The application of Miner's
Rule implies that the long-term distribution of stress range is
replaced by a stress histogram, consisting of a number of con-
D700 Fatigue stant amplitude stress or strain range blocks, (sr)i or (er)i, and
701 Reference is made to the following Rules, Classification the corresponding number of repetitions, ni. Thus, the fatigue
Notes (CN) and guidelines: criterion is given by:
~ CN 30.5 Environmental Conditions and Environmental
Loads.
Dfat = c,k
ni afat
(5.28)
~ DNV-RP-C203 Fatigue Strength Analysis of Ofshore
i=l
Steel Structures
~ DNV-RP-F105 Free Spanning Pipelines Where:
702 The pipeline systems shall have adequate safety against Dfat Miner's sum
=
fatigue failures within the design life of the system. k number of stress blocks
=
ni number of stress cycles in stress block i
=
703 All stress fluctuations imposed on the pipeline system Ni number of cycles to failure at constant stress range
=
during the entire design life, including the construction phase, of magnitude (sJi or strain range (e,)i.
which have magnitude and corresponding number of cycles afat = allowable damage ratio, see Table 5-9
large enough to cause fatigue effects shall be taken into ac-
count when determining the long-term distribution of stress 710 For detailed explanation regarding fatigue calculations/
ranges. The fatigue check shall include both low-cycle fatigue analysis reference is made to DNV-RP-F105 "Free Spanning
and high-cycle fatigue. The requirements regarding accumu- Piyelines". In cases where this guideline is not applicable, al-
lated plastic strain (D 1000 below) shall also be satisfied. lowable damage ratios are given in Table 5-9.
Guidance note: I Table 5-9 Allowable damage ratio for fatigue I
Typical causes of stress fluctuations in a pipeline system are:
- direct wave action; 113 115 1/10
- vibrations of the pipeline system, e.g. due to vortex shedding qat
(current, waves, wind, towing) or fluid flow;
- supporting structure movements; and
- fluctuations in operating pressure and temperature.
used shall be determined on a case-by-case basis, and shall re- been considered; and
tolerances in the relevant repair system are met.
flect the target safety levels in Section 2C 600.
~
706 When using calculation methods based upon fatigue 802 Ovalisation shall be checked for point loads at any point
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along the pipeline system. Such point loads may arise at free- D 1100 Fracture
span shoulders, artificial supports and support settlements. 1101 Pipeline systems shall have adequate resistance against
D 900 Ratcheting initiation of unstable fracture. This shall be achieved by select-
ing materials with the transition temperature from brittle to
901 Accumulated plastic deformation (ratcheting) caused by ductile behaviour sufficiently below the minimum design tem-
cyclic loads shall be considered. If the ratcheting causes accu- perature, see Table 6-4, and with high resistance to stable crack
mulated ovality, special consideration shall be made of the ef- growth.
fect on buckling resistance.
1102 The safety against unstable fracture is considered satis-
902 Under maximum operating temperature and pressure, factory if the materials, welding, workmanship and testing are
the equivalent plastic strain in the pipelines shall not exceed in accordance with the requirements of this standard and the
0.001 (0.1%). (Calculated based on elastic - perfectly plastic accumulated plastic strain is not exceeding 0.3%.
material. The calculations of the equivalent plastic strain as-
sume that the reference state for zero strain is the as-built state 1103 Pipeline systems transporting gas or mixed gas and liq-
(after pressure testing)). uids under high pressure shall have adequate resistance to
propagating fracture. This may be achieved by using:
903 Plastic deformation of the pipeline shall only occur
when the pipeline is fiist exposed to its maximum temperature ~ material with low transition temperature and adequate
and pressure. Charpy V-notch toughness,
adequate DWTT shear fracture area
904 Ratcheting due to local and global bending stresses shall
~
also be considered where this could eventually lead to loss of ~ lowering the stress level,
stability ~ use of mechanical crack arrestors, or
~ by a combination of these methods.
D 1000 Accumulated plastic strain
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to be of the "measured response versus actual flaw size" type. and procedures applied.
The probability of detection level with the applied testing
1206 A simplified design check with respect to accidental
equipment and procedures used shall be based on a confidence load may be performed as shown in Table 5-10 using appropri-
level of 95% or better. ate partial safety factors.. The adequacy of simplified design
1112 If adequate data is not available, the following ap- check must be assessed on the basis of the summation above in
proach shall be used: order to ver@ that the overall failure probability complies
with the target values in Section 2.
~ If the purpose of the ECA is to establish the tolerable de-
fect size for given material properties and stresses, 2 mm
shall be subtracted from the calculated defect height and
length, when acceptance criteria for non-destructive test- E. Special Considerations
ing are established.
~ If the purpose of the ECA is to establish the material prop- E 100 General
erties and stresses required to tolerate a given defect size, 101 This subsection gives guidance on conditions that shall
the defect size used as input into the ECA shall be in- be evaluated separately. Both the load effects and acceptance
creased in size by adding 2 mm to the stated height and criteria are affected.
width.
E 200 Pipe soil interaction
D 1200 Accidental limit state
201 For limit states influenced by the interaction between the
1201 The design against accidental loads may be performed pipeline and the soil, this interaction shall be determined tak-
by direct calculation of the effects imposed by the loads on the ing due account for all relevant parameters and the uncertain-
structure, or indirectly, by design of the structure as tolerable ties related to these.
to accidents.
In general pipeline soil interaction depends on the characteris-
1202 The acceptance criteria for ALS relate to the overall al- tics of the soil, the pipeline, and the loads, which shall all be
lowable probability of severe consequences properly accounted for in the simulation of the pipeline soil in-
1203 Design with respect to accidental load must ensure that teraction.
the overall failure probability complies with the target values 202 The main soil characteristics governing the interaction
in Section 2. This probability can be expressed as the sum of are the shear strength and deformation properties. The non-lin-
the probability of occurrence of the i'th damaging event, Pqi, ear stress - strain characteristics of the soil shall be accounted
times the structural failure probability conditioned on this for. If linear springs are used to represent the interaction, the
event, Pfl/2Di. The requirement is accordingly expressed as: response in the springs shall be checked in order to ver@ that
the load level is compatible with the spring stiffness used.
(5.30)
203 Pipeline characteristics of importance are submerged
where P is the relevant target probability according to Sec- weight, diameter stiffness, and roughness of the pipeline sur-
tion 2. %e number of discretisation levels must be large face, which shall all be accounted for as relevant for the limit
enough to ensure that the resulting probability is evaluated state in question.
with sufficient accuracy. 204 All relevant effects of load characteristics shall be con-
1204 The inherent uncertainty of the frequency and magni- sidered, including any long term load history effects such as
tude of the accidental loads, as well as the approximate nature varying vertical reactions from installation laying pressures,
of the methods for determination of accidental load effects, and variations in the unit weight of the pipe. Cyclic loading ef-
shall be recognised. Sound engineering judgement and prag- fects are also to be considered.
matic evaluations are hence required. Some soils have different resistance values for long term load-
ing and for short term loading, related to the difference in
I Table 5-10 SimDlified Design Check versus Accidental loads I drained and non-drained behaviour and to creep effects in
Prob. of occur- Safety Class Safety Class Safety Class drained and non-drained condition. This shall be taken into ac-
rence Low Normal High Y count.
Accidental loads may be regarded similar to envi-
ronmental loads and may be evaluated similar to
205 For limit states involving or allowing for large displace-
ULS design check ments (e.g. lateral pull-in, pipeline expansion of expansion
loops or when displacements are allowed for on-bottom condi-
- I
To be evaluated on a case by case basis
tion) the soil will be loaded far beyond failure, involving large
10-3 I
yc= 1.0 I
yc= 1.0 yc= 1.0 I non-linearities, remoulding of soil, ploughing of soil etc. Such
non-linear effects and the uncertainties related to these shall be
Accidental loads or events may considered.
be disregarded 206 Due to the uncertainties in governing soil parameters,
load effects etc., it is difficult to define universally valid meth-
Note to table: ods for simulation of pipeline soil interaction effects. The lim-
Standard industry practice assumes safety factors equal to 1.O for an acciden- itations of the methods used, whether theoretically or
tal event with a probability of occurrence equal to and survival of the empirically based, shall be thoroughly considered in relation to
pipeline is merely related to a conservative definition of characteristic resist- the problem at hand. Extrapolation beyond documented valid-
ance. In this standard, accidental loads and events are introduced in a more
general context with a link between probability of occurrence and actual fail- ity of a method shall be performed with care, as shall simplifi-
ure consequence.For combined loading the simplified design check proposes cations from the problem at hand to the calculation model
a total factor in the range 1.1-1.2, which is consistent with standard industry used. When large uncertainties exist, the use of more than one
practice interpreted as corresponding to safety class Normal for accidental calculation approach shall be considered.
loads with a probability of occurrence equal to
1205 If non-linear, dynamic finite element analysis is ap- E 300 Spanning risers/pipelines
plied, it shall be ensured that system performance and local 301 Spanning risers and pipelines shall have adequate safety
failure modes (e.g. strain rate, local buckling, joint overloading against excessive yielding, fatigue and ovality and these shall
and joint fracture) are adequately accounted for by the models be documented.
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302 For design of free spanning pipelines, reference is made reference is made to RP E305 “On Bottom Stability“.
to DNV-RP-F105; “Free Spanning Piyelines“.
410 The most unfavourable combination of simultaneously
E 400 On bottom stability acting vertical and horizontal forces on the pipeline shall be
considered. When determining this unfavourable combination,
401 The pipeline shall be supported, anchored in open the variation in forces along the line, including directionality
trench, or buried in such a way that under extreme functional effects of waves and current, shall be addressed.
and environmental loading conditions, the pipeline will not
move from its as-installed position. This does not include per- Guidance note:
missible lateral or vertical movements, thermal expansion, and The transverse pipeline stability may be assessed using three-di-
a limited amount of settlement after installation. mensional dynamic or two-dimensional static analysis methods.
The dynamic analysis methods allow limited pipe movements,
Guidance note: but require accurate three-dimensional modelling. The static
The acceptance criterion on permissible movements may vary analysis method may be expressed by:
along the pipeline route. Examples of possible limitations to
pipeline movements include: (5.31)
- yielding, buckling and fatigue of pipe;
- deteriorationíwearof coating;
- geometrical limitations of supports; and
- distance from other pipelines, structures or obstacles. factor of safety, normally not to be taken as
less than 1.1
hydrodynamic drag force per unit length
402 Liquid or gas pipelines in the air- or gas-filled condition hydrodynamic inertia force per unit length
--```,,`,`,,,`,,````,````,`,```-`-`,,`,,`,`,,`---
shall have a specific gravity which is higher than that of the hydrodynamic inertia force per unit length
surrounding sea water (negative buoyancy).
submerged pipe weight per unit length
403 When the pipeline is routed in areas that may be influ- hydrodynamic lift force per unit length
enced by unstable slopes, that could lead to slope failure and
flow of soil that will impact the pipeline, the probability of
such slope failures shall be evaluated. Any relevant slope fail-
ure triggering effect, such as wave loading, earthquake loading
or man made activities (e.g. the pipe-laying itself), shall be
considered. Possible flow rates and densities at the pipeline 411 The coefficient of equivalent friction, p may vary within
shall be evaluated for stability. If stability can not be guaran- a wide range depending on the seabed soil, surface roughness,
teed by sufficient weight of the pipeline, by burial of the pipe- weight and diameter of the pipeline. When the pipeline has
line or by other means, re-routing of the pipeline shall be some penetration into the soil, the lateral resistance includes
required. both friction type resistance and resistance due to mobilising
the soil outside the contact surface. In such cases the equiva-
404 For weight calculations of the pipe, the nominal wall lent friction coefficient may vary with the vertical load level.
thickness shall be reduced to compensate for the expected av-
erage weight reduction due to metal loss. For pipelines with 412 Axial (longitudinal) stability shall be checked. The an-
minor corrosion allowance this reduction may be omitted and ode structural connection (when exposed to friction, e.g., pipe-
the nominal thickness used. lines without weight coating) shall be sufficient to sustain the
anticipated friction force.
405 Buried pipelines shall have adequate safety against sink-
ing or flotation. For both liquid and gas pipelines, sinking shall 413 Pipeline movements due to thermal axial expansion,
be considered assuming that the pipeline is water filled, and shall be allowed for near platformslstructures (e.g. at riser tie-
flotation shall be considered assuming that the pipeline is gas in point) and where the pipeline changes direction (e.g. at off-
or air filled (if relevant). set spools). The expansion calculations shall be based upon
406 If the specific submerged weight of the water-filled pipe conservative values for the axial frictional resistance.
is less than that of the soil, then no further analyses are required 414 In shallow water, the repeated loading effects due to
to document safety against sinking. If pipelines are installed in wave action may lead to a reduction of the shear strength of the
soils having a low shear strength, then the soil bearing resist- soil. This shall be considered in the analysis, particularly if the
ance shall be documented. If the soil is, or is likely to be, liq- back fill consists of loose sand which may be susceptible to liq-
uefied, it shall be documented that the depth of sinking will be uefaction.
satisfactorily limited (either by the depth of liquefaction or by
the build-up of vertical resistance during sinking) meeting the 415 If the stability of the pipeline depends on the stability of
requirements of D above. the seabed, the latter should be checked.
407 If the specific submerged weight of the gas- or air-filled E 500 Trawling interference
pipe is less than that of the soil, it shall be documented that the
shear strength of the soil is adequate to prevent flotation. Thus, 501 The pipeline system shall be checked for all three load-
in soils which are or may be liquefied, the specific weight of ing phases due to trawl gear interaction, as outlined in Section
the buried gas- or air-filled pipeline is not to be less than that 4F. For more detailed description, reference is made to the
of the soil. Guideline 13;”Interference between Trawl Gear and Pipe-
lines”.
408 Pipelines resting directly on the sea bottom without any
special supporting structures or anchoring devices other than 502 The acceptance criteria are dependent on the trawling
weight coating, shall be designed against sinking as described frequency (impact) and the safety classification (pull-over and
under 405 above. Special considerations shall here be made to hooking) given in Section 2C 400.
mechanical components such as valves and Tee’s. 503 The acceptance criteria for trawl impact refer to an ac-
409 It shall be documented that pipelines situated on the sea ceptable dent size. The maximum accepted ratio of permanent
bottom have adequate safety against being lifted off the bottom dent depth to the pipe diameter is:
or moved horizontally. For assessment of horizontal (trans-
verse) stability of pipelines exposed to wave and current loads, Hp
D
5 0.0577 (5.32)
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505 Pullover loads shall be checked in combination with oth- govern the support design (weak link principle).
er relevant load effects. All relevant failure modes for lateral 202 For bolted connections, consideration shall be given to
buckling shall be checked. Accumulation of damage due to friction factors, plate or shell element stresses, relaxation, pipe
subsequent trawling is not normally allowed. crushing, stress corrosion cracking, fatigue, brittle failure, and
506 Hooking loads shall be checked in combination with other factors that may be relevant.
other relevant load effects. All relevant failures modes shall be 203 For supports with doubler and/or gusset plates consider-
checked. ation shall be given to lamellar tearing, pull out, element
stresses, effective weld length, stress concentrations and ex-
E 600 Third party loads, dropped objects cessive rotation.
601 The pipeline shall be designed for impact forces caused 204 In clamps utilising elastomeric linings, the long-term
by, e.g. dropped objects, fishing gear or collisions. The design performance of the material with regard to creep, sea water and
may be achieved either by design of pipe, protection or means air or sun light resistance shall be determined.
to avoid impacts. G 300 J-tubes
602 The design criteria shall be based upon the frequency/ 301 An overall conceptual evaluation shall be made in order
likelihood of the impact force and classified as accidental, en- to define the required:
vironmental or functional correspondingly, see D 1200.
~ safety class,
E 700 Insulation ~ impact design, and
pressure containment resistance.
701 When a submerged pipeline is thermally insulated, it
~
shall be documented that the insulation is resistant to the com- 302 The J-tube shall be designed against the failure modes
bination of water, temperature and hydrostatic pressure. given in D 100.
702 Furthermore, the insulation should be resistant to oil and Guidance note:
oil-based products, if relevant. The insulation shall also have 301 above includes evaluation of whether the j-tube shall be de-
the required mechanical strength to external loads, as applica- signed for the full design pressure and to which safety class (i.e.
ble. hoop stress usage factors). The J-tube concept may e.g. be based
on "burst disc" which will imply that a lower pressure contain-
703 With respect to corrosion, see Section 8. ment resistance shall be governing.
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Offshore Standard DNV-OS-FI 01, January 2000
Sec.5 - Page45
according to subsection D and E above. straightness of the pipeline. This shall be determined and eval-
Guidance note: uated with due considerations of effects on:
According to this standard, equivalent limit states are used for all instability:
phases. Hence the design criteria in this section also apply to the
~
installation phase. Installation is usually classified as a lower ~ positioning of pipeline components e.g. valves and Tee-
safety class (safety class low) than operation, corresponding to joints; and
lower partial safety factors (higher failure probability). ~ operation.
202 The possibility of instability due to out of straightness
102 The design analysis for risers and pipelines shall include during installation (twisting) and the corresponding conse-
both installation and repair activities, in order to ensure that quence shall be determined.
they can be installed and repaired without suffering damage or 203 If Tee-joints and other equipment are to be installed as
requiring hazardous installation or repair work. an integrated part of the pipeline assembled at the lay barge, no
103 The design shall veriSl adequate strength during all rel- rotation of the pipe due to plastification effects shall be permit-
evant installation phases and techniques to be used, including: ted. In this case the residual strain from bending at the over-
bend shall satisSl the following during installation:
initiation of pipe laying operation,
normal continuous pipe laying, Kot&, &,,rot (5.33)
pipe lay abandonment and pipeline retrieval,
termination of laying operation, where
tow out operations (bottom tow, off-bottom tow, control-
led depth tow and surface tow), E, = residual strain from over bend
pipeline reeling and unreeling, Xot = 1.3 safety factor for residual strain
trenching and back filling, =
riser and spool installation, limit residual strain from over bend.
tie-in operations and 204 The above equations only consider rotation due to resid-
landfalls. ual strain from installation along a straight path. Other effects
104 The configuration of pipeline sections under installation can also give rotation (curved lay route, eccentric weight, hy-
shall be determined from the laying vessel to the final position drodynamic loads, reduced rotational resistance during pulls
on the seabed. The configuration shall be such that the stress/ due to lateral play/elasticity in tensioners/pads/tracks etc) and
strain levels are acceptable when all relevant effects are taken need to be considered.
into account. Discontinuities due to weight coating, buckle ar- 205 Instability during operation, due to out of straightness
restors, in-line assemblies etc. shall be considered. caused by the installation method and the corresponding con-
105 The variation in laying parameters that affect the config- sequences, shall be determined. Residual stresses affecting
uration shall be considered. An allowed range of parameter present and future operations and modifications shall also be
variation shall be established for the installation operation. considered.
106 Critical values shall be determined for the installation 206 The requirement for straightness applies to the assumed
limit condition, see Section 9D 400. most unfavourable functional and environmental load condi-
tions during installation and repair. This requirement also ap-
107 Configuration considerations for risers and pipelines plies to sections of a pipeline where the strains are completely
shall also be made for other installation and repair activities, controlled by the curvature of a rigid ramp (e.g. stinger on in-
and the allowed parameter variations and operating limit con- stallation vessel), whether or not environmental loads are act-
ditions shall be established. ing on the pipe.
108 If the installation and repair analyses for a proposed Guidance note:
pipeline system show that the required parameters cannot be Rotation of the pipe within the tensioner clamps of the pipe due
obtained with the equipment to be used, the pipeline system to elasticity of the rubber and slack shall be included in the eval-
shall be modified accordingly. uation of the rotation.
109 The flattening due to a permanent bending curvature, to-
gether with the out-of-roundness tolerances from fabrication of
the pipe shall meet the requirements defined in D 800.
H300 Coating
H 200 Pipe straightness 301 Concrete crushing due to excessive compressive forces
201 The primary requirement regarding permanent deforma- for static conditions in the concrete during bending at the over-
tion during construction, installation and repair is the resulting bend is not acceptable.
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Offshore Standard DNV-OS-FI 01, January 2000
Page46 - Sec.6
SECTION 6
LINEPIPE
A. General pass made on the inside and one pass from the outside of the
pipe. An intermittent or continuous single pass tack weld may
A100 Scope be made by the gas metal arc welding method. The forming
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101 This section specifies the requirements for materials, may be followed by cold expansion to obtain the required di-
manufacture, testing and documentation of linepipe, with re- mensions.
gard to the characteristic properties of materials which shall be Seamless (SML) linepiye
obtained after heat treatment, expansion and final shaping. 403 Linepipe manufactured by a hot forming process with-
102 The requirements are applicable for linepipe in: out welding. In order to obtain the required dimensions, the hot
forming may be followed by sizing or cold finishing.
Carbon Manganese (C-Mn) steel,
High Frequency Welded (HFW) linepipe
~
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S e c 6 - Page47
202 The supplementary requirements shall be addressed in 106 If the cold forming during pipe manufacture of C-Mn
the MPS and the required tests shall be included in the qualifi- and cladlined steels exceeds 5% strain, strain ageing tests
cation of the MPS. shall be performed on the actual pipe without any straightening
and additional deformation. Strain ageing tests shall conform
B 300 Designations to Table 6-1 1. The absorbed energy shall not be less than 50%
301 Carbon Manganese linepipe and cladlined steel pipes, of the energy absorption obtained in the un-aged linepipe ma-
to be used to this standard, shall be designated with: terial, and the required Charpy V-notch impact properties of
Table 6-3 shall be met in the aged condition. The testing shall
~ process of manufacture (see A 400), be performed in accordance with Appendix B.
~ SMYS,
~ NDT level (see B 100 and, 107 Testing of Charpy V-notch impact properties shall, in
~ supplementary requirement suffix (see B 200). general, be performed on test specimens 10xlOmm. Where test
pieces with a width < 1Omm are used, the measured impact en-
e.g. “SML 450 I S“ designates a seamless pipe with SMYS 450 ergy (KV,) and the test piece cross-section measured under
MPa, NDT Level I and meeting sour environment require- the notch (A) (mm2) shall be reported. For comparison with the
ments. values in Table 6-3 the measured energy shall be converted to
the impact energy (KV) in Joules using the formula :
e.g. “SAWL 415 II L - UNS XXXXX” designates a submerged
arc welded pipe, with SMYS 415 MPa, NDT level II, lined
with a UNS designated material. 8 x 10 x K V ,
KV= A
302 Duplex stainless steel linepipe to be used to this standard
shall be designated with:
~ process of manufacture (see A 400), C 200 Carbon Manganese (C-Mn) steel linepipe
~ grade (see C 300), and 201 These requirements are applicable to welded or seamless
~ supplementary requirement suffix (see B 200). linepipe in C-Mn steel with SMYS up to 555 MPa. Use of
e.g. “SML 22Cr D ’ designates a seamless 22Cr grade meeting higher strength shall be subject to agreement.
the enhanced dimensional requirements. Chemical composition
202 The chemical composition of C-Mn steel parent materi-
als shall be within the limits given in Table 6-1 and Table 6-2
C. Material Properties for the appropriate yield stress levels. The chemical composi-
tion of mother pipes for bends shall be within the limits given
C 100 General in Section 7.
101 Requirements for steel making, chemical analysis, pipe Mechanical properties
manufacture, type and extent of mechanical testing and NDT
are given in E below. 203 Mechanical testing shall be performed after heat treat-
ment, expansion and final shaping. The testing shall be per-
102 For pipe OD > 300 mm, tensile properties shall be tested formed in accordance with Appendix B.
in both transverse and longitudinal direction to the pipe axis,
while the Charpy V-notch samples shall be tested only in the 204 Requirements for tensile and Charpy V-notch properties
transverse direction. All mechanical and corrosion testing shall are given in Table 6-3 and Table 6-4. Welds shall meet the re-
be conducted in accordance with Appendix B. quirement for KVT impact properties given in Table 6-3.
103 For pipe OD 5 300 mm, all mechanical testing shall be 205 Unless sour service is specified (see D loo), the hard-
conducted in the longitudinal direction. All mechanical and ness in the Base Material (BM) and weld (weld metal + HAZ)
corrosion testing shall be conducted in accordance with Ap- shall comply with Table 6-3.
pendix B.
206 Fracture toughness testing of the Base Material (BM)
104 If materials shall be used at a design temperature above and the Weld Metal (WM) (welded linepipe) shall be conduct-
50°C, the yield stress at the T, may be determined during the ed as part of the qualification (Table 6-1 1 and Table 6-12). The
qualification of the manufacturing procedure specification. measured fracture toughness of the BM and the WM, shall as
This information shall be obtained either by use of the curves a minimum have a CTOD value of 0.20 mm when tested at the
in Sec.5 B600 or by testing. minimum design temperature. The testing shall be performed
105 When applicable, linepipe to this standard shall also in accordance with Appendix B A 800. Testing is not required
meet the appropriate supplementary requirements. for pipes with ,t < 13 mm.
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Page48 - Sec.6
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6 5 15
12)
Pcm =
Si
c+-+ Mn + Cu + Cr + xi + g o + 1 + 5B
30 20 60 15 10
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S e c 6 - Page49
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Table 6-2
Seamless C-Mn steel 1ineDiDe. chemical comDosition 2, 3,
Product analysis, maximum weight %
SMYS 245 290 360 415 450 485 555
c 4) 0.14 0.14 0.14 0.14 0.15 0.16 0.16
Mn4) 1.35 1.65 1.65 1.65 1.65 1.75 1.85
Si 0.40 0.40 0.45 0.45 0.45 0.45 0.45
P 0.020 0.020 0.020 0.020 0.020 0.020 0.020
S 0.010 0.010 0.010 0.010 0.010 0.010 0.010
Cu 0.35 0.35 0.50 0.50 0.50 0.50 0.50
Ni 0.30 0.30 0.50 0.50 0.50 0.50 0.50
Mo 0.10 0.10 0.50 0.50 0.50 0.50 0.50
Cr 5 ) 0.30 0.30 0.50 0.50 0.50 0.50 0.50
Al (total) 6, 0.06 0.06 0.06 0.06 0.06 0.06 0.06
Nb 7) 0.04 0.05 0.05 0.05 0.05 0.06
v 7) 0.04 0.07 0.08 0.09 0.10 0.10
Ti 7, 0.04 0.04 0.04 0.06 0.06 0.06
N 6, 0.010 0.010 0.010 0.010 0.010 0.010 0.010
R 8) 0.0005 0.0005 0.0005 I 0.0005 I
0.0005 I I I I 0.0005 I 0.0005
t<15 0.34 0.34 0.37 0.39 0.40 0.41 0.43
15< t<26 0.35 0.35 0.38 0.40 0.41 0.42 0.44
1) Chemical composition applies for wall thicknesses up to 26 mm and shall be subject to agreement for larger wall thicknesses.
2) When scrap material is being used in steel production, the amount of the following residual elements shall be determined and reported, and the levels shall
not exceed: 0.03% As, 0.01% Sb, 0.02% Sn, 0.01% Pb, 0.01% Bi and 0.006% Ca.
3) Except for deoxidisation elements, other elements than those mentioned in this table shall not be intentionally added if not specifically agreed.
4) For each reduction of 0.01% carbon below the maximum specified value, an increase of 0.05% manganese above the specified maximum values is per-
mitted with a maximum increase of 0.1%.
5) 0.5-1.0% CI may be used subject to agreement.
6) A1:N 2 2: 1 (not applicable for titanium killed steels)
7) (Nb+V+Ti)% maxinlum : 0.12% This value may be increased to maximum 0.15% subject to agreement.
8) Boron (max 30 ppm) may be added subject to agreement.
Mn C r + M o + V k C u + N i
9, CE=C+-+
6 5 15
10) P c m = c + - + Mn + C u + C r + g i + m l +5B
Si +
30 20 60 15 10
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Page50 - Sec.6
360 460 0.90 270 20 36 30 not exceed SMYS by more than 120 MPa.
415 520 0.92 270 18 42 35 4) SMTS in the longitudinal direction, can be 5% less than
450 0.92 270 18 45 38 the required values in transverse direction.
485 570 0.92 300 18 50 40 The YS/UTS ratio in the longitudinal direction shall not
5)
555 625 0.92 300 18 56 45 exceed the maximum specified value in the transverse di-
rection, by more than 0.020 for standard material, and
more than 0.030 for sour service material.
6) The KVL values (when tested) shall be 50% higher than
I
the required KVT values.
Table 6-4 C-Mn steel linepipe, Charpy V-notch testing temperatures To (“C) as a function of T,, (“C) (Minimum Design Temper-
ature)
Nominal wall RISERS PIPELINES Notes
Thickness (mm) Gas I ) Liquid I ) 1) Mixed gas and liquid (s) are to be regarded as
t<20 To = T, - 10 To = T, - 10 To = T, gas.
20< t < 40 To = T, - 20 To = T, - 20 TO= Tmin- 10 2) Increasing thicknesses will require lower test
t>40 To = to be agreed in each case 2, temperatures. Alternatively higher absorbed en-
ergy at the same temperature shall be required.
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1) If other alloying elements than specified in this table are being used, the elements and the maximum content shall be agreed in each case.
2) PRE = %c1+3.3%Mo+16%N. A minimum PRE valueof 40 is recommended for pipelines to convey raw (Le. not deoxygenated) seawater and any similar
auulication
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SMYS 2)4) SMTS YS lRr0.5) Maximum Elongation Charpy V-notch
Hardness AS energy (KVT)
UTS @m) @VIO) min. % min. J a t
Grade TO = Tmin- 20% s,
MPa MPa
max
22 Cr 450 620
c h ) 3,
0.90
“I” 25
Mean
45
Single
35
25 Cr 550 750 0.90 15 45 35
Votes
C 400 Other stainless steel and nickel based corrosion sisting of a C-Mn steel base material and a thinner internal me-
resistant alloy (CRA) linepipe tallic layer.
401 The requirements below are applicable to austenitic 502 Linepipe is denoted “clad”if the bond between base and
stainless steels, martensitic (“13% Ci’) stainless steels and cladding material is metallurgical, and “lined”if the bond is
nickel based CRAs. mechanical.
402 The linepipe shall be supplied in accordance with a rec- 503 The cladding and the lined material shall be compatible
ognised standard that defines the chemical composition, me- with the service requirements and shall be determined and
chanical properties and all the issues listed in Section 5 B500 agreed in each case. The cladding/lined material thickness
and as specified in the following. If a recognised standard is shall not be less than 2.5 mm.
not available, a specification shall be prepared that defines Supply condition
these requirements.
504 Cladlined linepipe shall be supplied in the heat-treat-
403 For martensitic stainless steels (“13% Ci’) the same re- ment condition that is appropriate for both types of material.
quirements for fracture toughness as for C-Mn steels shall ap-
ply (see 206). Chemical composition and mechanical properties of base ma-
terial
Corrosion testing
505 The chemical composition of the base material shall
404 The same requirements as stated in 308 for duplex stain- comply with the requirements to C-Mn steel for linepipe given
less steel shall apply for other stainless steel and nickel based in Table 6-1 and Table 6-2.
corrosion resistant alloys with a specified PRE value of mini-
mum 40. 506 The mechanical properties of the base material shall
meet the requirements in Table 6-3 and Table 6-4. Mechanical
Metallographic examination of welds testing shall be performed after heat treatment, expansion and
405 Metallographic examination at a magnification of 400X final shaping.
of the weld metal and the HAZ shall be performed. The mate- 507 Fracture toughness testing of the Base Material (BM)
rial shall be essentially free from grain boundary carbides, ni- and the Weld Metal (WM) (welded linepipe), shall be conduct-
trides and intermetallic phases after solution heat treatment. ed as part of the qualification (Table 6-12 and Table 6-13). The
measured fracture toughness of the BM and the WM shall, as
C 500 Cladhined steel linepipe a minimum, have a CTOD value of 0.20mm, when tested at the
501 The requirements below are applicable to linepipe con- minimum design temperature. The testing shall be performed
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in accordance with Appendix B A 800. Testing is not required In order to improve HAZ toughness, it is essential to refine the
for pipes with tnom< 13mm. grain size and suppress the formation of bainite with M/A con-
stituents.
508 The claddinghing material shall be removed from the
test pieces prior to testing.
Chemical composition of claddingAined material 603 The linepipe supplier shall provide information with re-
gard to appropriate Post Weld Heat Treatment (PWHT) tem-
509 Cladding/lined materials shall primarily be selected on perature for the respective materials.
the basis of requirements to corrosion resistance, including
SSC. The chemical composition of cladding materials shall be Pre-production weldability testing
specified according to recognised standards. If a recognised 604 For qualification of pipeline materials and welding con-
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standard is not available, a specification shall be prepared that sumables, a weldability testing programme as specified below
defines these requirements. Applicable requirements in C 300 should be performed. The type and extent of testing, and the
and C 400 shall be met. acceptance criteria for weldability testing shall be agreed in
each case.
Chemical composition of weld metal
605 Relevant documentation may be agreed in lieu of the
510 The welding consumables shall be selected taking into weldability testing.
consideration the reduction of alloying elements by dilution of
iron from the base material. C-Mn steels and martensitic ("13% Cr'y stainless steels
Metallographic examination of welds 606 For steels with SMYS 2 415 MPa, the weldability test-
ing/documentation shall, as a minimum, include bead on plate,
511 Metallographic examination of the weld metal and the Y-groove, and also fracture toughness tests of base material
HAZ in the root area of the cladding material, shall be per- and HAZ. In addition, for steels with SMYS 2 450 MPa, met-
formed at a magnification of 400X. The microstructure shall allographic examination should be conducted to establish the
be essentially free from grain boundary carbides, nitrides and presence of LBZs. The testing program shall be in accordance
intermetallic phases. with Table 6-11, Table 6-12 and Appendix C. The maximum
and minimum heat inputs giving acceptable properties in the
Properties of clad material and linepiye weld zones of the linepipe, with corresponding preheat temper-
512 Two bend tests from each plate/strip shall be bent 18Ox atures and working temperatures, shall be determined for both
around a former with a diameter three times the plate thick- fabrication and installation welding.
ness. One test piece shall be bent with the cladding material in 607 For materials where only limited practical experience
tension, the other with the cladding material in compression. exists, the programme may further include HAZ thermal cy-
After bending there shall be no sign of cracking or separation cling tests, continuous cooling transformation tests, delayed
on the edges of the specimens. The bend test shall be carried cracking tests and controlled thermal severity tests.
out in as specified Appendix B.
Duplex stainless steel
513 Shear testing in accordance with Appendix B shall be 608 For duplex stainless steel, the weldability testing / docu-
performed as required in Table 6-1 1 and Table 6-12. The min- mentation shall determine the effect of thermal cycles on the
imum shear strength shall be 140 MPa. mechanical properties, hardness, and microstructure. The max-
514 Hardness testing of welded linepipe shall be performed imum and minimum heat inputs giving an acceptable ferrite/
on a test piece comprising the full cross section of the weld. In- austenite ratio and a material essentially free from intermetal-
dentations shall be made in the base material, the cladding ma- lic phases shall be determined for both fabrication and instal-
terial and the metallurgical bonding area as detailed in lation welding. Allowances for repair welding shall be
Appendix B. included.
Other stainless steels and nickel based alloys
515 The hardness of base material, cladding material, HAZ,
weld metal and the metallurgical bonding area shall meet the 609 For austenitic stainless steels and nickel based C U ' S ,
relevant requirements of this standard (see Table 6-3 and the weldability testing/documentation shall determine the ef-
Table 6-6). fect of thermal cycles on the mechanical properties, hardness
and microstructure. The range of heat inputs giving properties
C 600 Weldability shall be determined for both fabrication and installation weld-
ing, including allowances for repair welding.
601 Steels shall have adequate weldability for all stages of
manufacture, fabrication and installation of the pipeline, in- CladAined steel linepiye
cluding field and contingency conditions, hyperbaric welding 610 For cladlined linepipe, the weldability of the base mate-
and anode installation. rial shall be testeddocumented as required in 604 and 605. For
602 Welding and repair welding procedures, welding per- the cladding/lining material, the weldability testing/documen-
sonal, handling of welding consumables, and the execution of tation shall determine the dilution effects and the effect of ther-
welding shall meet the requirements in Appendix C. mal cycles on the mechanical properties, hardness and
microstructure. The range of heat inputs giving acceptable
Guidance note: properties shall be determined for both fabrication and instal-
Local brittle zones GBZs) can be formed in the HAZ of C-Mn lation welding. Allowances for repair welding shall be includ-
microalloyed steels. These areas tend to exhibit very low cleav- ed.
age resistance, resulting in low CTOD values. The LBZs are as-
sociated with the sections of the HAZ'S that are experiencing
grain coarsening during the welding operation. The microstruc-
ture in these zones consists predominantly of a bainitic structure, D. Supplementary Requirements
with a large amount of martensite/austenite @UA) constituents
@+-microstructure). The M/A constituents, as opposed to ferrite/ D 100 Supplementary requirement, sour service (S)
carbide aggregate such as pearlite, may have a detrimental affect
on the material's toughness. This should particularly be kept in 101 For pipelines to be used for fluids containing hydrogen
mind when selecting the chemical composition for steels with sulphide and defined as "sour service" according to NACE
SMYS t 450 m a . Standard MRO175 (Sulphide Stress Cracking Resistant Metal-
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lic Materials for Oil Field Equipment), all requirements to ma- Table 6-8 Chemical composition of seamless C-Mn steel line-
terials selection, maximum hardness, and manufacturing and pipe for supplementary requirement, sour service
fabrication procedures given in the latest edition of the said Product analysis, maximum weight %
standard shall apply. This includes pipelines which are nomi-
nally dry (i.e. free from liquid water during normal operation)
if other conditions for sour service according to the above
standard are valid. Further, the additional requirements, modi-
fications and clarifications defiied below shall apply.
102 Use of linepipe materials not listed for sour service in
NACE MRO175 (latest edition) and not covered by this section
shall be qualified according to the guidelines of the said docu-
ment. As an alternative, the guidelines for qualification in EFC
Publications No. 16 and No.17 may be used for C-Mn and
CRA linepipe respectively. The qualification shall include
testing of Sulphide Stress Cracking (SSC) resistance of base
materials and welds (seam welds and girth welds, as applica- 107 Additional requirements to steel making as given in
ble). E.403 shall apply.
108 Welded linepipe resistance to Hydrogen Pressure In-
Guidance note:
duced Cracking (HPIC) shall be verified by testing (ref. Ap-
SSC-testing as specified in the referenced NACE and EFC doc- pendix B) during qualification of the MPS and linepipe
ument has a duration of 720 hours and is, as such, unsuitable for manufacturing, as stated in E 800.
purchase release purposes.
Guidance note:
Hydrogen Pressure Induced Cracking (HPIC) as used in this doc-
ument is frequently referred to as either Hydrogen Induced
103 Qualification is also applicable to linepipe materials list- Cracking @€IC)or Stepwise Cracking (SWC).
ed for sour service in NACE MRO175, in case hardness or oth-
er requirements relating to manufacturing or fabrication
deviate from those in this document. 109 During welding procedure qualification and production,
hardness measurements shall be performed as given in Appen-
Guidance note: dix B. The hardness in the base material, weld and HAZ shall
It may also be considered to specify SSC testing of grades meet- notexceed250HVlOintherootarea, and275HVlOinthecap
ing all requirements for sour service in this standard, as a part of area.
a program for pre-qualification of linepipe manufacturing or in- Guidance note:
stallation procedures. It is recommended to specify a maximum hardness of 220 HV10
for the base material in order to allow for hardness increase dur-
ing girth welding.
104 All welding procedures (including repair welding) shall
be qualified and include hardness testing as specified in Ap-
pendix C, Paragraph E. Duplex steel linepipe
110 Linepipe grades, associated hardness criteria, and re-
C-Mn steel linepipe quirements to manufacturing/fabrication shall comply with
105 C-Mn steels with SMYS exceeding 450 MPa are not NACE MRO175 (latest edition). During welding procedure
covered by NACE MR0175 (as per 1998), and shall be pre- qualification and production, hardness measurements shall be
qualified for sour service as stated in 102 unless later included performed as given in Appendix B. For 22 Cr Duplex and 25Cr
Duplex, the hardness in the weld shall not exceed 310 HV10
in the said document. and 330 HV10 respectively.
106 The chemical composition shall be modified as given in CladAined steel linepiye
Table 6-7 and Table 6-8. Other elements not listed in these ta-
bles shall be in accordance with Table 6-1 and Table 6-2 re- 111 Materials selection for cladding/lining, the associated
hardness criteria, and requirements to manufacturing and fab-
spectively. The notes given Table 6-1 and Table 6-2 shall rication shall comply with NACE MRO175 (latest edition).
apply. The same applies to welding consumables for weldments ex-
posed to the internal fluid. The selection of the C-Mn steel base
Table 6-7 Chemical composition ofwelded C-Mn steel linepipe material is not subject to any special sour service requirements.
for supplementary requirement, sour service
Product analysis, maximum weight % 112 During qualification of welding procedures and produc-
tion, hardness measurements shall be performed as indicated in
Appendix B. The hardness in the internal heat-affected zone
and in the fused zone of the cladding/lining shall comply with
I
C max. I
0.10 I
0.10 I
0.10 I relevant requirements of NACE MR0175 (latest edition).
Mn max. 1.35 1.45 1.55
P max. 0.015 0.015 0.015 D 200 Supplementary requirement, fracture arrest
S max. 0.003 0.003 0.003
properties (F)
Cu max. 0.35 0.35 0.35 201 The requirements to fracture arrest properties are valid
I I
Ni max.
I
0.30
I
0.30
I
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given in Table 6-9 are valid for full size (10 mm x 10 mm) curve shall be established for the linepipe base material in the
specimens. strain-aged condition. The plastic deformation shall be equal to
C-Mn steel linepipe the actual deformation introduced during manufacturing (no
additional straining is required). The samples shall be aged for
202 A Charpy V-notch transition curve shall be established
for the linepipe base material. Five sets of specimens shall be 1 hour at 250°C. Five sets of specimens shall be tested at dif-
tested at different temperatures, including Tmin.The Charpy V- ferent temperatures, including Tmir The Charpy V-notch ener-
notch energy value in the transverse direction and at T, shall, gy value in the transverse direction, and at Tmin,shall not be
as a minimum, meet the values given in Table 6-9. The values less than 50% of the energy absorption obtained in the unde-
obtained in the longitudinal direction, when tested, shall be at formedun-aged condition (see 202), and shall as a minimum,
least 50% higher than the values required in the transverse di- meet the values given in Table 6-9 in the deformed and aged
rection. condition. Values obtained at other test temperatures are for in-
203 This paragraph shall apply for all linepipes to be deliv- formation. The values obtained in the longitudinal direction,
ered without a final heat treatment (normalising or quench and when tested, shall at least be 50% higher than the values re-
tempering) of the entire pipe. A Charpy V-notch- transition quired in the transverse direction.
Table 6-9 Charpy V-notch Impact Test Requirements for Fracture Arrest Properties tested at T,, (Joules; Transverse Values;
Average value of three snecimensì
thickness I 1 3 0 m m 2,
OD (mm) Notes
II
1610 I820 11120
SMYS 1) Minimum individual results to exceed 75% of
245 40 40 40 these values
290 40 43 52 2) Fracture arrest properties for larger wall thick-
nesses and diameters shall be subject to agree-
360 50 61 75 ment (see Section 5 D800)
415 64 77 95
450 I 73 I 89 I 109 I
485 82 1O0 124
555 103 126 155
204 Drop Weight Tear (DWT) testing shall only be per- materials are subject to agreement. The following additional
formed on linepipe with outer diameter > 500 mm, wall thick- requirements and modifications for linepipe material and di-
ness > 8 mm, and SMYS > 360 MPa. The DWT testing shall mensional tolerances shall apply.
include testing of one set for each of the following five temper- Guidance note:
atures: -70, -50, -30, O and +20"C. If one of these temperatures
equals the minimum design temperature, the set shall be tested Strain hardening capacity is an essential parameter for pipes
which are to be exposed to large plastic strain, ref. e.g. Section
10°C below this temperature. Two additional sets shall be test- 12K 400.
ed at the minimum design temperature. Each set shall consist
of two specimens taken from the same test coupon. The test The requirements of supplementary requirement P are hence of-
ten hard to meet for matenal grades with SMYS exceeding 415
shall be performed in accordance with Appendix B. The spec- MPa.
imens tested at the minimum design temperature shall as a
minimum, meet an average of 85% shear area with one mini-
mum value of 75%.
303 The dimensional tolerances should meet supplementary
205 For linepipe material with SMYS 2 450 MPa and a wall requirements for enhanced dimensional requirements for line-
thickness 2 25 mm, the acceptance criteria stated in 204 (aver- pipe (D) in D 400.
age and minimum shear area) may be subject to agreement
when supplementary requirements for sour service (D 100) are 304 The finished pipe is recommended to meet the following
specified concurrently with supplementary requirements for requirements prior to being tested according to 305:
fracture arrest (D 200).
~ the measured yield stress of base material should not ex-
Duplex stainless steel linepipe ceed SMYS by more than 100 MPa,
206 A Charpy V-notch transition curve shall be established ~ the YS/TS ratio should not exceed 0.85, and
for duplex stainless steel base material. Five sets of specimens ~ the elongation should be minimum 25%.
shall be tested in the temperature range from - 80 OC to +20 OC.
The Charpy V-notch energy value in the transverse direction, 305 Mechanical testing shall be performed on samples re-
at the Tmin,shall be according to Table 6-6. moved from finished pipe. The samples shall be successively
Cludílined steel linepipe deformed by uni-axial tension and compression, in steps corre-
sponding to those of the installation process. % shall be at least
207 For cladlined steel linepipe, the requirements as for C- equal to the introduced during installation and service. The
Mn steels apply to the base material. 3
samples shall e artificially aged at 250°C for one hour before
testing. The testing shall be conducted in accordance with Ap-
D 300 Supplementary requirement, linepipe for plastic pendix B.
deformation (P)
306 The testing shall include:
301 Supplementary requirement (P) is only applicable for
seamless linepipe material made of C-Mn and duplex stainless ~ tensile testing,
steels, exposed to an accumulated plastic strain from installa- hardness testing, and
tion and operation, % 2 2% (see Section 5D 800 and Section
~
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Page56 - Sec.6
manufacturer and manufacturing location of raw material oxygen decarburisation before casting.
andor plate for welded pipes; 403 For steel to be used for linepipe meeting the supplemen-
raw material scrap content including allowable variation; tary requirement for sour service (see D loo), special attention
steelmaking process, casting process, alloying practice, to impurities and inclusion shape control shall be required. De-
rolling or working condition and heat treatment, including tails of the inclusion shape control treatment shall be given in
target values and proposed allowable variation in process the MPS.
parameters;
target values for chemical composition, including a critical 404 Before undergoing plate/strip/pipe forming, the slabdin-
combination of intended elements and proposed allowable gots shall be inspected and fulfil the surface finish require-
variation from target values; ments specified in the MPS.
pipe forming process;
alignment and joint design for welding and production E 500 Manufacture of plate and strip
WPS (see Appendix C); Manufacturing
fiial heat treatment condition;
method for cold expansiodsizing/finishing, target and 501 All manufacturing of plate and strip shall be performed
maximum sizing ratio; following the sequence of activities and within the agreed al-
NDT procedures; lowable variations of the qualified MPS. The manufacturing
pressure test pro cedures; practice and the instrumentation used to ensure proper control
list of specified mechanical and corrosion testing; of the manufacturing process variables and their tolerances
dimensional control procedures; shall be described in the MPS.
pipe number allocation; 502 The following requirements shall apply for the manufac-
pipe tracking procedure; turing:
marking, coating and protection procedures;
handling, loading and shipping procedures, and the mill shall have proper control of start and finish rolling
reference to applicable supplementary requirements (see temperature, rolling reduction and post-rolling cooling
B 200). rate (i.e. accelerated cooling);
~ plate and strip thickness shall be controlled by continuous-
303 The MPS shall be subject to agreement. ly operating devices;
Manufacturing Procedure Qualification Test (MPQT) ~ heat treatment shall be controlled by temperature measur-
304 The MPS shall be qualified for each pipe size. Each ing devices;
MPQT shall include full qualification of two pipes from two ~ plate and strip edges shall be cut back sufficiently after
different lots (see 809). The minimum type and extent of rolling, to ensure freedom from defects; and
chemical, mechanical, and non-destructive testing are given in ~ strip end welds shall not be permitted unless specifically
Table 6-11, Table 6-12 andTable 6-13, and the acceptance cri- agreed.
teria for qualification of the MPS are given in this section.
Testing shall be performed as described in Appendix B and Non-destructive testing
Appendix D. 503 The following NDT shall be performed either at the
305 Qualification of welding procedures shall be performed plate/strip mill, or at the pipe mill:
in accordance with Appendix C.
full ultrasonic testing of plate and strip, or pipe body, for
--```,,`,`,,,`,,````,````,`,```-`-`,,`,,`,`,,`---
306 For C-Mn steels with SMYS 2 450 MPa, duplex stain- laminar imperfections;
less steels and cladlined steels the qualification of the MPS ~ full ultrasonic testing of clad plate, or clad pipe body, for
should be completed prior to start of production. Qualification laminar imperfections and lack of bonding;
during first day of production is performed at Manufacturer's ~ full ultrasonic testing of the edges of plate/strip covering
own risk. at least a 50 mm wide band on the inside of future weld
307 Additional testing may be required (e.g. weldability test- preparations.
ing, analysis for trace elements for steel made from scrap, etc.)
as part of the qualification of the MPS. The ultrasonic testing shall meet the requirements of Appendix
D. All NDT shall be performed after final heat treatment of the
308 The validity of the qualification of the MPS shall be lim-
ited to the steelmaking, rolling, and manufacturing /fabrication plate or strip.
facilities where the qualification was performed. Workmanship, visual examination and repair of defects
309 If one or more tests in the qualification of the MPS fail 504 Plates and strip shall be subject to 100% visual examina-
to meet the requirements, the MPS shall be reviewed and mod- tion on both sides. The inspection shall be performed in a suf-
ified as necessary, and a complete re-qualification performed. ficiently illuminated area (approximately 500 lx) by trained
310 For C-Mn steels with SMYS < 450 MPa that are not in- personnel with sufficient visual acuity (e.g. Jaegar J-w eye-
tended for sour service, relevant documentation may be agreed sight test at 300 mm within the last 12 months). The surface
in lieu of qualification testing. finish produced by the manufacturing process, shall ensure that
surface imperfections can be detected by visual inspection.
E 400 Steel making 505 The surface finish produced by the manufacturing proc-
401 All steel making shall be performed using the raw mate- ess, shall ensure that surface imperfections can be detected by
rials stated in the qualified MPS, follow the same activity se- visual inspection. Cracks, notches and gouges are not accepta-
quence, and stay within the agreed allowable variations. The ble. Other imperfections such as scabs, seams, laps, tears, sliv-
manufacturing practice and instrumentation used to ensure ers, impressed mill scale etc. shall only be acceptable if not
proper control of the manufacturing process variables and their exceeding 2% of the nominal wall thickness, with a maximum
tolerances shall be described in the MPS. of 0.5 mm. The actual remaining wall thickness shall be above
the minimum allowable wall thickness (Table 6-14, Table 6-15
402 All steels shall be made by an electric or one of the basic
oxygen processes. C-Mn steel shall be fully killed and made to as applicable). Surface defects shall not appear over large are-
a fine grain practice. Details and follow-up of limiting macro, as.
as well as micro, segregation shall be given in the MPS. Du- 506 Surface defects in the plate or strip may be removed by
plex stainless steel shall be refined by argon oxygen or vacuum local manual grinding provided that:
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~ the wall thickness is not in any position reduced to a value 605 Cladlined steel linepipe shall be supplied in the heat
below the minimum allowed, and never more than 3 mm; treatment condition which is appropriate for both types of ma-
and terial. The heat treatment shall be in line with the steel Manu-
~ the sum of all ground areas does not exceed 10% of the to- facturer's recommendations.
tal surface area of each plate or strip. Cold expansion and cold sizing
507 Grinding by the use of automatic equipment may be per- 606 The extent of cold sizing and cold forming expressed as
formed subject to agreement. the sizing ratio s,., shall be calculated according to the follow-
ing formula:
508 Grinding may introduce cold working and hardnesses
incompatible with the service requirements for plate and strip
intended to meet the supplementary requirements for sour
service (see D 100). In such cases hardness testing may be re-
quired in order to permit grinding. Da is the outside diameter after sizing
509 Repair of plate and strip by welding is not permitted. Db is the outside diameter before sizing
Mechanical testing of clad steel plate and striy Traceability
510 Clad steel plate and strip shall be tested according to, 607 A system for traceability of the heat number, heat treat-
and meet the requirements given in, C 500. ment batch, lot number and test unit number of the starting ma-
terial and the records from all required tests to each individual
E 600 Linepipe manufacture pipe shall be established and described in the MPS. Care shall
be exercised during storage and handling to preserve the iden-
601 Manufacturing of linepipe shall be performed using the tification of materials.
starting materials specified, following the sequence of activi-
ties, and within the agreed allowable variations and the essen- Manufacture of seamless piye
tial variables of the qualified WPS (see Appendix C). Jointers 608 The manufacturing practice and the instrumentation
should not be permitted. used to ensure proper control of the manufacturing process
Processes of manufacture variables and their tolerances shall be described in the MPS:
602 Manufacture of linepipe shall be in accordance with one ~ wall thickness shall be controlled by continuously operat-
of the processes given in A 400. ing devices;
Starting material and supply conditions ~ pipe ends shall be cut back sufficiently after rolling to en-
sure freedom from defects; and
603 Linepipe in C-Mn steel for Tmin5 +5"C shall be manu- ~ pipes may be sized to their final dimensions by expansion
factured using the starting materials and corresponding form- or reduction. This shall not produce excessive permanent
ing methods and final heat treatment as given in Table 6-10.
strain. In cases of cold sizing, where no further heat treat-
604 Duplex stainless steel pipe shall be delivered in solution- ment is performed, the sizing ratio, s,. shall not exceed
annealed and water-quenched condition. 0.015.
Manufacture of weldedpipe ~ plate and strip shall be cut to the required width and the
weld bevel prepared by milling or other agreed methods
609 Welding procedures, welding personnel, handling of before forming;
welding consumables and the execution and quality assurance ~ cold forming (i,e, below 2 5 0 0 ~ OfC-Mn
) steel shall not in-
of welding, shall meet the requirements of Appendix C. troduce a plastic deformation exceeding 5% for clad and
C-Mn steels, unless heat treatment is performed or strain
610 The manufacturing practice forming, ageing tests show acceptable results (see C, 106);
and heat treatment, and the methods used to control manufac- ~ normalised forming of materials and weldments shall be
turing process variables and their tolerances, shall be described performed as recommended by the Manufacturers of the
in the MPS. The following requirements apply: plate/strip and welding consumables;
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run-on and run-off tabs shall be of sufficient length such and the tests required for production testing are denoted "P".
that the welding arcs are stabilised before the welding pool Testing of other materials than those listed in Table 6-1 1 and
enters the pipe material, and the entire welding pool has Table 6-12 shall be subject to agreement, however, the testing
left the pipe material before stop of welding; should, as a minimum incorporate the testing stated in these ta-
high-frequency welded pipes should not contain strip end bles.
welds;
Mechanical and corrosion testing
spiral welded pipes should not contain strip weld connec-
tions; 805 Mechanical testing during manufacturing shall be per-
the strip width for spiral welded pipes, should not be less formed on one randomly selected pipe from each lot, (see 809)
than 0.8 and not more than 3.0 times the pipe diameter; or once per 50 pipes, whatever gives the highest testing fre-
arc stops during welding shall be repaired according to a quency. This number of pipes is denoted; "test unit".
qualified welding repair procedure; 806 HPIC testing during manufacturing shall be performed
cold expansion for SAWL pipe should be within the range on one randomly selected pipe from each of the three (3) fiist
0.003 < s, 5 0.015. Expansion shall not introduce high lo- heats, or until three consecutive heats have shown acceptable
cal deformations; test results.
HFW and SAWH pipes may be sized to their fiial dimen-
sions by expansion or reduction. This shall not produce ex- After three consecutive heats have shown acceptable test re-
cessive permanent strain. In cases of cold sizing, where no sults, the testing frequency for the subsequent production may
further heat treatment or only heat treatment of the weld be reduced to one per casting sequence. The Ca/S ratio shall be
area is performed, the sizing ratio, s,, shall not exceed greater than 1.5 (see Table 6-1).
0.015;
807 If any of the tests during the subsequent testing fail (one
welded clad steel linepipe shall be formed, welded and test per casting sequence), three pipes from three different
heat treated as recommended by the starting material Man- heats of the last ten heats, selecting the heats with the lowest
ufacturer; Ca/S ratio, shall be tested. Providing these three tests show ac-
heat treatment shall be performed as recommended by the ceptable results, the ten heats are acceptable. However, if any
material Manufacturer with regard to heating and cooling of these three tests fail, then all the ten heats shall be tested.
rates, soaking time, and soaking temperature; Further, one pipe from every heat following the initially failed
the outside andor internal weld bead shall be ground flush heat shall be tested until the test results from three consecutive
to an agreed length at both pipe ends. heats have been found acceptable. After three consecutive
heats have shown acceptable test results, the testing frequency
E 700 Chemical analysis may again be reduced to one test per casting sequence.
701 Product analysis during manufacture shall, as a mini-
mum, be performed on one randomly selected plate/pipe from 808 In order to accept or reject a particular heat, re-testing
each lot (see 809) or once per 100 platedpipes, whatever gives shall be conducted in accordance with 8 11 to 8 15.
the highest test frequency. 809 A 'lot' is defined as pipes from:
702 Methods and procedures for chemical analysis shall be
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I ~~~~~i~~
I I IC-Mn
Steel
Duplex
Steel
Clad/
lined
Steel
Tensile tests
Charpy V-notch test
Weldability tests 3, Q Q
Q&P
Q&P
Q&P
Q&P
Q
Q&P2)
Q&P2)
1) All testing shall be performed in accordance with the requirements of 6) See C.512 andC.513.
Appendix B 7) Not applicable for materials meeting all Supplementary Requirements
2) Test of base material and weld metal. for sour service in D 1OO.
3) Acceptance criteria are different for sour and ordinary service. E 900 Non-destructive testing
4) Only when cold forming during pipe manufacture of C-Mn and clad/
lined steels exceeds 5% strain (see C.106). General
5) Test shall be performed unless otherwise agreed (ref. C600). 901 Linepipe shall be subjected to non-destructive testing
6) See C.308/C.309,and C.404. (NDT). Requirements for personnel, methods, equipment, pro-
7) SeeC.512 andC.513. cedures and acceptance criteria for NDT are given in Appendix
8) Not applicable for materials meeting all supplementary requirements D.
for sour service in D 1OO.
902 When automatedNDT equipment is used, a short area at
9) HFW, EBW and LBW pipes, only.
both pipe ends may not be tested. The untested ends may either
be cut off or the ends subjected to NDT, as detailed in Appen-
dix E. The extent of untested ends and description of the tech-
nique, sensitivity and parameters used for testing of the pipe
ends shall be included in the MPS.
903 NDT of linepipe shall be performed after completion of
all cold straightening, forming, heat treatment and expansion.
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Type and extent of non-destructive testing 905 If deviations from the requirements are found, the extent
904 NDT for qualification ofthe MPS and during production Of testing shall be increased as agreed until a COnSiStent Com-
shall be carried out according to Table 6- 13. pliance to the given requirements is re-established.
E 1000 Visual inspection, workmanship and correction of by visual inspection. Cracks, notches and gouges are not ac-
defects ceptable. Other imperfections such as scabs, seams, laps, tears,
Visual inspection slivers, impressed mill scale etc. shall only be acceptable if not
exceeding 2% of the nominal wall thickness, and with a maxi-
1001 Each linepipe shall be subject to 100% visual inspec- mum of 0.5 mm. The acceptance limit for surface imperfec-
tion of the outside of the pipe body.
tions on seamless pipes is 5% of the nominal wall thickness.
1002 For pipe with an internal diameter (ID) 2 610 mm, the The actual remaining wall thickness shall be above the mini-
interior of the pipe shall be 100% visually inspected. For pipe mum allowable wall thickness (Table 6-14, Table 6-15 as ap-
with an ID < 610 mm, the interior shall be inspected from both plicable). Surface defects shall not appear over large areas.
ends as far as access permits. Boroscopes or similar devices
should be used to extend the access. The interior of duplex 1005 The pipe surface of cold-formed welded linepipe shall
stainless steel and cladlined material should be 100% visual have an even curvature without "flats" along the longitudinal/
inspected. spiral weld seam, local thinning, steps and wavy edges. Dents,
1003 The inspection shall be performed after heat treatment, offset at plate edges, and out-of-line weld bead shall not ex-
expansion and final shaping, and in a sufficiently illuminated ceed the limits given in Appendix D.
area (approximately 500 lx) by trained personnel with suffi- 1006 Irregularities in the pipe curvature of cold-formed
cient visual acuity (e.g. Jaegar J-w eyesight test at 300 mm
within the last 12 months). welded linepipe that may be caused by uneven hardness distri-
bution shall be investigated to determine the hardness and di-
Workmanshiy mensions of the area. Any hard spot exceeding 50 mm in any
1004 The surface finish produced by the manufacturing direction shall not have a hardness exceeding values given in
process shall ensure that surface imperfections can be detected Table 6-3, Table 6-6 as relevant.
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Page62 - Sec.6
for 10% of the specified tests. All other results shall be record- measured internally (when access permits) and externally, us-
ed for 100% of the specified tests. ing a gauge with the correct curvature according to the speci-
Diameter ofpipe ends andpiye body fied nominal diameter. The distance between pipe body and
the correct curvature shall be measured. Dial type gauges may
1204 The actual diameter of pipe ends and body shall be cal- be used subject to agreement.
culated based on circumferential measurements taken within
100 mm from each pipe end and for the pipe body, at the loca- Wu11 thickness at pipe end andpiye body
tions given in Table 6-14 or Table 6-15 as relevant. Unless oth- 1208 The wall thickness shall be measured with a mechani-
erwise agreed, the diameter tolerance shall relate to the inside cal calliper or calibrated non-destructive testing device. Meas-
diameter for pipe ends and outside diameter for pipe body. A urements for seamless pipe shall be taken in the same positions
circumferential tape or calliper gauge can be used. External as specified in 1206. For welded pipe three measurements shall
measurements shall be corrected by using the actual wall thick- be taken; on both sides of the weld immediately adjacent to the
ness. weld, and directly opposite to the weld.
Out-ofroundness for piye ends and piye body Straightness
1205 The out-of-roundness for pipe ends shall be calculated 1209 Straightness measurements shall be taken using a taut
by the following formula: string or wire from end to end along the pipe measuring the
greatest deviation or by other equivalent methods.
Preparation ofpipe ends and end squareness.
where 1210 Pipe ends shall be cut square and shall be free from
burrs. The out of squareness shall be measured. End prepara-
O = out-of-roundness in inm tions shall meet the specified dimensions and tolerances.
Dmax = the largest measured inside or outside diameter Radial ofset (High-Low)
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Dmin = the smallest measured inside or outside diameter 1211 The radial offset shall be measured at regular intervals
along the length of the pipe. If radial offset is equal to or ex-
Unless otherwise agreed, out-of-roundness values shall relate ceeds the acceptance criterion, the entire length of the pipe
to the inside diameter for pipe ends, and to outside diameter for shall be accurately measured.
pipe body.
Weight
1206 The largest and smallest inside diameters shall be
measured at a minimum of four equally spaced positions 1212 Each pipe/pipe bundle shall be weighed separately and
around the circumference. Pipe end measurements shall be tak- the weight recorded.
en in the same cross-sectional plane, within 100 mm from the Length
pipe end. Body measurements shall be taken in the same cross-
sectional plan, approximately in the middle of the pipe length. 1213 The length of each pipe shall be measured and record-
ed. The individual length and the average length of the deliv-
Local out-ofroundness. ered pipes shall meet the specified dimensions and tolerances,
1207 Local out-of-roundness, dents and peaking, shall be as given in the purchase order.
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S e c 6 - Page63
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4) Dimensions of pipe body to be measured approximately in the middle of the pipe length.
5) To be measured as a distance from a template with the same OD as the pipe and with a length of OD/4, m a . 200mm
6) 100% means testing of every pipe.
7) t m n ~=
" actual measured minimum wall thickness of each measured pipe.
8) tnlin = specified minimum wall thickness.
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Offshore Standard DNV-OS-FI 01, January 2000
Sec.7 - Page65
SECTION 7
COMPONENTS AND ASSEMBLIES
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Offshore Standard DNV-OS-FI 01, January 2000
Page66 - Sec.7
tests, and manufacturers shall be considered in each case. The may be used provided electrical continuity is verified by meas-
consideration shall take into account the complexity and criti- urements.
cality of the product to be supplied, and the requirements of Cadmium plating shall not be used.
this standard.
406 If other bolting materials are required for corrosion re-
B 300 Flanged and mechanical connections sistance or other reasons, the material shall be selected in ac-
301 Flanges shall meet the requirements of IS0 7005-1 or cordance with the material selection requirements of the
another recognised code. standard. For subsea applications, Inconel 625 (UNS N06625)
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shall be used when corrosion resistant bolts and nuts are re-
302 The flange bore should match the internal diameter of quired at ambient temperature, i.e. when bolts are exposed to
adjoining pipe. aerated seawater and cathodic protection cannot be ensured. It
303 Flanges of proprietary design, including swivel joint shall be verified that the materials have acceptable mechanical
flanges and hub type pipeline joints, shall be designed accord- properties at the minimum and maximum design temperature.
ing to relevant sections of pressure vessel codes such as ASME 407 Proprietary bolting materials may be used for CRA pipe-
VI11 or BS5500. Additional calculations may be required to lines. It shall be verified that the materials have acceptable me-
demonstrate that the requirements of 102, 103 and 104 are met. chanical properties at the minimum and maximum design
304 The sealing faces of flanges shall have a surface finish, temperature, and are tested for compatibility with cathodic
hardness and roughness suitable for the gaskets to be applied. protection systems.
305 Gaskets shall be capable of withstanding the maximum B 500 Valves
pressure to which they could be subjected, as well as installa-
tion forces if flanges are laid in-line with the pipeline. Gaskets 501 Valves shall meet the requirements of IS0 14313, API
for flanges shall be made from metallic materials that are re- 6D or equivalent codes or standards. Additional calculations
sistant to the fluid to be transported in the pipeline system. Gal- may be required to demonstrate that the requirements of 102,
vanic corrosion shall be avoided. Mechanical properties shall 103 and 104 are met.
be maintained at the anticipated in service pressures and tem- 502 The design shall ensure that internal gaskets are able to
peratures. seal, and shall include a documented safety margin which is
306 Seals shall be designed to allow testing without pressu- valid during all relevant pipeline operating conditions. Sealing
rising the pipeline. will be sensitive to internal deflections, enlargement of gaps
and changes in their support conditions. Valve operation will
307 For guidance for design of couplings (sleeve type cou- be sensitive to friction and clearances.
plings) reference is made to DNV RP-F104, "Submarine Piye-
line Couplings". The principles of this RP may also be applied 503 Consideration should be given to requirements for dura-
to clamps. bility when exposed to abrasive material (e.g. weld scale, sand
etc.) or to fire loads.
308 Specifications for the tools required to install and make-
up the components shall be established. 504 Valves with requirements for fire durability shall be
qualified by applicable fire tests. Reference may be made to
B 400 Bolting API 6FA and BS 6755 Part 2 for test procedures.
401 Bolts and nuts for subsea use shall be in accordance with 505 Valve control systems and actuators shall be designed
Table 7-2. Equivalent standards may be used subject to agree- and manufactured in accordance with recognised standards.
ment. The valve actuator specification should define torque require-
ments for valve operation, with a suitable safety margin to ac-
Table 7-2 Bolts and nuts for subsea use commodate deterioration and friction increase during service.
Bolt I Nut I Size range B 600 Pressure vessels
ASTM A320,
Grade L7 II
ASTM Al 94, Grade 4lS3 (Low-
temuerature reauirement for
Grade 4 and Grade 7 nuts)
I <50mm 601 Pressure vessels such as pig traps and slug catchers shall
be designed in accordance with ASME VIII, BS 5500 or equiv-
ASTM A320. I ASTM A194. Grade 7 I <1ûûmm alent standard.
Grade L43 602 The design of closures and items such as nozzle rein-
forcements, saddle supports, vent- kick and drain branches
402 Bolts and nuts for use in above water and onshore com- shall comply with the applied design standard.
ponents shall be in accordance with Table 7-3. Equivalent
standards may be used, subject to agreement. 603 Closures shall be designed such that the closure cannot
be opened while the pig trap is pressurised. An interlock ar-
I Table 7-3 Bolts and nuts for use above water/onshore. rangement with the main pipeline valve should be provided.
Bolt Nut Size B 700 Components fabricated by welding
range
ASTM A193. Grade B7 ASTM A194. Grade 2H All 701 The design of components fabricated by welding of
plate shall be in accordance with industry recognised engineer-
I ASTM A193, Grade B16 I
ASTM A194, Grade 7 IAll I ing practices. Where such components cannot be designed in
403 Bolts and nuts for bolts with diameter 25mm and above accordance with this standard, the design shall be in accord-
shall be impact tested to the same requirements as for the steel ance with ASME VIII, BS 5500 or equivalent standards. Addi-
to be bolted. tional calculations may be required to demonstrate that the
requirements of 102, 103 and 104 are met.
404 The hardness of bolts in carbon steel and/or low alloy
material shall be less than 350HV10. B 800 Insulating joints
405 Carbon steel and/or low alloy bolting material shall be 801 Prefabricated insulating joints shall be designed in ac-
hot dip galvanised or have similar corrosion protection. For cordance with ASME VIII, BS 5500 or equivalent standards.
submerged applications or when bolting torque is specified, Additional calculations may be required to demonstrate that
electrolytic galvanising or phosphating shall be used. Hot dip the requirements of B102, B103 and B104 are met.
and electrolytic galvanising shall be followed by post-baking. 802 The insulating and spacing materials shall be resistant to
For subsea use, polytetrafluorethylene (PTFE) based coatings the fluid transported in the pipeline system. Mechanical prop-
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erties shall be maintained at the anticipated in service pressures 907 Steel socket welding fittings shall not be used.
and temperatures.
B 1000 Anchor flanges
803 Insulating joints shall be pressure tested at a constant
temperature as follows: 1001 Anchor flanges shall be designed for pressure contain-
ment according to ASME VIII, BS 5500 or equivalent stand-
~ hydrostatic test to 1.50 x design pressure with a holding ards.
time of minimum 2 hours; and 1002 Additional calculations may be required to demon-
~ hydraulic fatigue test consisting of 40 consecutive cycles strate that the requirements of 102 and 103 are met.
with the pressure changed from about lobar to 85% of the
hydrostatic test pressure. At the completion of the test cy- B 1100 Other components
cles the pressure shall be increased to the hydrostatic test
pressure and maintained for 30 minutes. 1101 System components which are not specifically covered
in this subsection shall be demonstrated as fit for purpose as
804 No pressure drops are allowed during hydrostatic test- stated in B 100.
ing, and no leaks are allowed during the tests.
B 1200 Structural items
805 After having passed the pressure tests, the joint shall be
dried with hot air and tested to confirm electrical discontinuity 1201 Structural items such as support and protective struc-
with the joint in the vertical position as follows: tures that are not welded onto pressurised parts are considered
as structural elements. See Section 5G.
~ electrical resistance test, and 1202 Structural items acting as a pressure containing part of
~ dielectric strength test the pipeline system shall meet the requirements for the section
of the pipeline system where they shall be located.
806 The electrical resistance test shall give a resistance of at
least 5 M o h s at 1000 V of applied continuous current. If the 1203 Structural items shall not be welded directly to pressure
joint shows electrical resistance below the required value it containing parts or linepipe. Supports, attachments etc. shall be
shall be dried again and re-tested. One re-test only shall be al- welded to a doubler plate or ring.
lowed. 1204 Girth welds shall not be inaccessible under doubler
807 The dielectric strength test shall be performed by apply- rings, clamps or other parts of supports.
ing an AC sinusoidal current with a frequency of 50 - 60 Hz to 1205 Permanent doubler plates and rings shall be made from
the joint. The current shall be applied gradually, starting from a material satissling the requirements of the pressure contain-
an initial value not exceeding 1.2kV increasing to 2.5kV in a ing parts. Doubler rings shall be made as fully encircling
time not longer than 10 seconds and shall be maintained at sleeves with the longitudinal welds made with backing strips,
peak value for 60 seconds. The test is acceptable if no break- and avoiding penetration into the pressure containing material.
down of the insulation or surface arcing occurs during the test. Other welds shall be continuous, as small as possible, and
made in a manner to minimise the risk of root cracking and la-
B 900 Pipeline fittings mellar tearing.
901 Tees shall be of the extruded outlet, integral reinforce-
ment type. The design shall be according to ASME B31.4,
B3 1.8 or equivalent. Additional calculations may be required
to demonstrate that the requirements of 102 and 103 are met. C. Material and Manufacturing Specifications
902 Bars of barred tees should not be welded directly to the for Components
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maximum forces that can occur in the pipeline, both under weldments shall be suitable for the specific application and op-
installation and operation and the requirements of 102 and erational requirements of the pipeline system.
103.
106 Suitable allowances for possible degradation of the me-
906 End caps for permanent use shall be designed according chanical properties of a material, e.g. as a result of subsequent
to ASME VIII, BS 5500 or equivalent standards. fabrication activities, should be included in the specification.
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Manufacture and Testing mising macro and micro segregation, and shall be Ca or rare
107 The specification shall state the: earth inclusion shape treated.
109 Requirements for SSC and HIPC testing are given in
type and extent of destructive and non-destructive testing; Appendix B.
test acceptance criteria; and
extent and type of documentation, records and certifica- 110 Plate material shall be 100% ultrasonic tested in accord-
tion which shall be applied for verification of the material ance with Appendix D, subsection F.
properties. 111 Requirements for material properties shall be fulfilled in
the fiial condition, i.e. in the finished components. Materials
108 Where additional requirements beyond those of the ref- for auxiliary items such as guide bars etc. shall be made from
erenced code/standard are needed to achieve the mechanical a material satisfiing the requirements to chemical composi-
properties, these shall also be detailed in the specification. tion, mechanical properties and documentation of pressure
containing parts.
D 200 Components made of low alloy C-Mn steel
D. Material for Hot Formed, Forged and Cast
Components 201 These requirements are applicable to forged, hot formed
and cast components made of low alloyed C-Mn steel with
D 100 General SMYS up to 555 MPa. Use of higher strength materials shall
be subject to agreement.
101 The materials should comply with internationally recog-
nised standards, provided that such standards have acceptable 202 The steel shall be fully killed and made to a fiie grain
equivalence to the requirements given in Section 6 and this melting practice. The material shall be produced by using the:
section. Modification of the chemical composition given in
such standards may be necessary to obtain sufficient weldabil- ~ basic oxygen furnace,
ity, hardenability, strength, ductility, toughness and corrosion ~ electric arc furnace,
resistance. ~ vacuum arc re-melting furnace (VAR), or
~ an electroslag re-melting furnace (ESR) followed by vac-
Sour Service uum degassing.
102 For components in pipeline systems to be used for fluids
containing hydrogen sulphide and defiied as "sourservice" ac- Chemical composition
cording to NACE Standard MRO175 (Sulphide Stress Crack- 203 The chemical composition, taken from the product anal-
ing Resistant Metallic Materials for Oil Field Equipment), all ysis, of material for hot-formed components, castings and
requirements to materials selection, maximum hardness, and forgings, shall not exceed the values given in Table 7-4. The
manufacturing and fabrication procedures given in the latest notes given in Table 7-5 shall apply, except Note 9 and Note
edition of the above standard shall apply. This includes pipe- 10.
lines that are nominally dry (i.e. free from liquid water during
normal operation) if other conditions for sour service accord- 204 The maximum Carbon Equivalent (CE) shall not exceed
ing to the above standard are valid. Further, the additional re- 0.52, when calculated in accordance with:
quirements, modifications and clarifications defiied below
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207 The chemical composition shall be agreed prior to start 1000°C. Adequate temperature control shall be performed and
of production. the component shall be allowed to cool in still air.
Mechanical properties 103 For duplex stainless steel material, the hot forming shall
208 Tensile, hardness and Charpy V-notch properties shall be conducted within the temperature range 1000 -1 150°C.
meet the requirements given in Table 6-3 and Table 6-4. E 200 Forging
209 Mechanical testing shall be performed after heat treat- 201 Forging shall be performed in general compliance with
ment. The testing shall be performed in accordance with Ap- ASTM A694. Each forged product shall be hot worked as far
pendix B and F 700. as practicable, to the final size and shape with a minimum re-
210 For materials with a thickness > 40 mm the impact test duction ratio of 4: 1.
temperature and the energy absorption requirements shall be 202 Weld repair of forgings shall not be permitted.
specially considered. Increasing thickness will require lower
test temperatures. Alternatively, higher energy absorption at E300 Casting
the same test temperature should be required. The energy ab-
sorption shall not in any case be lower than required in Table 301 Casting shall be performed in general compliance with
6-3, nor shall impact testing be performed at temperatures ASTM A352.
higher than the minimum design temperature. 302 A casting shall be made from a single heat and as a sin-
211 Requirements for fracture toughness testing of the base gle unit.
material and weld metal shall be considered for material thick- 303 Castings may be repaired by grinding to a depth of max-
ness > 50 mm. The measured fracture toughness should, as a imum 10% of the actual wall thickness, provided that the wall
minimum, be a CTOD value of O. 15 mm at the minimum de- thickness in no place is below the minimum designed wall
sign temperature. thickness. The ground areas shall merge smoothly with the sur-
212 Ductility, also in the thickness direction, shall be ade- rounding material.
quate for the part in question, taking manufacturing and serv- 304 Defects deeper than those allowed by 303 may be re-
ice conditions into consideration. Through thickness tensile paired by welding. The maximum extent of repair welding
testing may be required. should not exceed 20% of the total surface area. Excavations
213 For design temperatures above 50"C, the actual yield for welding shall be ground smooth and uniform and shall be
stress at the maximum design temperature shall comply with suitably shaped to allow good access for welding.
the requirements stated in Section 5B 600. 305 All repair welding shall be performed by qualified weld-
ers and according to qualified welding procedures.
D 300 Components made of ferritic-austenitic (duplex)
steel, other stainless steel and nickel based corrosion E 400 Heat treatment
resistant alloy (CRA) 401 Heat treatment procedures shall be prepared and agreed
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301 All requirements with regard to chemical composition, prior to start of heat treatment.
mechanical properties and supplementary requirements (when 402 Heat treatment procedures shall as a minimum contain
applicable) for 22Cr and 25Cr duplex stainless steel, austenitic the following information:
and martensitic stainless steel and other CRAs shall be in ac-
cordance with Section 6. heating facilities;
302 For components made of duplex stainless steel, other fumace (if applicable);
stainless steels or nickel based corrosion resistant alloys insulation(if applicable);
( C U ) intended for seawater service, corrosion testing shall be measuring and recording equipment, both for fumace con-
conducted in accordance with Section 6C.308 and Section trol and recording of component temperature;
6C.404 as relevant. calibration intervals;
fixtures and loading conditions;
D 400 Delivery condition heating and cooling rates;
401 Forgings and hot formed components in low alloy steel temperature gradients;
shall be delivered in the normalised or in the quenched and soaking temperature range and time;
tempered condition. maximum time required for moving the component from
the fumace to the quench tank (if applicable),
402 Castings in low alloy steel shall be delivered in the ho- cooling rates (conditions);
mogenised, normalised and stress relieved or in the homoge- type of quenchant (if applicable); and
nised, quenched and tempered condition. start and end maximum temperature of the quenchant (if
403 Duplex steel components shall be delivered in the solu- applicable).
tion annealed and water quenched condition.
403 Components should be rough machined to near final di-
404 For component material delivered in the quenched and mensions prior to heat treatment
tempered condition the tempering temperature shall be suffi-
ciently high to allow effective post weld heat treatment during 404 The fumace temperature shall be controlled to within I
later manufacture / installation. 10°C and thermocouples shall be attached to each component
during the entire heat treatment cycle.
405 For components which are to be water quenched, the
time from removal of components from the oven until they are
E. Hot Forming, Forging, Casting and Heat immersed in the quenchant shall not exceed 90 seconds for C-
Treatment Mn and low alloy steel, and 60 seconds for duplex stainless
steels.
E 100 Hot forming 406 The water shall be heavily agitated, preferably by cross
101 Hot forming shall be performed to the agreed procedure flow to ensure rapid, adequate quenching. The start and end
according to the guidance given in G 500 temperature of the quenching water shall be recorded and shall
102 Hot forming, including extrusion of branches in low al- not exceed 40°C.
loy steel, shall be done within a temperature range of 800 - 407 The heat treatment equipment shall be calibrated at least
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once a year in order to ensure acceptable temperature stability ~ production process control procedures;
and uniformity. ~ welding procedures;
~ heat treatment procedures;
~ NDT procedures;
pressure test procedures;
F. Manufacturing of Components, Equipment
~
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F 400 Manufacture of pressure-containing equipment by random selection of components of the same type and
and components fabricated by welding form, from the same heat and heat treatment batch.
401 Pressure-containing equipment such as pig traps, slug All mechanical testing shall be conducted after final heat treat-
catchers, and components fabricated by welding of plates shall ment.
be manufactured, inspected, tested and documented in accord-
ance with: 702 The material thickness and forging reduction for inte-
grated test coupons shall be representative of the actual com-
~ recognised practices, ponent.
~ the requirements of this standard, 703 Separate test coupons should not be used but may be al-
~ the requirements the referenced design standard, and lowed subject to agreement, provided that they are heat treated
~ the material and manufacturing specification. simultaneously with the material they represent, and the mate-
rial thickness, forging reduction, and mass are representative
The specified starting materials and the methods and proce- of the actual component.
dures agreed and qualified for the manufacture shall be used.
704 A simulated heat treatment of the test piece shall be per-
402 Hydrostatic testing shall be performed as required in the formed if welds between the component and other items such
referenced design standard, except that the holding time shall as linepipe are to be post weld heat treated at a later stage or if
be minimum 2 hours if a shorter time is specified by the refer- any other heat treatment is intended.
enced design standard.
705 One component from each lot (i.e. components of the
F 500 Manufacture of other equipment and components same size, type and form from each heat or heat treatment
batch, whichever occurs more frequently) shall be tested as
501 Other components and equipment, such as insulating follows:
joints, mechanical connectors, tees and Y-pieces and other fit-
tings and components fabricated by hot forming of plate, shall ~ two tensile specimens taken from the base material in the
be manufactured inspected, tested and documented in accord- transverse direction at 1/3 thickness;
ance with: ~ two sets of Charpy V-notch specimens taken in the trans-
verse direction at each location 2 mm below the inner and
~ recognised practices, outer surface, and two sets of specimens from the same lo-
the requirements of this standard,
cation as the tensile specimens. The notch shall be perpen-
~
~ the material and manufacturing specification. ~ metallographic samples taken from the same location as
The specified starting materials and the methods and proce- the Charpy V-notch specimens and at 1/3T, 1/2T and 2/3T.
dures agreed and qualified for the manufacture, shall be used. A minimum of 3 hardness measurements shall be taken on
each sample. The 1/3T and 2/3T specimens shall include
502 Pressure containing components shall be subject to hy- the nearest surface "as is" after the heat treatment (not ma-
drostatic testing unless such testing is impracticable. The test chined).
pressure shall be 1.50 times the design pressure, and the hold-
ing time shall be 2 hours. If the applied design code requires 706 The distance from the edge of the test piece to the near-
higher pressures or a longer holding time, then the more strin- est edge of any specimen shall not be less that 1/3 of the thick-
ness. For welded components, the testing shall also include
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gent requirements shall apply.
testing of the welds in accordance with Appendix C.
503 The hydrostatic test pressure shall be recorded during
the test using equipment with calibration certificates not older 707 Samples for corrosion testing shall be taken such that the
than one year. No pressure drops or leaks are allowed during surface exposed to the corrosive medium will be tested.
hydrostatic testing. 708 The mechanical properties shall meet the specified re-
504 Insulating joints shall be tested as detailed in B 800. quirements. The reduction of area shall be at least 35%. For
heavy wall components with SMYS > 420 MPa, a higher duc-
505 Qualification testing of sleeve type couplings and tility level should be required.
clamps for the particular pipeline dimensions, dimensional tol-
erances and surface finish shall be performed according to 709 The hardness of the accessible surfaces of the compo-
agreed procedures. nent shall be tested. The testing shall be sufficient to establish
the efficiency of the heat treatment. The hardness for compo-
F 600 Fabrication of structural items nents intended for non-sour service shall not exceed the re-
601 Structural items shall be fabricated, inspected, tested and quirements given in Table 6-3 for C-Mn and low alloy steel
documented in accordance with: and Table 6-6 for duplex steels.
For components intended for sour service the hardness shall be
~ recognised practices, in accordance with Section 6D 100.
~ the requirements of this standard,
~ the requirements of the referenced design standard, and
~ the material and manufacturing specification.
G Manufacture of Bends
The specified materials and the methods and procedures
agreed and qualified for the fabrication shall be used. G100 General
F 700 Mechanical testing of hot formed, cast and forged 101 The Manufacturer shall develop a Manufacturing Proce-
dure Specification.
components
Manufacturing Procedure Specification (MPS)
701 Testing of the mechanical properties of components af-
ter hot forming, casting or forging shall be performed on a test 102 Before production commences the Manufacturer shall
material taken from: prepare an MPS. The MPS shall demonstrate how the specified
properties may be achieved and verified through the proposed
~ a prolongation of the component; manufacturing route. The MPS shall address all factors which
~ an integrated test coupons, that is removed from the com- influence the quality and reliability of production. All main
ponent after final heat treatment; or manufacturing steps from control of received material to ship-
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Offshore Standard DNV-OS-FI 01, January 2000
Page72 - Sec.7
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ment of the finished product(s), including all examination and 108 Bends may be made from spare sections of normal line-
check points, shall be covered in detail. References to the pro- pipe. It should be noted that "normal" linepipe, particularly
cedures and acceptance criteria established for the execution of pipe manufactured from TMCP plate, may not have adequate
all steps shall be included. hardenability to achieve the required mechanical properties af-
103 The MPS shall as a minimum contain the following in- ter hot or induction bending and subsequent post bending heat
formation: treatment.
109 Hot expanded mother pipe may experience dimensional
~ plan(s) and process flow descriptioddiagram; instability after post bending heat treatment.
~ project specific quality plan;
~ bending process used 110 Mother pipe and other pipe for use in bend shall meet all
~ supply of material; manufacturer and manufacturing loca- applicable requirements given in Section 6. Waiving of the
tion of material; mill pressure test according to Section 6E. 1108 is not applica-
~ bending process control procedures; ble.
~ heat treatment procedures; Mechanical properties of mother pipe
~ NDT procedures;
~ list of specified mechanical and corrosion testing; 111 Mother pipe made of C-Mn steels and duplex stainless
~ dimensional control procedures; steels shall, as a minimum, comply with the requirements for
~ marking, coating and protection procedures; and linepipe and the Supplementary Requirements (as applicable)
~ handling, loading and shipping procedures. given in Section 6.
112 Hardness requirements for C-Mn steels and duplex
104 Materials for use in factory-made bends shall be selected stainless steels shall be in accordance with Section 6C.205 and
taking into account the chemical composition and the influ- 306 respectively.
ence of the manufacturing method upon mechanical proper-
ties, dimensions and wall thickness. 113 Chemical composition of motherpipe
105 Induction bending is the preferred method for manufac- 114 The chemical composition of C-Mn steel mother pipe
ture of bends. shall be in accordance with Table 7-5. The chemical composi-
tion for duplex steel mother pipe shall be in accordance with
106 Bends may be made from dedicated straight lengths of Table 6-5 in Section 6.
pipe without girth welds (mother pipe), that are hot, cold or in-
duction bent, or from forgings. Mitre or wrinkle bends are not Metallographic examination of mother pipe in duplex steel
permitted. 115 Metallographic examination of dedicated mother pipe in
107 Mother pipe in C-Mn steels shall be delivered in the nor- duplex stainless steels shall be performed in accordance with
malised, quenched and tempered or TMCP condition. Section 6C.304 and 305, and Appendix B.
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Sec.7 - Page73
Chemical composition applies for wall thicknesses up to 45 mm and shall be subject to agreement for larger wall thicknesses.
When scrap material is being used in steel production, the amount of the following residual elements shall be determined and reported, and the levels shall
not exceed: 0.03% As, 0.01% Sb, 0.02% Sn, 0.01% Pb, 0.01% Bi and 0.005% Ca.
Except for deoxidation elements, other elements than those mentioned in this table shall not be intentionally added if not specifically agreed
For each reduction of 0.01% carbon below the maximum specified value, an increase of 0.05% manganese above the specified maximum values is per-
mitted with a maximum increase of 0.1%.
0.5 -1.0% CI may be used subject to agreement.
A1:N 2 2: 1 (not applicable for titanium killed steels)
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(Nb+V+Ti)% maxinlum : 0.12% This value may be increased to maximum 0.15% subject to agreement.
Boron (max 30 ppm) may be added subject to agreement.
Mn C r + M o + V , C u + N i
CE = C + - +
6 5 15
Pcm =
Si
c+-+
Mn + C u + C r + E + m+ y+ 5 B
30 20 60 15 10
G 200 Mother pipe for seawater sewice G 500 Required post bending heat treatment
201 For dedicated mother pipe in duplex stainless steels, oth- 501 Post bending heat treatment of induction bends made of
er stainless steels or nickel based corrosion resistant alloys C-Mn steels, duplex stainless steels, other stainless steels (ex-
( C U ) intended for seawater service, corrosion testing shall be cept martensitic) and nickel based corrosion resistant alloys is
conducted in accordance with Section 6 C308 and 404 as rele- required if the test material after bending does not comply with
vant. the requirements to the mother pipe. The heat treatment shall
G 300 Supplementary requirements to mother pipe
be according to an agreed procedure proposed by the bend
Manufacturer. A bending procedure, including post bending
Supplementary requirement, sour service (S) heat treatment, shall be qualified according to G 500.
301 In general all the requirements given in Sec.6 D100 shall 502 Bends made of forged low alloy steels shall be quenched
apply. The chemical composition of pipe for bends shall com- and tempered, or normalised, subsequent to forging.
ply with Table 6-7 and Table 6-8 as relevant.
503 Bends made of martensitic stainless steels shall be heat
302 Subject to agreement the corrosion testing may be per- treated after hot forming and induction bending, according to
formed on the mother pipe. In this case samples representing the steel Manufacturer's recommendation.
the maximum wall thickness of the bend shall be taken from
the mother pipe and heat-treated prior to corrosion testing. The 504 Bends made of cladlined material shall be heat treated
heat treatment of the test samples shall include the heat cy- after hot forming and induction bending, according to the steel
cle(s) the material is exposed to during bending, in addition to Manufacturer's recommendation.
any post bend heat treatment.
505 Bends manufactured by cold bending shall be stress re-
Supplementary requirement, fracture arrest properties (7;) lieved when the total deformation exceeds 3%. For wall thick-
303 Requirements to fracture arrest properties are not appli- nesses less than 25 mm, the total cold deformation may be
cable to bends. increased without requiring subsequent stress relieving subject
to agreement. The total deformation percentage shall be calcu-
G 400 Requirements to pipe other than dedicated lated in percentage by using the following equation:
mother pipe
401 In situations where dedicated mother pipes are not avail- %Deformation = (2' tmax
tmax
) x 100
able for manufacturing of bends, the factors given in G100 and +
G200, especially G108, should be considered in order to select ,,t = Maximum pipe wall thickness
the most appropriate pipe for bend manufacturing. r = Deformation radius
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Offshore Standard DNV-OS-FI 01, January 2000
Page74 - Sec.7
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~
602 The bending procedure shall be qualified by mechanical Macro, micro and hardness testing:
and non-destructive testing, visual inspection and dimensional ~ Two full wall macro sections of the weld, taken parallel to
control. If agreed the qualification of the bending procedure the longitudinal axis of the bend, shall be removed from
may be attempted without post bending heat treatment for C- the stop and start transition areas (total 2 samples);
Mn steels, duplex stainless steels, other stainless steels (except ~ For duplex steel, other stainless steels and nickel based
martensitic) and nickel based corrosion resistant alloys. corrosion resistant alloys the specified macro sections
603 Testing for qualification of the bending procedure shall shall be substituted by micro section of the weld in order
include the testing as required in 604 to 610. to conduct full metallographic examination.
Bends from seamless pipe Applicable to all bends
604 For bends manufactured from seamless pipes the extent 606 Tensile test specimens shall be taken from the middle of
of tensile and Charpy V-notch impact testing shall be as fol- the material thickness. Charpy V-notch impact test specimens
lows: shall be taken 2 mm below the inner surface and macro/micro
Tensile testing: specimens shall represent the full material thickness.
base material in the arc inner radius longitudinal and trans- 607 For bends where the stop and start transition zones and
verse (total 2 specimens), the tangent length are not retained in the delivered bend, me-
base material in the arc outer radius longitudinal and trans- chanical testing in these areas is not required.
verse (total 2 specimens), 608 The requirements for tensile Charpy V-notch and hard-
base material in the start transition area inner radius longi- ness testing shall be in accordance with Section 6 Table 6-3
tudinal and transverse (total 2 specimens), and Table 6-4 for C-Mn steels, and Table 6-6 for duplex steels.
base material in the start transition area outer radius longi- For duplex steel, other stainless steels and nickel based corro-
tudinal and transverse (total 2 specimens), and sion resistant alloys the metallography shall meet the require-
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Offshore Standard DNV-OS-FI 01, January 2000
Sec.7 - Page75
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ments given in Section 6C.305. bend and at both neutral axis as far as access permits. The hard-
609 For supplementary requirement S, the required testing ness for bends intended for non-sour service shall not exceed
shall be performed in accordance with Section 6. the requirements given in Section 6 Table 6-3 for C-Mn and
low alloy steel and Table 6-6 for duplex steels.
610 If the test results do not meet the specified requirements
to mother pipe, the bending procedure shall be re-qualified in- 810 After end preparation the complete end preparation and
cluding a full post bending heat treatment. 1OOmm of the weld seam withmagnetic particles for ferromag-
netic pipe or with liquid penetrant for non-magnetic pipe.
G 700 Bending and post bend heat treatment 811 Final NDT, including dimensional check, shall be per-
701 Before bending the wall thickness shall be measured on formed after post bending heat treatment.
each length of pipe.
G 900 Production testing of bends
702 If the bending operation is interrupted during hot or in-
duction bending, the bend subject to interruption shall be re- 901 During production, one bend of the heaviest wall thick-
jected. ness for each diameter produced within each lot shall be sub-
ject to mechanical testing.
703 The longitudinal weld of welded pipe shall be in the neu-
tral axis during bending. 902 Testing of induction bent bends may be performed pro-
longations of the pipe that have been subject to the same tem-
704 Bending shall be performed in accordance with qualified perature cycle(s) as the bent areas of pipe.
procedures and established essential variables. The tempera-
ture during induction and hot bending shall be controlled with- 903 Testing of the start transition areas are not required for
in I 15°C using an optical pyrometer. The temperature data bends that have been given a full heat treatment restoring the
shall be recorded for each bend. The bending equipment shall microstructure.
be calibrated at least once a year in order to ensure acceptable 904 For bends made from pipe with outside diameter less
temperature stability and uniformity. than 300 mm testing is required in the longitudinal direction
705 Post bend heat treatment shall be performed according only.
to E 400. Bends from seamless piye
706 A minimum of one thermocouple shall be attached to a 905 For bends manufactured from seamless pipes the extent
minimum of one bend per heat treatment batch. For compo- of mechanical testing shall be as follows:
nents to be quenched and tempered (Q/T), the temperature of
the quenching medium shall be recorded during the quenching Tensile testing:
operation. ~ Base material in the arc outer radius longitudinal and
G 800 Non-destructive testing and visual inspection transverse (total 2 specimens)
~ Base material in the start transition area outer radius lon-
801 Requirements for NDT personnel, NDT equipment, gitudinal and transverse (total 2 specimens) unless 903 is
methods, procedures and acceptance criteria are given in Ap- applicable.
pendix D.
802 Bends shall be blast cleaned to IS0 8501, SA21/2 to re- Charpy V-notch impact testing:
move scale from the bend area prior to visual inspection and
non-destructive testing ~ Base material in the arc outer radius longitudinal and
transverse (total 2 sets)
803 Provided that the material has been 100% ultrasonic ~ Base material in the start transition area outer radius lon-
tested for laminar imperfections as plate or pipe, the following gitudinal and transverse (total 2 sets) unless 903 is appli-
testing shall be performed on each bend: cable.
804 100% visual examination of external and accessible
parts of internal surfaces. The bends shall be free from gouges, Macro, micro and hardness testing:
dents, grooves, wrinkles, bulges, kinks and surface spalling. One full wall macro section, taken parallel to the longitu-
Cracks are not permitted.
~
dinal axis of the bend, shall be removed from the inner and
805 Minor buckles in the bend inside radius profile will be outer radii and from start transition area (unless 603 is ap-
acceptable if the height and depth of the buckle does not ex- plicable)
ceed 1% of the nominal internal diameter and the length to ~ For duplex steel, other stainless steels and nickel based
depth ratio is greater than 12:1. The distance between accepta- corrosion resistant alloys the specified macro sections
ble minor buckles in the bend inside radius profile shall be shall be substituted by micro section in order to conduct
greater than one nominal internal diameter. full metallographic examination.
806 100% radiographic or ultrasonic testing of the weld in ~ Hardness testing shall be performed on the macro and mi-
the arc and transition zones + the end 250 mm of the tangent if cro sections according to Appendix B.
not tested on the mother pipe prior to bending.
Bends from weldedpipe
807 100% magnetic particle testing over an arc of 90" both
sides of the extrados for ferromagnetic pipe, or 100% testing 906 For bends manufactured from welded nines the follow-
with liquid penetrant + 100% ultrasonic testing over the same ing testing shall be performed in addition to ih'e testing speci-
area for non-ferromagnetic pipe, in order to ver@ freedom fied in 905:
from transverse defects. Tensile testing:
808 Ultrasonic wall thickness measurements taken around
the circumference at the inside and outside radius of the bend ~ Cross weld tensile testing in the arc area (one specimen)
and at both neutral axes at a spacing of 150 mm along the entire ~ Cross weld tensile testing in the start transition area (one
length of the bend. The wall thickness shall not be below the specimen) unless 903 is applicable
specified minimum at any of these locations.
Charpy V-notch impact testing:
809 The hardness of the exterior surface of the bend shall be
tested at the locations given in 808. The hardness of the interior Weld metal, FL, FL + 2 mm and FL + 5 mm in the arc (4
surface shall be tested at the inside and outside radius of the sets)
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Offshore Standard DNV-OS-FI 01, January 2000
Page76 - Sec.7
Weld metal in the start transition area (1 set) unless 903 is H. Fabrication of Risers, Expansion Loops, Pipe
applicable. Strings for Reeling and Towing
Macro, micro and hardness testing: H100 General
~ One full wall transverse macro section of the weld, shall 101 The following requirements are applicable for the fabri-
be removed from the bend area and one from the start tran- cation of risers, expansion loops, pipe strings etc. in C-Mn, du-
sition area (unless 903 is applicable). plex stainless, and clad/lined steel.
~ For duplex steel, other stainless steels and nickel based 102 The fabrication shall be performed according to a speci-
corrosion resistant alloys the specified macro sections fication giving the requirements for fabrication methods, pro-
shall be substituted by micro section of the weld in order cedures, the extent of testing, acceptance criteria and required
to conduct full metallographic examination. documentation. The specification shall be subject to agreement
prior to start of production.
Applicable to all bends
H 200 Quality Assurance
907 Tensile test specimens shall be taken from the middle of
the material thickness. Charpy V-notch impact test specimens 201 Requirements to Quality Assurance given in Section 2B
shall be taken 2 mm below the inner surface and macro speci- 500 shall be applied.
mens shall represent the full material thickness.
H 300 Materials for risers, expansion loops, pipe strings
908 For bends where the transition zones and the tangent for reeling and towing
length are not retained in the delivered bend, mechanical test-
Piye material
ing in these areas is not required.
301 Pipe made of C-Mn steels and duplex stainless steels
909 The requirements for tensile, Charpy V-notch and hard- shall, as a minimum, comply with the requirements for line-
ness testing shall be in accordance with Section 6 Table 6-3 for pipe, including supplementary requirements (as applicable)
C-Mn steels, and Table 6-4 for duplex steels. For duplex steel, given in Section 6.
other stainless steels and nickel based corrosion resistant al-
loys the metallography shall meet the requirements given in 302 In addition, pipe used in pipe strings for reeling shall, as
Section 6C.304. a minimum, comply with supplementary requirement P given
in Section 6.
G 1000 Dimensions, tolerances and marking 303 Use of higher strength material shall be subject to agree-
1001 Dimensions and tolerances at bend ends shall be com- ment.
patible with the adjoining pipe. Use of straight tangent lengths Guidance note:
equal to one diameter is recommended. Ovality of cross sec- For steel with S M Y S > 485 m a , it may be necessary to conduct
tions shall be kept within the specified tolerances, and the bend Post Weld Heat Treatment (PWHT) of the weld zone in order to
radius shall be large enough (e.g. 5 x outer diameter) to allow achieve the required hardness level and mechanical properties.
passage of inspection vehicles when relevant.
1002 Dimensional control shall include: . .
Forged and cast material
ID at bend ends; 304 Forged and cast material shall as a minimum meet the re-
OD for bend body at inner and outer radii and both neutral quirements given in D of this section.
axis;
passing of gauge consisting of two aluminium plates of di- H 400 Fabrication procedures and planning
ameter 96% of nominal ID and fixed rigidly at a distance 401 Before production commences, the fabricator shall pre-
of 1.5 x ID; pare a Manufacturing Procedure Specification.
out-of-roundness of bend ends: maximum 1.5% and of Manufacturing Procedure Specification (MPS)
body maximum 3%;
402 The MPS shall demonstrate how the fabrication will be
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outer bend radius, measured as the deviation from the
specified radius to (the bend centre line + 1/2 OD) I 1%, performed and verified through the proposed Fabrication
max 25 mm; steps. The MPS shall address all factors which influence the
the radius of bend curvature within I 1% max I 12.7 mm; quality and reliability of production. All main fabrication steps
the included angle between the centrelines if the straight from control of received material to shipment of the fiiished
portions of the bend within I0.75"; product(s), including all examination and check points, shall
be covered in detail. References to the procedures and accept-
lineadplane straightness: the specified bend angle divided ance criteria established for the execution of all steps shall be
by 90" x 10 mm, max 10 mm; included.
location of weld seam; and
end squareness angle within I 0.5", maximum 3 mm. 403 The MPS shall contain the following information:
~ plan(s) and process flow descriptionkhagrarn;
1003 Bends shall be marked as required in Section 6F 100. ~ project specific quality plan;
G 1100 Repair ~ fabrication processes used;
~ supply of material, i.e. manufacturer and manufacturing
1101 Welding repair of the bend base material is not permit- location of material;
ted. ~ fabrication process control procedures;
welding procedures;
1102 Any welding repair of longitudinal weld seams shall be
~
NDT procedures;
ified welding procedure and shall be subject to the NDT re-
~
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Sec.7 - Page77
404 The MPS shall be subject to agreement. cedures, welding consumables, welding personnel, handling of
405 Due consideration shall be given to the access and time welding consumables and fabrication shall meet the require-
required for adequate inspection and testing as fabrication pro- ments of Appendix C.
ceeds. H 700 Hydrostatic testing
406 During fabrication of pipe strings for reeling and towing, 701 Hydrostatic testing shall be performed if specified.
the sequence of pipes included in the pipe string should be con-
trolled such that variations in stiffness on both sides of welds 702 The extent of the section to be tested shall be shown on
are minimised. This may be achieved by matching as closely drawings or sketches. The limits of the test, temporary blind
as possible the wall thickness / diameter of the pipes on both flanges, end closures and the location and elevation of test in-
sides of the weld. struments and equipment shall be shown. The elevation of the
test instruments shall serve as a reference for the test pressure.
407 Due consideration during fabrication shall be given to
the control of weight and buoyancy distribution of pipe strings 703 End closures and other temporary testing equipment
for towing. shall be designed, fabricated, and tested to withstand the max-
imum test pressure, and in accordance with a recognised code.
408 The procedures prepared by the fabricator shall be sub-
ject to agreement. 704 Testing should not be performed against in-line valves,
unless possible leakage and damage to the valve is considered,
H 500 Material receipt, identification and tracking and the valve is designed and tested for the pressure test con-
501 All material shall be inspected for damage upon arrival. dition. Blocking off or removal of small-bore branches and in-
Quantities and identification of the material shall be verified. strument tappings should be considered in order to avoid
Damaged items shall be clearly marked, segregated and dis- possible contamination. Considerations shall be given to pre-
posed of properly. filling valve body cavities with an inert liquid unless the valves
have provisions for pressure equalisation across the valve
502 Pipes shall be inspected for loose material, debris, and seats. All valves shall be fully open during filling.
other contamination, and shall be cleaned internally before be-
ing added to the assembly. The cleaning method shall not 705 Welds shall not be coated, painted or covered. Thin
cause damage to any internal coating. primer coatings may be used where agreed.
503 A system for ensuring correct installation of materials 706 Instruments and test equipment used for measurement of
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and their traceability to the material certificates shall be estab- pressure, volume, and temperature shall be calibrated for accu-
lished. The identification of material shall be preserved during racy, repeatability, and sensitivity. All instruments and test
handling, storage and all fabrication activities. equipment shall possess valid calibration certificates with
traceability to reference standards within the 6 months preced-
504 A pipe tracking system shall be used to maintain records ing the test. If the instruments and test equipment have been in
of weld numbers, NDT, pipe numbers, pipe lengths, bends, cu- frequent use, they should be calibrated specifically for the test.
mulative length, anode installation, in-line assemblies and re-
pair numbers. The system shall be capable of detecting 707 Gauges and recorders shall be checked for correct fùnc-
duplicate records. tion immediately before each test. All test equipment shall be
located in a safe position outside the test boundary area.
505 The individual pipes of pipe strings shall be marked in
accordance with the established pipe tracking system using a 708 The following requirements apply for instruments and
suitable marine paint. The location, size and colour of the test equipment:
marking shall be suitable for reading by ROV during installa-
tion. It may be required to mark a band on top of the pipe string Testers shall have a range of minimum 1.25 times the
to ver@ if any rotation has occurred during installation. specified test pressure, with an accuracy better than I O. 1
bar and a sensitivity better than 0.05 bar.
506 If damaged pipes or other items are replaced, the se- ~ Temperature-measuring instruments and recorders shall
quential marking shall be maintained. have an accuracy better than I 1.0"C.
~ Pressure and temperature recorders are to be used to pro-
H 600 Cutting, forming, assembly, welding and heat vide a graphical record of the pressure test for the total du-
treatment ration of the test.
601 The Contractor shall be capable of producing welded
joints of the required quality. This may include welding of 709 Calculations showing the effect of temperature changes
girth welds, other welds, overlay welding and post weld heat on the test pressure shall be developed and accepted prior to
treatment. Relevant documentation of the Contractor's capabil- starting the test. Temperature measuring devices, if used, shall
ities shall be available if requested by the Purchaser. be positioned close to the pipeline and the distance between the
devices shall be based on temperature gradients along the pipe-
602 Attention shall be paid to local effects on material prop- line route.
erties and carbon contamination by thermal cutting. Preheating
of the area to be cut may be required. Carbon contamination 710 The test medium should be fresh water or inhibited sea
shall be removed by grinding off the affected material. water.
603 Forming of material shall be according to agreed proce- 711 During pressurisation the pressure shall be increased at
dures speciSling the successive steps. a steady rate up to 95% of the test pressure. The last 5% up to
604 The fabrication and welding sequence shall be such that the test pressure shall be raised by a linear diminishing rate
the amount of shrinkage, distortion and residual stress is mini- down to 0.5 bar per minute. Time shall be allowed for confi-
mised. mation of temperature and pressure stabilisation before the test
hold period begins.
605 Members to be welded shall be brought into correct
alignment and held in position by clamps, other suitable devic- 712 The test pressure requirement for system pressure tests
is given in Section 5D.204.
es, or tack welds, until welding has progressed to a stage where
the holding devices or tack welds can be removed without dan- 713 The holding time at test pressure shall be 6 hours.
ger of distortion, shrinkage or cracking. Suitable allowances 714 The pressure shall be recorded during pressurisation,
shall be made for distortion and shrinkage where appropriate. stabilisation and hold periods. Temperatures and pressure shall
606 Welding procedures shall be qualified and welding pro- be recorded at least every 10 minutes during the hold period.
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Offshore Standard DNV-OS-FI 01, January 2000
Page78 - Sec.7
715 During testing, all welds, flanges, mechanical connec- to establish conformance with the required dimensions and tol-
tors etc. under pressure shall be visually inspected for leaks. erances.
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716 The pressure test shall be acceptable if there are no ob- 902 Dimensional verification of pipe strings for towing shall
served leaks or pressure drop. A pressure variation up to include weight, and the distribution of weight and buoyancy.
I 1.0% of the test pressure is normally acceptable provided
that the total variation can be demonstrated as caused by tem- H 1000 Corrosion protection
perature fluctuations, or otherwise accounted for. If greater
pressure variations are observed, the holding period shall be Application of coatings and installation of anodes shall meet
extended until a hold period with acceptable pressure varia- the requirements of Section 8.
tions has occurred.
717 Documentation produced in connection with the pres-
sure testing of the pipeline system shall include: I. Documentation, Records, Certification and
Test drawings or sketches, Marking
pressure and temperature recorder charts,
log of pressure and temperatures, I 100 Documentation, records, certification and mark-
calibration certificates for instruments and test equipment,
and 101 All base material, fittings and, flanges, etc. shall be de-
calculation of Pressure and temperature relationship and livered with Inspection Certificate 3.1.B according to Europe-
justification for acceptance. an Standard EN 10204 or accepted equivalent.
H 800 Non-destructive testing and visual examination 102 The inspection certificate shall include:
801 All welds shall be subject to: ~ identification the products covered by the certificate with
~ 100% visual inspection; and reference to heat number, heat treatment batch etc.;
~ 100% radiographic or ultrasonic testing, (automated ultra- ~ dimensions and weights of products;
sonic testing should be preferred for girth welds). ~ the results (or reference to the results) of all specified in-
spections and tests; and
802 Guidance on applicable and preferred NDT methods is ~ the supply condition and the temperature of the fiial heat
given in Appendix D, A 400. treatment.
803 Requirements to automated ultrasonic testing of girth
welds are given in Appendix E. 103 Each equipment or component item shall be adequately
and uniquely marked for identification. The marking shall, as
804 If allowable defect sizes are based on an ECA, ultrasonic a minimum, provide correlation of the product with the related
testing, preferably automated ultrasonic testing is required. inspection documentation.
805 All NDT shall be performed after completion of all cold
forming, heat treatment and hydrostatic testing. 104 The marking shall be such that it easily will be identi-
fied, and retained during the subsequent activities.
806 Requirements for personnel, methods, equipment, pro-
cedures, and acceptance criteria, for NDT are given in Appen- 105 Other markings required for identification may be re-
dix D. quired.
106 Equipment and components shall be adequately protect-
H 900 Dimensional verification ed from harmfùl deterioration from the time of manufacture
901 Dimensional verification should be performed in order until taken into use.
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Offshore Standard DNV-OS-FI 01, January 2000
Sec.8 - Page79
SECTION 8
CORROSION PROTECTION AND WEIGHT COATING
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Offshore Standard DNV-OS-FI 01, January 2000
Page80 - Sec.8
by permeability for water, dissolved gases and salts, adhe- frequency of inspection, testing and calibrations, and accept-
sion, freedom from pores, etc; ance criteria. Reference shall be made to applicable specifica-
resistance to physical, chemical and biological degrada- tions and procedures for inspection, testing and calibrations.
tion, primarily in service but also during storage prior to Handling of non-conforming coating materials and products
installation (operating temperature range and design life shall be described.
are decisive parameters);
requirements for mechanical properties during installation
and operation;
compatibility with fabrication and installation procedures, D. Special Riser Coatings
including field joint coating (see E 100) and field repairs;
D 100 General
compatibility with concrete weight coating (see F loo), if
applicable; 101 Adverse corrosive conditions occur in the zone above
compatibility with cathodic protection, and capability of lowest astronomical tide (LAT) where the riser is intermittent-
reducing current demand for cathodic protection (see G ly wetted by waves, tide and sea spray (splash zone). Particu-
loo), if applicable; larly severe corrosive conditions apply to risers heated by an
requirement for thermal insulation properties, if applica- internal fluid. In the splash zone, the riser coating may be ex-
ble; and posed to mechanical damage by surface vessels and marine op-
environmental compatibility and health hazards during erations, whilst there is limited accessibility for inspection and
coating application, fabricatiodinstallation and operation. maintenance.
102 Pipeline components shall have external coatings prefer- 102 The riser section in the atmospheric zone (i.e. above the
ably matching the properties of those to be used for linepipe. If splash zone) is more shielded from both severe weathering and
this is not practical, cathodic protection design may compen- mechanical damage. Furthermore, there is better accessibility
sate for inferior properties. However, risks associated with hy- for inspection and maintenance.
drogen induced cracking by cathodic protection shall be duly 103 In the submerged zone and in the splash zone below the
considered (see Section 5B.507). lowest astronomical tide (LAT), an adequately designed ca-
103 Coating properties (functional requirements) which ap- thodic protection system is capable of preventing corrosion at
ply for the coated pipes shall be defined in a purchase specifi- any damaged areas of the riser coating. In the tidal zone, ca-
cation. The following properties may be specified as thodic protection will be marginally effective.
applicable: 104 For a specific riser, the division into corrosion protection
maximum and minimum thickness, zones is dependent on the particular riser or platform design
density, and the prevailing environmental conditions. The upper and
adhesion, lower limits of the splash zone may be determined according
to the definitions in Section 1.
tensile properties,
impact resistance, 105 Different coating systems may be applied in the three
cathodic disbondment resistance, corrosion protection zones defined above, provided they are
flexibility, compatible. The considerations according to a), b), c), I), g)
thermal resistance or conductivity, and h) in C. 101 above apply for all of the three zones.
abrasion resistance Guidance note:
electrical resistance, and Fastening devices for risers are normally selected to be compati-
resistance to hydrostatic pressure ble with a specific riser coating rather than vice versa.
cutbacks.
Project specific requirements to quality control shall be de-
scribed. 106 The following additional considerations apply in the
splash and atmospheric zones:
104 DNV RP-F106 gives detailed requirements and recom-
mendations to manufacturing of linepipe coatings, including ~ resistance to under-rusting at coating defects,
inspection and testing associated with quality control. ~ maintainability,
~ compatibility with inspection procedures for internal a n d
C 200 Coating materials, surface preparation and appli- or external corrosion,
cation ~ compatibility with equipment/procedures for removal of
201 The coating Manufacturer shall be capable of document- biofouling (if applicable), and
ing their ability to produce coatings meeting specified proper- ~ fire protection (if required).
ties. A coating manufacturing qualification should be executed
and accepted by Purchaser before starting the coating work, es- 107 Use of a corrosion allowance to compensate for external
pecially for novel products where there is limited experience corrosion due to coating damage shall be duly considered in
from manufacturing. the splash zone (see B. 103 and O). The needs for, and benefits
of, a corrosion allowance depend on the type of coating, corro-
202 All coating work shall be carried out according to a qual- sive conditions, design life, consequences of damage and ac-
ified manufacturing procedure specification. The following cessibility for inspection and maintenance.
items shall be described in the coating manufacturing proce-
dure specification: 108 In the submerged zone, the considerations for selection
of coating in C. 101 apply. In addition, resistance to biofouling
~ coating materials, is relevant in surface waters of the submerged zone and the
~ surface preparation, lowermost section of the splash zone.
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~ maximum water absorption: 8% (by volume), (testing of chemical potential into the range -0.80 to - 1.1 V rel. Ag/AgCV
coated pipe according to agreed method); and seawater. Potentials more negative than - 1.1 V rel. Ag/AgCV
~ minimum density: 1900 kg/m3 (ASTM C 642). seawater can be achieved using impressed current. Such poten-
tials may cause detrimental secondary effects, including coat-
204 The concrete coating shall be reinforced by steel bars ing disbondment and hydrogen-induced (stress) cracking (or
welded to cages or by wire mesh steel. The following recom- "hydrogen embrittlement") of linepipe materials and welds.
mendations apply: For welded cages, the spacing between cir- Guidance note:
cumferential bars should be maximum 120 mm. Steel bars
should have a diameter of 6 mm minimum. The average cross Pipeline system components in C-Mn steel and ferritic, marten-
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Offshore Standard DNV-OS-FI 01, January 2000
Sec.8 - Page83
successive anodes does not exceed 150 m. (Larger distances 109 Marking of anodes shall ensure traceability to heat
should be validated taking into account electric resistance in number. Anodes should be delivered according to EN 10204,
pipeline, likelihood of damage to anodes and any contingency Inspection Certificate 3.1.B or an equivalent standard.
measures) .
H 200 Anode installation
205 For anodes clamped to the pipeline or riser, each anode
segment shall have an electrical cable for electrical continuity 201 Anode installation may be carried out onshore e.g. for
to the pipe. pipeline barge welding and for tow-out installation. For reel
laying, pipeline anodes are typically attached offshore
206 Outline anode drawings, including fastening devices,
shall be prepared for each anode type/size. Connection cables 202 Anodes shall be installed according to a procedure de-
shall be detailed where applicable. Net anode weights and di- scribing handling of anodes, installation and subsequent in-
mensional tolerances shall be specified on drawings. spection.
207 The detailed engineering documentation shall contain 203 All welding or brazing of anode fastening devices and
the following: connector cables shall be carried out according to a qualified
procedure (see Appendix C).
~ design premises, including design life and reference to rel- 204 For linepipe that is to be concrete weight coated, electri-
evant project specifications, codes, standards, etc; and cal contact between concrete reinforcement and the anodes
~ surface area and current demand calculations. shall be avoided. The gaps between the anode half shells may
be filled with asphalt mastic or similar. Any spillage of filling
In addition, design documentation for sacrificial anode sys- compound on the external anode surfaces shall be removed.
tems shall contain the following:
~ anode mass calculations,
~ anode resistance calculations, I. Design and Manufacturing/Fabricationof
anode number calculations, and
~
~ anode detailed drawings (including fastening devices and Internal Corrosion Protection
connector cables if applicable). I100 General
208 Reference is made to DNV RP B401 for design docu- 101 Most fluids for transportation in pipeline systems are po-
mentation of impressed current systems. tentially corrosive to ordinary C-Mn steel linepipe material.
102 The selection of a system for internal corrosion protec-
tion of pipelines and risers has a major effect on detailed de-
H. Manufacturing and Installation of Sacrificial sign and must therefore be evaluated during conceptual design
(see B 200 and Section 5B 500). The following options for cor-
Anodes rosion control may be considered:
H 100 Anode manufacturing a) processing of fluid for removal of liquid water andor cor-
101 Requirements to anode manufacturing, including di- rosive agents;
mensions and weight, requirements to quality control (defect b) use of linepipe or internal (metallic) lining/cladding with
tolerances, electrochemical performance during testing, etc.), intrinsic corrosion resistance;
marking and documentation shall be detailed in a purchase
specification. c) use of organic corrosion protective coatings or linings
(normally in combination with a) or d)); and
102 For each anode type/size, the Manufacturer shall prepare
a detailed drawing showing location and dimensions of anode d) chemical treatment, i.e. addition of chemicals with corro-
inserts, anode gross weight and other details as specified in sion mitigating function.
purchase documentation (see G.206). In addition, the benefits of a corrosion allowance (see B 200
103 Manufacturing of anodes shall be carried out according and O) shall be duly considered.
to a manufacturing procedure specification. General require- 103 The need for temporaiy corrosion protection of internal
ments for anode manufacturing are given in DNV-RP B40 1. surfaces during storage, transportation and flooding should be
104 A procedure for electrochemical testing of anode mate- considered. Optional techniques include end caps, rust protec-
rial performance during anode manufacturing is given in Ap- tive oil/wax, and for flooding, chemical treatment (biocide
pendix A of RP B40 1. andor oxygen scavenger).
105 Inserts to be welded to the pipe shall be made of steel Guidance note:
with adequate weldability. For stainless steel linepipe, such in- The use of a biocide for treatment of water for flooding is most
serts shall always be welded on to doubler plates of the same essential (even with short duration) as incipient bacterial growth
material as, or otherwise compatible with, the linepipe. For C- established during flooding may proceed during operation and
Mn steel inserts, the carbon equivalent or Pcm value for any cause corrosion damage. For uncoated C-Mn steel pipelines, an
doubler plates shall not exceed that specified for the pipe ma- oxygen scavenger may be omitted since oxygen dissolved in sea-
water will become rapidly consumed by uniform corrosion with-
terial. out causing significant loss of wall thickness. Film forming or
106 Detailed requirements for weight and dimensional toler- "passivating" corrosion inhibitors are not actually required and
ances are given in e.g. NACE RP 0492-92. may even be harmful.
107 All anodes shall be visually examined for cracks and
other significant defects. Requirements are given in e.g. NACE
RP 0492-92. I200 Internal corrosion protection by fluid processing
108 A quality plan shall be prepared and submitted to Pur- 201 Corrosion control by fluid processing may involve re-
chaser for acceptance. The quality plan shall d e f i e methods, moval of water from gadoil (dehydration), or of oxygen from
frequency of inspection and testing, and acceptance criteria. seawater for injection (deoxygenation), for example. Conse-
Reference shall be made to applicable procedures for inspec- quences of operational upsets on material degradation shall be
tion, testing and calibrations. --```,,`,`,,,`,,````,````,`,```-`-`,,`,,`,`,,`---
evaluated. The necessity for corrosion allowance and redun-
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dant systems for fluid processing should be considered. On- duction in dry gas pipelines ("flow coatings"). Although internal
line monitoring of fluid corrosion properties downstream of coatings can not be expected to be fully efficient in preventing
processing unit is normally required. For oil export pipelines corrosion attack if corrosive fluids are conveyed, any coating
carrying residual amounts of water, a biocide treatment should with adequate properties may still be efficient in reducing forms
of attack affecting membrane stresses and hence, the pressure re-
be considered as a back up (see I 500). taining capacity of the pipeline.
I300 Internal corrosion protection by use of linepipe in
Corrosion Resistant Alloys (CRAs)
301 The selection of corrosion resistant materials has nor- I500 Internal corrosion protection by chemical treat-
mally been preceded by an evaluation of a C-Mn steel option, ment
where the material was concluded to provide inadequate safety
andor cost effectiveness in terms of operational reliability (see 501 Chemical treatment of fluids for corrosion control may
B 200). include:
302 For the subsequent selection of corrosion resistant mate- ~ corrosion inhibitors (e.g. "film forming");
rials, the following major parameters shall be considered: ~ pH-buffering chemicals;
biocides (for mitigation of bacterial corrosion);
mechanical properties;
~
ease of fabrication, particularly weldability; and ~ glycol or methanol (added at high concentrations for hy-
internal and external corrosion resistance, in particular hate inhibition, diluting the water phase);
with respect to environmentally induced cracking. ~ dispersants (for emulsification of water in oil); and
~ scavengers (for removal of corrosive constituents at low
Guidance note: concentrations).
Procurement conditions such as availability, lead times and costs
should also be considered. 502 The reliability of chemical treatment shall be evaluated
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Offshore Standard DNV-OS-FI 01, January 2000
S e c 9 - Page85
SECTION 9
INSTALLATION
A. General tion manual shall include all factors that influence the quality
and reliabilitv of the installation work. includinp normal and
A 100 Objective contingency Situations, and shall address all installation steps,
including examinations and check points. The manual shall re-
101 The objective of this section is to provide requirements flect the results of the FMEA analysis or HAZOP studies, and
as to which studies and documentation be pre- shall state requirements for the parameters to be controlled and
pared and agreed for the and further to provide re- the allowable range ofparameter variation during the installa-
quirements for the installation and testing of the complete
tion,
pipeline system which are not covered elsewhere in the stand-
ard. The following shall, as a minimum, be covered:
A 200 Application ~ quality system manual,
mobilisation manual,
201 This section is applicable to installation and testing of
~
construction manual,
pipelines and rigid risers designed and manufactured accord-
~
Ch.4 Sec.2.
~ materials, equipment and documents to be used;
~ how the activity is performed in order to meet specified re-
quirements; and
~ how the activity is controlled and documented.
A 400 Installation and testing specifications and draw-
ings 504 The installation manual shall be updatedírevised as
needed as installation proceeds.
401 Specifications and drawings shall be prepared covering
installation and testing of pipeline systems, risers, protective 505 The installation manuals are subject to agreement
structures etc. through:
402 The specifications and drawings shall describe, in suffi- ~ review of methods, procedures and calculations,
cient detail, requirements to installation methods and the proc- ~ review and qualification of procedures,
esses to be employed and to the fiial result of the operations. ~ qualification of vessels and equipment, and
403 The requirements shall reflect the basis for, and the re- ~ review of personnel qualifications
sults of, the design activities. The type and extent of verifica- 506 Requirements to the installation manual and acceptance
tion, testing, acceptance criteria and associated documentation are given in the various subsections. The results of the FMEA
required to verisl that the properties and integrity of the pipe- analysis or HAZOP studies (see A 300) shall also be used in
line system meet the requirements of this standard, as well as determining the extent and depth of verification of equipment
the extent and type of documentation, records and certification and procedures.
required, shall be stated.
507 In cases where variations in manner of performance of
404 Requirements to the installation manual and the extent an activity may give undesirable results, the essential variables
of tests, investigations and acceptance criteria required for and their acceptable limits shall be established.
qualification of the installation manual shall be included.
A 600 Quality Assurance
A 500 Installation Manuals
601 The installation Contractor shall as a minimum have an
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501 Installation manuals shall be prepared by the various implemented quality assurance system meeting the require-
Contractors. ments of IS0 9001/1S09002 or equivalent. Further require-
502 The installation manual is a collection of the manuals merits for quality m ~ a n c are
e given in Section 2B 500.
and procedures relevant to the specific work to be performed.
It is prepared in order to demonstrate that the methods and A 700 Welding
equipment used by the Contractor will meet the specified re- 701 Requirements for welding processes, welding procedure
quirements, and that the results can be verified. The installa- qualification, execution of welding and welding personnel are
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given in Appendix C. testing are unsatisfactory, the welding shall be suspended until
702 Requirements for mechanical and corrosion testing for the causes of the defects have been established and rectified.
qualification of welding procedures are given in Appendix B. 807 For "Golden Welds" (critical welds e.g. tie-in welds that
703 The mechanical properties and corrosion resistance of will not be subject to pressure testing, etc.) 100% ultrasonic
weldments shall at least meet the requirements given in the in- testing, 100% radiographic testing, and 100% magnetic parti-
stallation and testing specifications. cle testing or 100% liquid penetrant testing of non- erromag-
netic materials shall be performed. If the ultrasonic testing is
704 For weld repair at weld repair stations where the pipeline performed as automated ultrasonic testing, see Appendix E,
section under repair is subjected to tensile and bending stress- the radiographic and magnetic particleAiquid penetrant testing
es, a weld repair analysis shall be performed. The analysis shall may be omitted subject to agreement.
determine the maximum excavation length and depth combi-
nations that may be performed, taking into account all stresses 808 Magnetic particle testing or liquid penetrant testing of
acting at the area of the repair. The analysis shall be performed non-ferromagnetic materials shall be performed to veriSl com-
in accordance with the requirements to Engineering Criticality plete removal of defects before commencing weld repairs, and
Assessment (ECA) given in Section 5D. for 100% lamination checks at re-bevelled ends of cut pipe.
The analysis shall consider the reduction of yield and tensile 809 Visual Examination shall include:
strength in the material due to the heat input from defect exca- 100% examination of completed welds for surface flaws,
vation, preheating, and welding and also dynamic amplifica-
~
tion due to weather conditions and reduced stiffness effect at shape and dimensions;
field joints. The stresses in the remaining section shall not be ~ 100% examination of the visible pipe surface, prior to field
above 80% of SMYS. joint coating; and
~ 100% examination of completed field joint coating.
705 The weld repair analysis shall be subject to agreement.
706 The root and the fiist filler pass shall, as a minimum, be A 900 Production tests
completed at the first welding station before moving the pipe. 901 One production test is required for each Welding Proce-
Moving the pipe at an earlier stage may be permitted if an anal- dure Specification (WPS) used for welding of the pipeline
ysis is performed showing that this can be performed without girth welds.
any risk of introducing damage to the deposited weld material.
This analysis shall consider the maximum misalignment al- 902 Production tests should not be required for welding pro-
lowed, the height of the deposited weld metal, the possible cedures qualified specifically for tie-in welds, flange welds,
presence of flaws, support conditions for the pipe and any dy- Tee-piece welds etc.
namic effects. 903 Production tests may, subject to agreement, be omitted
in cases where fracture toughness testing during welding pro-
A 800 Non-destructive testing and visual examination cedure qualification is not required by this standard, or for C-
801 Requirements for methods, equipment, procedures, ac- Mn steel linepipe with SMYS < 450MPa.
ceptance criteria and the qualification and certification of per- 904 The extent of production tests shall be expanded if
sonnel for visual examination and non-destructive testing
(NDT) are given in Appendix D. ~ the Contractor has limited previous experience with the
802 Requirements to automated ultrasonic testing (AUT) are welding equipment and welding methods used,
given in Appendix E. ~ the welding inspection performed is found to be inade-
quate,
803 The extent of NDT for installation girth welds shall be severe defects occur repeatedly
100% ultrasonic or radiographic testing. It is recommended
~
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Offshore Standard DNV-OS-FI 01, January 2000
Page88 - Sec.9
other subsea installations or other pipelines or cables. ~ Class 2 for operations < 500 m away from existing instal-
303 Anchor patterns shall be according to the results of a lations and for tie-driser installation operations,
Class 3 for manned subsea operations or other operations
mooring analysis, using an agreed computer program, and
~
shall be verified to have the required capacity for the proposed where a sudden horizontal displacement of the vessel may
location, time of year and duration of operation. Distance to have fatal consequences for personnel.
other installations and the possibility to leave the site in an
502 Subject to agreement and on a case by case basis, vessels
emergency situation shall be considered. with displacement > 5000 t performing operations < 500 m
304 Station-keeping systems based on anchoring shall have away from existing installations or performing tie-driser in-
adequate redundancy or back-up systems in order to ensure stallation operations may have Class 2 provided that the con-
that other vessels and installations are not endangered by par- sequences of fire or flooding will not seriously affect the safety
tial failure. of the installation or the integrity of the pipeline.
305 Each anchor pattern shall be clearly shown on a chart of C 600 Cranes and lifting equipment
adequate scale. Care shall be taken in correlating different
chart datum, if used. 601 Cranes and lifting equipment including lifting gear, lift-
ing appliances, slings, grommets, shackles and pad-eyes, shall
306 Minimum clearances are to be specified between an an- meet applicable statutory requirements. Certificates for the
chor, its cable and any existing fixed or subsea installations or equipment, valid for the operations and conditions under
other pipelines or cables, both for normal operations and emer- which they will be used, shall be available on board for review.
gency conditions.
C 400 Positioning systems C 700 Anchor handling and tug management
401 Requirements for the positioning system and its accura- 701 Anchor handling vessels shall be equipped with:
cy for each type of vessel and application shall be specified. ~ a surface positioning system of sufficient accuracy for an-
402 The accuracy of horizontal surface positioning systems chor drops in areas within 500 m of existing installations
shall be consistent with the accuracy required for the operation and pipelines, and
and sufficient to perform survey work, placing of the pipeline, ~ computing and interfacing facilities for interfacing with
supporting structures or anchors within the specified toleranc- lay vessel, trenching vessel or other anchored vessels.
es, and to establish reference points for local positioning sys-
tems. 702 Procedures for the anchor handling shall be established,
ensuring that:
403 Installation in congested areas and work requiring pre-
cise relative location may require local systems of greater ac- anchor locations are in compliance with the anchor pattern
curacy, such as acoustic transponder array systems. Use of for the location;
ROV's to monitor the operations may also be required. requirements of owners of other installations and pipelines
404 The positioning system shall provide information relat- for anchor handling in the vicinity of the installation are
ing to: known, and communication lines established;
position prior to anchor drop is confiied;
~ position relative to the grid reference system used, anchor positions are monitored at all times, particularly in
~ geographical position, the vicinity of other installations and pipelines; and
~ offsets from given positions, and any other requirement due to the nature of the operations
~ offsets from antenna position. is fulfilled.
405 Positioning systems shall have minimum 100% redun- 703 All anchors transported over subsea installations shall be
dancy to allow for system errors or breakdown. secured on deck of the anchor handling vessel.
406 Documentation showing that positioning systems are 704 During anchor running, attention shall be paid to the an-
calibrated and capable of operating within the specified limits chor cable and the catenary of the cable, to maintain minimum
of accuracy shall be available for review prior to start of the in- clearance between the anchor cable and any subsea installa-
stallation operations. tions or obstacles.
C 500 Dynamic positioning C 800 Contingency procedures
501 Vessels using dynamic positioning systems for station 801 Contingency procedures shall be established for the ma-
keeping and location purposes shall be designed, equipped and rine operations relating to:
operated in accordance with IMO MSCK3c.645 (Guidelines
for Vessels with Dynamic Positioning Systems), or with earlier ~ work site abandonment including emergency departure of
NMD requirements for consequence class, and shall have cor- the work location and when anchors cannot be recovered,
responding class notations from a recognised classification so- ~ mooring systems failure, and
--```,,`,`,,,`,,````,````,`,```-`-`,,`,,`,`,,`---
ciety as follows: ~ any other requirement due to the nature of the operations.
Vessels > 5000 t displacement:
~ Class 1 for operations > 500 m away from existing instal-
lations, D. Pipeline Installation
~ Class 3 for operations < 500 m away from existing instal-
lations and for tie-idriser installation operations, D 100 General
~ Class 3 for manned subsea operations or other operations 101 The requirements of this subsection are generally appli-
where a sudden horizontal displacement of the vessel may cable to pipeline installation, regardless of installation method.
have fatal consequences for personnel. Additional requirements pertaining to specific installation
methods are given in the following subsections.
Vessels < 5000 t displacement:
102 Interfaces shall be established with other parties that
Class 1 for operations > 500 m away from existing instal- may be affected by the operations. The responsibilities of all
lations, parties and lines of communication shall be established.
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D 200 Installation Manual D 300 Review and qualification of the installation man-
201 The laying Contractor shall prepare an installation man- and
ual. As a minimum, the installation manual shall include all Review of methods, procedures and calculations.
documentation required to perform the installation, and shall 301 The review of methods, and calculations
demonstrate that the pipeline can be safely installed and com- shall include:
pleted to the specified requirements by use of the dedicated
spread. ~ Failure mode effect analysis,
202 The installation manual shall cover all applicable as- ~ HAZOP studies,
pects such as: ~ installation procedures,
~ contingency procedures,
spread, including modifications and upgrading, if any; ~ engineering critical assessments for girth welds,
supervisory personnel, inspectors, welders and NDT per- ~ engineering critical assessments for weld repair lengths,
sonnel; ~ other calculations made as part of the installation scope.
communications and reporting;
navigation and positioning; Review and qualijication ofprocedures
anchor handling, anchor patterns and catenary curves (if
applicable); 302 Review and qualification of procedures shall as a mini-
dynamic positioning system (if applicable); mum include:
stresdstrain and configuration monitoring, control, and re- ~ welding procedures for production and repair welding (see
cording during all phases of installation activities; Appendix C);
operating limit conditions; ~ non-destructive testing procedures and automated NDT
normal pipe-lay; equipment (see Appendix D, Appendix E);
anode installation (where applicable); ~ field joint coating and field joint coating repair proce-
piggyback pipeline saddle installation (where applicable); dures; and
piggyback pipeline installation (where applicable); ~ internal and external coating repair procedures.
pipe-lay in areas of particular concern, e.g. shipping lanes,
platforms, subsea installations, shore approach; Qualification of vessels and equiyment
vessel pull management system;
abandonment and recovery; 303 Qualification of vessels and equipment prior to start of
start-up and lay-down; work shall include:
method of buckle detection; dynamic positioning system test;
installation of in-line assemblies and equipment;
pipe handling, hauling, stacking and storage; combined review and dynamic positioning systemhen-
maintaining pipeline cleanliness during construction; sioner system tests (simulate vessel pull and tensioner fail-
pipe tracking; ures and redundancy tests during pull);
repair of damaged pipe coating; tensioner system review test (test combinations of tension-
internal coating repair; ers, testing of single tensioner failure when running two or
three tensioners, test redundancy of single tensioners, sim-
internal cleaning of pipe before and after welding; ulate main power loss and loss of signal power);
welder qualification;
welding equipment, line-up clamps, bevelling procedures, abandonment and recovery winch test (fail safe actions,
welding procedures, production welding, weld repair, simulate main power loss and loss of signal power);
welding production tests; friction clamp test (fail safe actions and test clamps during
NDT equipment, visual examination and NDT proce- vessel pull);
dures, visual examination and NDT of welds; remote operated buckle detector;
weld repair analysis extent of weld repair at repair station, pipeline support geometry;
determined by ECA (Ref. A 700); stinger configuration and control devices;
field joint coating and field joint coating repair; review of calibration records of criticaUessentia1 equip-
touchdown point monitoring; ment, including welding machines and automated NDT
pipeline repair in case of wet or dry buckle; equipment;
crossings; and review of maintenance records for criticauessential equip-
provisions for winter laying, prevention of ice build-up, ment, including welding machines and automated NDT
removal of ice, low temperature reservoirs in steel and equipment; and
concrete coating, etc. maintenance/calibration records of criticaUessentia1
equipment on support vessels.
I I I .
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changes in welding joint design and process parameters sion. The forces applied shall be controlled such that no dam-
beyond that allowed in Appendix C; age to the pipeline or coating will occur.
changes in NDT method, NDT equipment and NDT 702 The installation vessel tensioning system arrangement
equipment calibration beyond that allowed in Appendix D shall therefore be such that:
and Appendix E;
weld repair lengthddepths in areas where the pipe is sub- the tensioners, brakes and holding clamps shall be able to
ject to bending moments/axial stress. The maximum hold the pipeline throughout an accidental flooding;
lengtwdepth of excavation shall be determined by ECA the tensioning system shall have sufficient redundancy to
calculations (see A.704); prevent simultaneous breakdown of tensioners;
changes in field joint coating procedure; ~ the tensioner capacity shall have sufficient redundancy to
operating limit conditions; and allow failure of individual tensioners, without compromis-
any other requirement due to the nature of the operations. ing the pipeline integrity; and
in case of tensioner failure or failure in the tensioner sys-
307 The validity of the installation manual is limited to the
~
lay-vesseyspread where the qualification was performed and tem, the pipeline installation shall not re-start before the
to the pipeline or section of pipeline in question. system has been repaired.
D 400 Operating limit conditions 703 When applicable for the laying method, the pipeline
shall be fully supported along the length of the vessel and on
401 Operating limit conditions shall be established and to the stinger by rollers, tracks or guides that allow the pipe to
agreed. move axially. Supports shall prevent damage to coating, field
402 The operating limit conditions shall be based on stress joint coatings, anodes and in-line assemblies, and rollers shall
--```,,`,`,,,`,,````,````,`,```-`-`,,`,,`,`,,`---
and strain calculations, FMEA analysis or HAZOP study data, move freely. The vertical and horizontal adjustment of the sup-
and shall refer to objective, critical values indicated by meas- ports shall ensure a smooth transition from the vessel onto the
uring devices. The operating limit conditions shall be referred stinger, to maintain the loading on the pipeline within the spec-
to in the procedure for stredstrain and configuration control. ified limits. The support heights and spacing shall be related to
Continuous monitoring and recording of the measuring devic- a clear and easily identifiable datum. The pipeline support ge-
es required for control of the operating limit conditions shall be ometry shall be verified prior to laying, and the accepted height
performed during all phases of installation activities. and spacing of supports shall be permanently marked or other-
wise indicated.
403 Operating limit criteria may, subject to agreement, be
based on a defiied seastate for areas where dependable histor- 704 Stingers shall be adjusted to the correct configuration to
ical environmental data and regular weather forecasts are ensure a smooth transition from the vessel to the outboard
available. stinger end, and to maintain the loading on the pipeline within
the specified limits. The geometry shall be verified prior to lay-
404 Regular weather forecasts from a recognised meteoro- ing. If the stinger can be adjusted during laying operations, it
logical centre shall be available onboard the lay vessel, and shall be possible to determine the stinger position and config-
shall be supplemented by historical environmental data. uration by reference to position markings or indicators. Buoy-
405 If the critical values are about to be exceeded, prepara- ant stingers shall be equipped with indication devices showing
tions for lay-down shall commence. If the critical condition is the position of the rollers relative to the water surface.
weather dependent only, and if weather forecasts indicate that 705 A buckle detector shall be continuously pulled through
the weather condition will subside, the lay-down may be post- the pipeline during laying, unless the same degree of control in
poned subject to agreement. detection of buckles is achieved by other means. The manner
406 Decision to recover the pipeline shall be based on com- in which the same degree of control is achieved shall be docu-
parison of the actual seastate with the limiting seastate, togeth- mented. Exceptions are also when buckle detectors are not
er with weather forecasts. suitable due to the installation method, e.g. reeling, or for small
diameter pipelines, where the gap between the inner pipe wall
D 500 Installation procedures and the buckle detector disc will be very small, and contact
501 Installation procedures meeting the requirements of this with the internal weld bead can give false indications. The
standard, including all requirements of the installation and test- buckle detector shall be positioned such that the critical areas
ing specifications, shall be prepared by the Contractor for are monitored, (normally a distance after the touch down
agreement. point). The diameter of the buckle detector disc shall be chosen
with due regard to the pipeline internal diameter and tolerances
D 600 Contingency procedures on ovality, wall thickness, misalignment and internal weld
bead.
601 Contingency procedures meeting the requirements of
this standard, including all requirements of the installation and 706 The abandonment and recovery (A & R) winch should
testing specifications, shall be prepared by the Contractor for be able to recover the pipeline when waterfilled, or alternative
agreement. The contingency procedures shall at least cover: methods for recovering the pipeline should be available.
707 A sufficient amount of instrumentation and measuring
~ failure of dynamic positioning system, devices shall be installed to ensure that monitoring of essential
~ failure of tensioner system, equipment and all relevant parameters required for stresdstrain
~ failure of anchors and anchor lines, and configuration control and control of the operating limit
~ ROV breakdown, conditions can be performed.
~ breakdown of positioning system, and
~ other critical or emergency situations identified in FMEA The following instrumentation is required:
analysis or HAZOP studies. Tensioners.
D 700 Layvessel arrangement, laying equipment and ~ total pipeline tension recorders,
instrumentation ~ tension at each tensioner,
701 The tensioners shall operate in a fail-safe mode and shall ~ tensioner setting and variance to set point (dead band), and
have adequate pulling force, holding force, braking capacity indication of applied pulling, holding and squeeze pres-
and squeeze pressure to maintain the pipe under controlled ten- sure.
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~ direct or indirect indication of sagbend curvature and trol, pipeline tension and stress monitoring. The function of
strain. essential measuring devices shall be verified at regular inter-
All measuring equipment shall be calibrated and adequate doc- vals and defective or non-conforming devices shall repaired or
umentation of calibration shall be available onboard the vessel replaced.
prior to start of work. All measuring equipment used shall be 810 The buckle detector load chart, if a buckle detector is
provided with an adequate amount of spares to ensure uninter- used (see 705) shall be checked at regular intervals. The buckle
rupted operation. detector shall be retrieved and inspected if there is reason to
Essential equipment shall be provided with back-up. believe that buckling can have occurred. If the inspection
shows indications of buckling or water ingress, the situation
Direct reading and processing of records from all required es- shall be investigated and remedial action performed.
sential instrumentation and measuring devices, shall be possi-
ble at the vessels bridge. 811 The position of pipeline start up and lay-down shall be
verified as within their respective target areas prior to depar-
Correlation of recorded data and pipe numbers shall be possi- ture of the lay vessel from site, and adequate protection of
ble. pipeline and lay-down head shall be provided.
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708 Other equipment shall be available to monitor pipeline 812 Pipelaying in congested areas, in the vicinity of existing
lay down point and other operations that are critical to the in- installations and at pipeline and cable crossings, shall be car-
tegrity of the pipeline or represent a risk for fixed installations ried out using local positioning systems with specified accura-
or other subsea installations and pipelines. ROVs shall be ca- cy and appropriate anchor patterns. Measures shall be taken to
pable of operating under the seastates expected for the opera- protect existing installations, cables and pipelines from dam-
tion in question. age. Such operations and the pipeline touch down point shall
709 Other measuring and recording systems or equipment be monitored by ROV.
shall be required if they are essential for the installation oper- 813 Other critical operations such as laying in short radii
ation. curves, areas with steep slopes, use of very high or low pulling
tension values etc. shall be identified and special procedures
D 800 Requirements for installation for the operation shall be prepared.
801 Handling and storage of materials on supply and laying 814 In the event of buckling a survey of the pipeline shall be
vessels shall ensure that damage to pipe, coatings, assemblies performed before repair to establish the extent of damage and
and accessories are avoided. Slings and other equipment used feasibility of the repair procedure. After completion of the re-
shall be designed to prevent damage. Storage of pipes shall be pair, a survey shall be performed of the pipeline over a length
in racks and suitable shoring shall be used. Maximum stacking sufficient to ensure that no further damage has occurred.
heights shall be determined to avoid excessive loads on the
pipe, coating or anodes. All material shipped for installation 815 If loss or major damage to weight and corrosion coating
shall be recorded. or anodes and their cables/connectors are observed, repair shall
be performed and inspected according to established proce-
802 All material shall be inspected for damage, quantity and dures.
identification upon arrival. Damaged items shall be quaran-
tined, repaired or clearly marked and returned onshore. 816 Prior to abandonment of the pipeline, all internal equip-
ment except the buckle detector shall be removed and all
803 Pipes and in-line assemblies shall be inspected for loose welds, including the abandonment and recovery head welds,
material, debris and other contamination and cleaned internal- shall be completely filled. In the event that the cable will have
ly before being added to the line. The cleaning method shall to be released from the vessel, a buoy and pennant wire should
not cause damage to any internal coating. be attached to the abandonment and recovery head. The buoy
804 A pipe tracking system shall be used to maintain records shall be large enough to remain on the surface when exposed
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to the weight of the pennant wire, as well as any hydrodynamic ~ testing of pipe coating durability; and
loads from waves and current. ~ testing of straighteners and resulting pipe straightness.
Alternatively, seabed abandonment with a ROV friendly hook- 302 An Engineering Criticality Assessment shall be per-
ing loop may be used. Winch tension and cable lengths shall be formed as required in Section 5D 1000.
monitored, and the specified values shall not be exceeded dur-
ing the abandonment and recovery operation. 303 The characteristic strain capacity, E,, determined by an
ECA shall be validated by realistic testing of girth welded pipe,
Before recovery the pipeline shall be surveyed over a length e.g. by full scale bend testing. The extent of testing and the de-
away from the abandonment and recovery head, sufficient to tails of the test procedure are subject to agreement, but all as-
ensure that no damage has occurred. pects of significance to unstable fracture shall be considered,
817 An as-laid survey shall be performed either by continu- such as:
ous touch down point monitoring or by a dedicated vessel, and
shall, as a minimum, include the requirements given in J. mechanical material properties of linepipe and girth weld,
including weld metal overmatch and possible effects of
strain ageing;
geometric effects, e.g. on crack tip constraint, net section
E. Additional Requirements for Pipeline Instal- yielding and gross section yielding;
lation Methods Introducing Plastic Deforma- mode of loading, multiples and magnitudes of loads and
tions displacements;
strain concentration effects, such as geometric mismatch,
E 100 General material strength mismatch of adjacent pipes, weld metal
overmatch, weld toe strain concentration and coating stiff-
101 The requirements of this subsection are applicable to ness discontinuities;
pipeline installation by methods which give an accumulated defect type, location, shape and size; and
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plastic strain >2% during installation and operation when all effect of temperature on resistance to brittle fracture.
Strain Concentration Factors (SNCF) are included. The appli-
cable requirements given in D shall also be satisfied. The testing shall demonstrate, conservatively, that possible
102 The specific problems associated with these installation weld defects will not result in unstable fracture during pipe lay-
methods shall be addressed in the installation and testing spec- ing, and will not extend by stable crack growth beyond a size
ifications. that is acceptable with respect to fatigue and unstable fracture
in the operational phase.
103 Pipes used for such installation methods shall meet the
supplementary requirement, pipe for plastic deformation (P), 304 Bending tests on pipe coating shall also be performed to
see Section 6D 300. demonstrate that successive bending and straightening will not
impair the pipe coating and field coating. No degradation of
104 For installation welding, the sequence of pipes included the coating properties shall occur. For this test the coating test
in the pipestring shall be controlled such that variations in stiff- may be carried out on plates.
ness on both sides of welds are maintained within the assump-
tions made in the design. This may be achieved by matching, 305 The straighteners shall be qualified using pipe which is
as closely as possible, wall thickneddiameter of the pipes and delivered to the pipeline and bent corresponding to the mini-
the actual yield stress on both sides of the weld. mum curvature fed into the straighteners. It shall be demon-
strated that the strain resulting from the straightening is within
105 Selection of welding consumables and welding of pipes- the assumptions made for the validation testing, and that the
trings shall be according to the requirements given in Appen- specified straightness is achieved. The straightening shall not
dix C. cause damage to coating. The maximum deformation used dur-
106 100% automated ultrasonic testing (AUT) according to ing straightening to the specified straightness shall be recorded
the requirements given in Appendix E should be performed. and regarded as an essential variable during installation.
E 200 Installation Manual E 400 Installation procedures
201 An installation manual shall be prepared by the Contrac- 401 In addition to the applicable procedures of this subsec-
tor for acceptance by the Purchaser and in addition to the re- tion, the following procedures are required as applicable:
quirements of A 500 and applicable requirements of D 200, it
shall include: ~ reel loading;
~ pipe straightening;
the amount of displacement controlled strain, both accu- ~ anode and anode double plate installation;
mulated and maximum for each single strain cycle; ~ installation, welding and NDT of additional pipe strings;
method for control of, and allowable variation in, curva- and
ture of the pipe between the point of departure from the ~ any other procedure needed due to the nature of the oper-
reel and entry into the straighteners; ations.
description of straighteners; and
proposed procedure for qualification of the installation E 500 Requirements for installation
method by fracture mechanics assessment and validation 501 Adequate support of the pipestring shall be provided
testing. when loading the reel. Tension shall be applied and monitored
during reeling in order to ensure that the successive layers on
E 300 Qualification of the Installation Manual the reel are sufficiently tightly packed to prevent slippage be-
301 In addition to the applicable requirements of D 300, tween the layers. Adequate measures shall be taken to protect
qualification of the installation manual shall include: the coating during reeling.
~ qualification of welding procedures according to the spe- 502 The reel shall not be used for control of the pipeline ten-
cific requirements given in Appendix c , including CTOD sion during installation, unless it can be demonstrated that such
or critical J testing and 6-R or J-R testing; use will give acceptable redundancy and will not induce exces-
~ engineering critical assessments to determine the charac- sive stresses or have other detrimental effects.
teristic strain capacity, E,; 503 The curvature of the pipe, peaking and sagging, between
~ validation of engineering critical assessment by testing, the point of departure from the reel and entry into the straight-
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eners shall not exceed the maximum values assumed in design F 600 Contingency procedures
and ECA and validated in the material testing of the girth weld-
601 In addition to the applicable procedures of D 600, con-
ed pipes. tingency procedures are required for:
504 Anodes should be installed after the pipe has passed
through the straightener and tensioner. The electrical connec- ~ weather conditions in excess of the operating limit condi-
tion between anodes and pipe shall meet the specified require- tions,
ments and shall be verified at regular intervals, see Section 8. ~ ballast system breakdown or partial failure,
~ loss of towing tension,
~ excessive towing tension,
pre-designation of temporary mooring area(s) along the
F. Pipeline Installation by Towing
~
F 300 Qualification of Installation Manual de-ballasting. Care shall be exercised to prevent over-stressing
of the pipestring. The use of drag chains during the installation
301 Qualification of the installation manual shall include the is recommended. The installation operation shall be monitored
applicable requirements of D 300. by ROV.
F 400 Operating limit conditions
401 Operating limit conditions with regard to weather win-
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dow for the tow, the seastate and current and allowed strain G. Other Installation Methods
gauge values (if installed) shall be established.
G100 General
F 500 Installation procedures
101 Other installation methods may be suitable in special
501 Installation procedures meeting the requirements of this cases. A thorough study shall be performed to establish the fea-
standard and the installation specifications shall be prepared sibility of the installation method and the loads imposed during
and agreed. In addition to the applicable procedures of D 500, installation. Such methods are subject to agreement in each
procedures are required for, but not limited to: case.
~ control of weight- and buoyancy distribution, 102 Installation of flexible pipelines, bundles and multiple
~ launching of the pipestring, pipelines shall be performed after a thorough study to establish
~ ballast control during tow, the feasibility of the installation method and the loads imposed
~ ballast control during installation, and during installation. The installation is subject to agreement in
~ installation and joining of additional pipestrings. each case.
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~ description of offshore plant arrangement, equipment and secure connection.
instrumentation;
~ description of onshore plant arrangement, equipment and 804 Buoyancy aids should be used if required to keep pulling
instrumentation; and tension within acceptable limits.
~ special operations. 805 During the operation, continuous monitoring of cable
tension and pulling force is required. Monitoring with ROVs
H 300 Qualification of Installation Manual may be needed.
301 Qualification of the installation manual shall include the
applicable requirements of D 300.
H 400 Operating limit conditions I. Tie-in Operations
401 Operating limit conditions with regard to the seastate I100 General
and current shall be established if relevant.
101 The requirements of this subsection are applicable to tie-
H 500 Installation procedures in operations using welding or mechanical connectors. The op-
501 Installation procedures meeting the requirements of this erations can be performed onboard a laying vessel (in which
standard and the installation specifications, shall be prepared case welding is the preferred method) or underwater. The spe-
cific problems associated with tie-in operations shall be ad-
and agreed. In addition to the applicable procedures of D 500, dressed in the installation and testing specifications.
procedures are required for, but not limited to:
102 Tie-in operations, by means of hot or cold taps, are sub-
installation of pulling head; ject to special consideration and agreement.
tension control;
twisting control; I200 Installation Manual
ROV monitoring where applicable; 201 An installation manual shall be prepared by the Contrac-
other critical operations; tor and shall, in addition to the requirements of A 500 and D
site preparation and winch Set-up; 200, cover:
buoyancy aids, where applicable; and
position control in trench, tunnels, etc., as applicable. ~ description of diving plant arrangement, equipment and
instrumentation; and
H 600 Contingency procedures ~ special operations.
601 Contingency procedures meeting the requirements of
this standard and the installation and testing specification shall I 300 Qualification of Installation Manual
be prepared. 301 Qualification of the installation manual shall include the
602 The contingency procedures shall cover: applicable requirements of D 300.
led such that no damage to the pipeline anodes or coating will ~ mechanical connector installation.
occur. If underwater methods are used, additional procedures are re-
703 The winches shall be equipped with wire tension and quired to cover the safety and operational aspects of the under-
length indicators and recorders. All measuring equipment shall water operations.
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E VERITAS
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I 600 Contingency procedures requirements to survey vessel, survey equipment, the extent of
601 In addition to the requirements of D 600, the following survey, tolerances for the as-laid pipe line, and the maximum
contingency procedure is required: acceptable length and gap height of spans at various locations.
The extent of procedures to be prepared and qualified shall be
weather conditions in excess of the operating limit condi- specified.
tions before completion of tie-in.
J 300 As-laid suwey
If underwater methods are used, additional contingency proce- 301 The as-laid survey should include the following:
dures are required to cover the safety and operational aspects
of the underwater operations. ~ determination of the position and depth profile of the en-
tire pipeline,
I700 Tie-in operations above water
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~ identification and quantification of any spans with speci-
701 The position of the tie-in shall be verified prior to start fied accuracy to length and gap height,
of operations. A survey shall be performed to establish that the ~ determination of position of start-up and lay down heads,
location is free of obstructions and that the seabed conditions ~ determination of the presence of debris, and
will permit the tie-in to be performed as specified. ~ as laid-video documentation of the pipeline to the extent
702 To avoid overstressing during lifting and lowering of the specified.
pipeline sections, the winch tension shall be monitored contin-
uously and shall not exceed the specified for operation. Lifting J 400 As-laid suwey of corrosion protection systems
arrangements and equipment shall be designed, and lifting 401 Prior to any pipeline protection operations, a video sur-
points attached, in amanner that prevents any over-stressing of vey of the corrosion protection system shall be carried out
the pipeline section during lifting and lowering into fiial posi- along the full length of the pipeline, including risers. Signifi-
tion. cant damage to the coating and sacrificial anodes shall be doc-
703 ROV/diver monitoring of the operation should be per- umented.
formed to confirm correct configuration of the pipeline sec- 402 In the case of extensive damage to coating or sacrificial
tions from the seabed and onto the vessel. anodes, consequences for long-term performance shall be con-
704 The alignment and position of the tie-in ends shall be sidered. Potential measurements at any bare surfaces should be
within the specified tolerances before completing the tie-in. carried out to c o n f i i adequate protection. Corrective actions
may include retrofitting of anodes and coating repairs, includ-
705 Installation of mechanical connectors shall be per- ing risers. Satisfactory level of protection shall be documented
formed in accordance with the Manufacturer's procedure. For after the corrective action has been performed.
flanged connections hydraulic bolt tension equipment shall be
used. During all handling, lifting and lowering into the fiial
position, open flange faces shall be protected against mechan-
ical damage. K. Span Rectification and Pipeline Protection
706 A leak test to an internal pressure not less than the local
incidental pressure should be performed for all mechanical K l o 0 General
connections whenever possible. 101 The requirements of this subsection are applicable to
707 Corrosion protection of the tie-in area shall be per- span rectification and the protection of pipelines, e.g. by
formed and inspected in accordance with accepted procedures. trenching and backfilling, gravel dumping, grout bags, con-
crete mattresses etc.
708 After completion of the tie-in, a survey of the pipeline on
both sides of the tie-in, and over a length sufficient to ensure 102 A specific survey of the work area should be required in
that no damage has occurred, should be performed addition to, or supplementing, the as-laid survey if
709 It shall be verified that the position of the tie-in is within ~ significant time has elapsed since the as-laid survey,
the target area prior to departure of the vessel from site. The ~ a change in seabed conditions is likely,
pipeline stability shall be ensured and adequate protection of ~ heavy marine activity is present in the area,
pipeline provided. ~ new installations are present in the area, and
I800 Tie-in operations below water ~ the as-laid survey does not provide sufficient information.
801 In addition to the requirements of I 700, the require- 103 The survey of the work area, if required, shall as a min-
ments in 802 and 803 are valid for tie-in operations involving imum include :
underwater activities.
a video inspection of the pipeline to identiSl any areas of
802 Diving and underwater operations shall be performed in
~
accordance with agreed procedures for normal and contingen- damage to pipeline, coating and anodes;
cross profiles of the pipeline and adjacent seabed at regu-
cy situations covering applicable requirements.
~
lar intervals;
803 Requirements for underwater welding are given in Ap- ~ depth profiles along the pipeline and the seabed at both
pendix C. sides of the pipeline; and
~ any existing subsea installations.
The undisturbed seabed level shall be included in the cross pro-
J. As-Laid Survey files.
J100 General K 200 Span rectification and protection specification
101 These requirements are applicable to as-laid surveys 201 The requirements applicable to the specific methods of
performed by ROV either by continuous touch down point span rectification and protection regarding execution, monitor-
monitoring from the lay vessel or by a dedicated vessel. ing and acceptance. Requirements for vessels, survey equip-
ment etc. shall be addressed in the installation and testing
J 200 Specification of as-laid suwey specifications. The extent of procedures to be prepared and
201 The installation and testing specification shall contain qualified shall be specified.
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K 300 Span rectification controlled manner, such that the required material is deposited
301 Span rectification is required for all spans exceeding the over and under the pipeline, supports, subsea assemblies, etc.
specified acceptable length or height for the specific location. without disturbing their vertical or lateral position, and over
Rectification of other spans shall be considered if scour or sea- the adjacent seabed.
bed settlement could enlarge the span length and gap height 503 The gravel dumping operation shall ensure rectification
above maximum acceptable dimensions before the first of all spans to meet the specified requirements. Stabilisation of
planned pipeline inspection. free spans should be carried out in a continuous operation,
302 Adequate rectification of spans shall be documented by where the distance between spans to be stabilised is not too
a video survey. All rectified spans shall be identified and the large, so as to avoid scouring and formation of free spans be-
length, gap and height shall be within the requirements. tween gravel dumps.
504 If the fall pipe technique is used for gravel dumping,
K 400 Trenching minimum clearances shall be specified such that the fall pipe
401 Where trench excavation is performed after pipelaying, cannot touch the pipeline, any other subsea installation or the
the trenching equipment shall be of a type that does not place seabed. Deployment operations shall be performed well away
significant loads on the pipeline and minimises the possibility from the pipeline or any other subsea installation. Before the
of damage to the pipeline. fall pipe is moved to the dumping location, the clearance be-
neath the fall pipe shall be verified. The clearance shall be con-
402 Trenching equipment shall be equipped with sufficient tinuously monitored during dumping.
instrumentation to ensure that damage and excessive pipe con-
tact is avoided. 505 The completed gravel dump shall leave a mound on the
seabed with a smooth contour and profile and a slope not steep-
403 Special care shall be taken during trenching operations er than specified. If the gravel dumping is performed over ca-
of piggy back / bundle pipelines, so that strapping arrange- ble and pipeline crossings, the gravel mound shall provide the
ments will not be disturbed / damaged during trenching. For specified depth of cover over both the raised and the crossed
small pipelines without any weight coating, trenching shall not pipeline. During the dumping operations inspections shall be
damage / dismantle the anodes. performed with a sonar survey system, or when visibility is re-
404 Where mechanical backfilling is required, it shall be car- stored, a video camera, to determine the completeness and ad-
ried out in a manner that minimises the possibility of damage equacy of the dumping.
or disturbance to the pipeline. 506 Upon completion of the gravel dumping, a survey shall
405 The trenching equipment monitoring system shall be be performed to confirm compliance with the specified re-
calibrated and include: quirements. The survey shall, as a minimum, include:
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~ devices to measure depth of pipe, ~ a video inspection of the pipeline length covered,
~ a monitoring system and control system preventing hori- ~ cross profiles of the mound and adjacent undisturbed sea-
zontal loads on the pipeline or devices to measure and bed at regular intervals,
record all vertical and horizontal forces imposed on the ~ length profiles of the mound,
pipeline by trenching equipment, and devices to measure ~ confirmation that minimum required buried depth is
the proximity of the trenching equipment to the pipeline, achieved, and
horizontally and vertically relative to the pipeline; ~ any existing installations and their vicinity in order to en-
~ underwater monitoring systems enabling the trenching sure that the installation(s) have not suffered damage.
equipment operator to view the pipeline and seabed profile
forward and aft of the trenching equipment; K 600 Grout bags and concrete mattresses
~ measuring and recording devices for trenching equipment 601 Concrete mattresses and grout bags shall meet the spec-
tow force; and ification with regard to size, shape and flexibility of the mate-
~ devices monitoring pitch, roll, depth, height and speed of rial, location of filling points, and the specific gravity,
the trenching equipment. composition and grading of grout.
406 Jet sleds shall have a control and monitoring system for 602 Placing of grout bags and concrete mattresses shall be
the position of the jetting arms and the overhead frame, hori- performed in a controlled manner, such that the bags or mat-
zontally and vertically relative to the pipeline. The location of tresses are placed as required. Restrictions on vessel move-
the sled shall not be controlled by the force between sled and ments during the operation shall be given.
pipeline. Devices indicating tension in the tow line and show- 603 During the placing operations, inspections shall be per-
ing the depth of the trench, shall be installed. formed with a ROV-mounted video camera to determine the
407 The trench depth shall be referenced to the undisturbed completeness and adequacy of the installation.
seabed adjacent to the pipeline and to the top of the pipeline. 604 Upon completion of the placing operation, a survey shall
408 An allowable range of values, indicated by the measur- be performed to confirm compliance with the specified re-
ing devices of the trenching equipment, shall be established. quirements. The survey shall as a minimum include:
The possibility of damage to coating shall be considered. Dur- a video inspection of the completed work,
ing trenching operations the measuring devices shall be contin-
~
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be performed according to specifications and procedures meet- appurtenances shall prevent any damage to coating and paint.
ing the requirements of the applicable design code. In addition, special precautions shall be taken to protect flange
faces and other specially prepared surfaces from damage.
603 All tolerances and measurements required in order to in-
stall the riser in accordance with drawings and specifications
M. Installation of Risers shall be verified in the field before installation commences. Di-
M100 General ameter, roundness and cleanness of J-tubes shall be checked by
gauging pigs, pulling a test pipe or similar to prevent the pull-
101 The installation and testing specification shall cover the ing head and riser from jamming.
riser installation operations and address the specific problems
associated with these operations. Diving and underwater oper- 604 Adequate control shall be performed to ensure that the
ations shall be performed in accordance with agreed proce- angularity and straightness of risers, the distance between ris-
dures covering applicable requirements. ers and bracing, the spacing between adjacent risers and other
critical dimensions meet the specified requirements.
102 The following methods may be used:
605 Tie-ins between riser and pipeline shall be performed in
~ integral installation by surface vessel, where the riser and accordance with I.
pipeline are welded on deck of the vessel and the pipeline 606 Prior to pull-in of risers into J-tubes, it shall be verified
and riser lowered to the seabed. The riser is then posi- that the bellmouth is clear of debris and obstructions, that the
tioned in clamps installed on the structure; bellmouth height above the seabed is within design limits, and
~ installation by J-tube method, where the riser is pulled that no damage to the bellmouth, J-tube or J-tube clamps (if ap-
through a pre-installed J-shaped conduit on the structure, plicable) has occurred. Entry of the pipeline into the bellmouth
~ installation by bending shoe, where the pipeline is de- shall be monitored by ROV, and the tension in the pull-in cable
formed around a quarter circle shaped bending shoe. In- shall be monitored by calibrated load cells and shall not exceed
stallation by bending shoe is subject to acceptance by the the specified maximum. Proper sealing as specified shall be
Purchaser in each case; ensured at the bell-mouth for a riser in a J-tube in case the cor-
~ installation of prefabricated risers, where the riser is in- rosion protection system is designed with for a non-corrosive
stalled in clamps fitted on the structure by a surface vessel. fluid in the annulus.
Hyperbaric welding or mechanical connector are then
used to connect the riser and pipeline, 607 All clamps, protection frames, anchor flanges etc., shall
~ stalk-on risers installed by a installation vessel, and be installed in accordance with specification and drawings, us-
~ flexible, free-hanging risers. ing appropriate bolt torque and to the specified tolerances.
608 Repair of damage to coating and paint shall be per-
M 200 Installation Manual formed in accordance with accepted procedures.
201 The installation manual should, in addition to the re- 609 Upon completion of the installation, a ROV or diver sur-
quirements given in A 500 and D 200, cover: vey shall be performed to c o n f i i the position of the riser rel-
communication line and interface procedure with the plat- ative to the platform, the position of any expansion loops,
~
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depth of cover or trench depth as applicable; samples shall be analysed and suitable actions shall be taken to
quantification of span lengths and heights, including remove andor inhibit harmfùl substances.
length and height reporting tolerances; 405 If water is to remain in the pipeline for an extended pe-
location of areas of damage to pipeline, coating and an- riod of time, consideration shall be given to control of bacteria
odes; growth and internal corrosion.
location of any areas with observed scour or erosion along
pipeline and adjacent seabed; 406 Added corrosion inhibitors, oxygen scavengers, bio-
verification that the condition of weight coating (or an- cides, dyes, etc. shall be considered for possible harmfùl inter-
choring systems that provide for on-bottom stability) is in actions and their impact on the environment during and after
accordance with the specification; disposal of the test water.
description of wreckage, debris or other objects which 407 The pipeline cleaning concept shall consider:
may affect the cathodic protection system or otherwise im-
pair the pipeline; and protection of pipeline components and facilities (e.g.
as-built video for the entire pipeline. valves) from damage by cleaning fluids and pigs,
testing devices such as isolation spheres etc.,
N 400 Inspection of impressed current cathodic corro- removal of substances that may contaminate the product to
sion protection system be transported,
401 Impressed current cathodic corrosion protection systems particles and residue from testing and mill scale,
shall be inspected, including cables, conduits, anodes and rec- organisms and residue resulting from test fluids,
tifiers. Readings from the corrosion monitoring system shall be chemical residue and gels, and
verified by independent potential measurements, and adequate removal of metallic particles that may affect future inspec-
electrical insulation from other installations (if applicable) tion activities.
shall be confiied.
408 The basic requirement for gauging is to run a metallic
402 If the required protection level is not attained, the causes gauge plate with a diameter of 97% of the nominal inner diam-
shall be identified and adequate corrective actions performed. eter through the pipeline. Alternatively, other gauging tools
Satisfactory performance shall be documented after the correc- such as electronic gauging pigs etc. may be used. Tolerances
tive action. on diameter, wall thickness, misalignment and weld penetra-
tions shall be considered for small bore pipelines when select-
ing the diameter of gauge plate.
O. Final Testing and Preparation for Operation 409 Cleaning and gauging train design, number and type of
pigs, need for chemical cleaning, train velocity etc., shall be
O 100 General decided based on type and length of pipeline, steep gradients
along the pipeline route, type of service, construction method,
101 All work on the pipeline, including crossings, trenching, downstream process etc.
gravel dumping, artificial backfill, subsea assemblies, riser in-
stallation, as-built survey etc., should be completed before the 410 If cleaning and gauging are performed on separate sec-
fiial testing commences. tions of the pipeline prior to tie-in, a minimum of one cleaning
and gauging pig should be run through the completed pipeline
102 Disposal of cleaning and test fluids shall be performed system prior to, or during, product filling.
in a manner minimising danger to the environment. Any dis-
posal of fluids shall be in compliance with requirements from O 500 System pressure testing
National Authorities. 501 A pipeline system pressure test shall be performed based
O 200 Specification of final testing and preparation for upon the system test pressure determined according to Section
operation 5B.202 unless the test is waived as allowed by Section 5B.203.
The extent of the test should normally be from pigtrap to
201 The installation and testing specification shall contain pigtrap, including all components and connections within the
requirements for equipment, the extent of testing and prepara- pipeline system. The test shall be performed after completion
tion for operation, performance of tests and preparation for op- of all installation, construction and pipeline protection works.
eration and associated acceptance criteria. The extent of The pressure test is normally performed as a combined
procedures to be prepared and qualified shall be specified. strength and leak test.
O 300 Procedures for final testing and preparation for 502 The system may be tested as separate sections provided
operation that the tie-in welds between sections have been subject to
100% radiographic, ultrasonic and magnetic particle testing, or
301 All operations and tests shall be performed in accord- by a combination of other methods which provide the same or
ance with agreed procedures. improved verification of acceptable weld quality.
O 400 Cleaning and gauging 503 The pipeline section under test shall be isolated from
other pipelines and facilities. Pressure testing should not be
401 Cleaning and gauging may be combined with the initial performed against in-line valves, unless possible leakage and
flooding of the pipeline, be run as a separate operation, or be damage to the valve is considered, and the valve is designed
combined with the weld sphere removal after completion of and tested for the pressure test condition. Blocking off or re-
hyperbaric tie-in.
moval of small-bore branches and instrument tappings, should
402 Appropriate measures shall be taken to ensure that any be considered to avoid possible contamination.
suspended and dissolved substances in the fluid used for this 504 End closures, temporary pigtraps, manifolds and other
operation are compatible with the pipe material and internal temporary testing equipment, shall be designed and fabricated
coating (if applied), and that deposits are not formed within the according to a recognised code and with design pressure equal
pipeline. to the pipeline's design pressure. Such items shall be individu-
403 Water should have a minimum quality corresponding to ally pressure tested to at least the same test pressure as the
filtration through a 50 m filter, and an average content of sus- pipeline.
pended matters not exceeding 20 g/m3. 505 Filling of the pipeline with test water should be per-
404 If water quality or the water source is unknown, water formed in a controlled manner, using water behind one or more
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Offshore Standard DNV-OS-FI 01, January 2000
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body cavities with an inert liquid, unless the valves have pro-
vision for pressure equalisation across the valve seats. All
valves shall be fully open during line filling. A pig tracking
system and the use of back-pressure to control the travel speed
of the pig shall be considered if steep gradients occur along the
pipeline route.
506 Instruments and test equipment used for the measure-
ment of pressure, volume and temperature shall be calibrated
for accuracy, repeatability and sensitivity. All instruments and
test equipment shall possess valid calibration certificates, with
traceability to reference standards within the 6 months preced-
ing the test. If the instruments and test equipment have been in
frequent use, calibration specifically for the test should be re-
quired.
507 Gauges and recorders shall be checked for correct fùnc-
tion immediately before each test. All test equipment shall be
located in a safe position outside the test boundary area. Figure 9-1 Determination of volume of air
508 The test pressure should be measured using a dead 513 During pressurisation of the pipeline, the pressure shall
weight tester. Dead weight testers shall not be used before a be increased at a maximum 1 bar per minute up to 95% of the
stable condition is confirmed. When pressure testing is per- test pressure. The last 5% up to the test pressure shall be raised
formed from a vessel, where a dead weight tester can not be by a linear diminishing rate down to 0.1 bar per minute. Time
shall be allowed for c o n f i a t i o n of temperature and pressure
utilised due to the vessel movements, the test pressure shall be stabilisation before the test hold period begins.
measured by using one high accuracy pressure transducer in
addition to a high accuracy large diameter pressure gauge. 514 The pressure level requirement for the system pressure
test is given in Section 5B.202.
509 The following requirements apply for instruments and 515 The test pressure hold period after stabilisation shall be
te st equipment : held for a minimum 24 hours.
516 Subject to agreement, shorter pressure hold periods ma
~ dead weight testers shall have a range of minimum 1.25
times the specified test pressure, and shall have an accura-
be accepted for pipelines with test volumes less than 5 O00 m , Y
ref. M.610.
cy better than I O . l bar and a sensitivity better than 0.05
bar; 517 The pressure shall be continuously recorded during pres-
the volume of water added or subtracted during a pressure surisation, stabilisation and hold periods. Temperature and
pressure shall be recorded simultaneously at least every 30
~
test shall be measured with equipment having accuracy minutes during the hold period.
better than I 1.O% and sensitivity better than O. 1%;
518 If possible, flanges, mechanical connectors etc. under
~ temperature measuring instruments and recorders shall pressure shall be visually inspected for leaks during the pres-
have an accuracy better than I 1.O°C, and a sensitivity bet- sure test, either directly or by monitors.
ter than O. 1OC; and 519 The pressure test is acceptable if the pipeline is free from
~ pressure and temperature recorders shall be used to pro- leaks, and the pressure variation is within I 0.2% of the test
vide a graphical record of the pressure test for the total du- pressure. A pressure variation up to an additional I0.2% of the
ration of the test. test pressure is normally acceptable if the total variation (i.e.
I 0.4%) can be documented to be caused by temperature fluc-
If a pressure transducer is used instead of a dead weight tester, tuations or otherwise accounted for. If pressure variations
the transducer shall have a range of minimum 1.1 times the greater than I 0 . 4 % of the test pressure are observed, the hold-
specified test pressure, and the accuracy shall be better than ing period shall be extended until a hold period with acceptable
pressure variations has occurred.
I 0 . 2 % of test pressure. Sensitivity shall be better than 0.1%.
520 De-pressurisation of the pipeline shall be performed as a
510 A correlation that shows the effect of temperature controlled operation, normally at a rate not exceeding 1 bar per
changes on the test pressure, shall be developed and accepted minute.
prior to starting the test. Temperature measuring devices, if 521 Documentation produced in connection with the pres-
used, shall be positioned close to the pipeline, and the distance sure testing of the pipeline system shall include:
between the devices shall be based on temperature gradients
along the pipeline route. pressure and temperature recorder charts,
log of pressure and temperatures,
511 The test medium should be water meeting the require- calibration certificates for instruments and test equipment,
ments given in O 400. calculation of air content,
calculation of pressure and temperature relationship and
512 The air content of the test water shall be assessed by con- justification for acceptance, and
structing aplot of the pressure against volume during the initial endorsed test acceptance certificate.
filling and pressurisation, until a definite linear relationship is
apparent, see Figure 9-1. This should be done at 35% of test O 600 Cleaning, de-watering and drying
pressure. The assessed air content shall not exceed 0.2% of the 601 Upon completion of pressure testing, the pipeline should
calculated total volume of the pipeline under test. be cleaned. Residues, organisms etc. shall not remain in the
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Page 100 - Sec.9
pipe after testing (see 407). plosive mixtures and, in the case of gas or condensate, to avoid
602 De-watering is required before introducing the product hydrate formation. The injection rate shall be controlled so that
into the pipeline. Drying may be required in order to prevent pressure and temperature do not exceed allowable limits for
an increase in the corrosion potential or hydrate formation, or the pipeline material or dewpoint conditions.
if omission of drying is deemed to have an adverse effect on
the product transported. O 900 Operational verification (start-up inspection)
603 Introduction of the product may be accepted in special 901 After stable production has been reached it shall be ver-
cases. The separation pig train between the test medium and ified that the operational limits are within design conditions.
the product will then require special qualification in order to Important parameters can be:
avoid contact between the residual test water and the product.
~ expansion,
604 Selection of de-watering and drying methods and chem- ~ movement,
icals shall include consideration of any effect on valve and seal lateral snaking,
materials, any internal coating and trapping of fluids in valve
~
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Offshore Standard DNV-OS-FI 01, January 2000
Sec.10 - Page 101
SECTION 10
OPERATION, INSPECTION, AND REPAIR
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Offshore Standard DNV-OS-FI 01, January 2000
Page 102 - Sec.10
the basis for the detailed inspection program in terms of in- 208 The frequency of future external inspections shall be de-
spection methods and intervals. termined based upon an assessment of:
203 The long term inspection program shall include the en- ~ degradation mechanisms and failure modes,
tire pipeline system. The following items, at minimum, should ~ l&elihood and consequences of failure,
be considered:
~ results from previous inspections,
pipeline, ~ changes in the operational parameters,
risers, ~ repair and modifications, and
valves, ~ subsequent pipelay operation in the vicinity.
Tee and Y connections,
mechanical connectors, 209 Critical sections of the pipeline system vulnerable to
damage or subject to major changes in the seabed conditions
flanges, i.e. support andor burial of the pipeline, shall be inspected at
anchors, short intervals, normally on an annual basis. The remaining
clamps, sections should also be inspected, ensuring a full coverage of
protecting structures, the entire pipeline system within a 5 to 10 years period.
anodes,
coating.
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204 A detailed inspection program including specifications c . Inspection and Monitoring of External cor-
for the inspections shall be prepared for each survey. The de-
tailed inspection program should be updated based on previous rosion
inspections as required.
C 100 General
205 systems that are Out Of 101 In the splash zone and in the atmospheric zone, damaged
also be subject to periodical survey.
andor disbonded coatings can cause severe corrosion damage.
206 Inspection shall be carried out to ensure that the design Risers carrying hot fluids are most vulnerable to such damage.
requirements remain and that no damage has Oc-
The inspection program as a ad- 102 In the submerged zone, coating malfunctions are not
dress: critical unless they are combined with deficiency in the cathod-
ic protection system. (For definition of zones, see Section SD
exposure and burial depth of buried or covered lines, if re- 10ô).
quired by design, regulations or other specific require- 103 For risers contained in J-tubes filled with non-corrosive
ments; fluid (see Section SB.105) inspection of external corrosion
free spans including mapping of length, height and end- may not be required if adequate properties of the fluid is veri-
support conditions; fied by periodic testing.
condition of artificial supports installed to reduce free
104 Inspection by special internal tools may be used to detect
span; external corrosion of risers and pipelines in all three zones (see
local seabed scour affecting the pipeline integrity or at- D 200) including risers contained in J-tubes, if required.
tached structures;
sand wave movements affecting the pipeline integrity; C 200 Risers in the Splash zone and the Atmospheric
excessive pipe movements including expansion effects; Zone
identification of areas where upheaval buckling or exces-
sive lateral buckling has taken place; 201 In the splash and atmospheric zones, visual examination
integrity of mechanical connections and flanges; of the coating shall be performed in order to assess the needs
integrity of sub-sea valves including protective structure; for preventive maintenance. Besides visual indications of di-
rect damage to the coating, effects such as rust discoloration
Y- and Tee connections including protective structure;
and bulging or cracking of the coating are indicative of under-
pipeline settlement in case of exposed pipeline, particular- rusting. Coating systems which prevent close inspection of un-
ly at the valve/Tee locations, der-coating corrosion shall require special consideration.
the integrity of pipeline protection covers (e.g. mattresses,
covers, sand bags, gravel slopes, etc.); 202 The frequency of the external inspection in the splash
mechanical damage to pipe, coatings and anodes; zone of risers shall be determined based on the fluid category,
major debris on, or close to, the pipeline that may cause the line pipe material, coating properties and any corrosion al-
damage to the pipeline or the external corrosion protection lowance.
system; and
leakage. C 300 Pipelines and Risers in the Submerged Zone
c
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Offshore Standard DNV-OS-FI 01, January 2000
Sec.10 - Page 103
304 A survey of the external corrosion protection system, ~ corrosion probes; i.e. weight loss coupons or other retriev-
should be carried out within one year of installation. able probes for periodic or on-line determination of corro-
sion rates;
~ in-situ wall thickness measurements, i.e. repeated meas-
urements of wall thickness at defiied locations using port-
D. Inspection and Monitoring of Internal Corro- able or permanently installed equipment.
sion
302 Techniques and equipment for corrosion monitoring
D 100 General shall be selected based upon:
101 Inspection of internal corrosion is carried out in order to ~ monitoring objectives, including requirements for accura-
c o n f i i the integrity of the pipeline system, primarily by cy and sensitivity;
means of in situ wall thickness measurements. ~ fluid corrosivity and the corrosion preventive measures to
102 The objective of monitoring internal corrosion is to con- be applied;
f i i that the fluid remains non-corrosive or, more often, to as- ~ potential corrosion mechanisms.
sess the efficiency of any corrosion preventive measures, and 303 A typical major objective of corrosion monitoring is to
accordingly to identiSl requirements for inspection of corro- detect changes in either intrinsic corrosivity of the fluid, or in
sion. the efficiency of the corrosion prevention measures. For pipe-
103 Corrosion monitoring as defined above does not normal- lines carrying dry (i.e. fully processed) gas, inspection of inter-
ly give any quantitative information of critical loss of wall nal corrosion may be postponed provided that monitoring
thickness. Although monitoring may be carried out as actual demonstrates that no corrosive liquids have entered the pipe-
wall thickness measurements in a selected area, it cannot re- line, or been formed by condensation downstream of the inlet.
place pipeline inspection schemes that cover the pipeline sys-
tem, or section thereof, in its full length and circumference. On
the other hand, inspection techniques for internal corrosion are
not normally sensitive enough to replace monitoring. E. Defects and Repair
104 The requirements for corrosion inspection and monitor- E 100 General
ing, and the capability of optional techniques, shall be evaluat-
ed at an early stage of pipeline system design. 101 Repair and modification shall not impair the safety level
of the pipeline system below the specified safety level.
105 Pipelines and risers manufactured from Corrosion Re-
sistant Alloys ( C U ) do not normally require inspection and 102 All repairs shall be carried out by qualified personnel in
monitoring of internal corrosion. accordance with agreed specifications and procedures, and up
to the standard defined for the pipeline.
D 200 Corrosion inspection If the repair involves welding, the personnel, method, and
201 Internal corrosion inspection shall be carried out with a equipment shall be agreed upon according to Appendix C.
carrier tool ("inspection pig") capable of inspecting the internal For other types of repair the requirements for personnel, meth-
surface of the pipeline along its full circumference and length, od and necessary equipment to carry out the work shall be
or a critical part thereof. agreed upon in each case.
202 The technique for detection of internal corrosion (e.g. 103 All repairs shall be tested and inspected by experienced
magnetic flux leakage or ultrasonic examination) shall be se- and qualified personnel in accordance with agreed procedures.
lected based on considerations of linepipe material, diameter NDT personnel, equipment, methods, and acceptance criteria
and wall thickness, expected form of damage, and require- shall be agreed upon in accordance with Appendix D.
ments to detection limits and defect sizing capability. The lat-
ter shall be determined based on pipeline design and 104 Pipeline systems with defects may be operated tempo-
operational parameters. rarily under the design conditions or reduced operational con-
ditions until the defect has been removed or repair has been
203 Candidate operators of inspection tools should be re- carried out. It must, however, be documented that the pipeline
quired to document the capability of their systems with respect integrity and the specified safety level is maintained, which
to detection limits and sizing of relevant corrosion defects (in- may include reduced operational conditions andor temporary
cluding localised corrosion at girth welds) for the pipe dimen- precautions.
sions considered.
105 Alternatively, a pipeline system with defects may be
204 The frequency of internal inspections shall be deter- permanently re-qualified to lower operational conditions see
mined based on factors such as: Section 11 and Section 5 , e.g. reduced pressure, which may al-
low for omitting repair.
criticality of pipeline,
potential corrosivity of fluid, 106 When a defect is observed, a evaluation of the defect
shall be performed and shall, as a minimum, include:
detection limits and accuracy of inspection system,
results from previous surveys and monitoring, ~ determined details of the defect,
changes in pipeline operational parameters, etc. ~ mechanisms causing the defect,
~ accuracy and uncertainties in the inspection results,
See also Section 9 0 900. ~ options for further operational conditions of the pipeline
D 300 Corrosion monitoring system,
~ repair methods.
301 The following major principles of corrosion monitoring
may be applied: 107 In each case a thorough evaluation of the defect and the
impact on safety and reliability for the operation of the pipeline
fluid analyses; i.e. monitoring of fluid physical parameters shall be performed. The requirements given in the following
and sampling of fluid for chemical analysis of corrosive sections regarding required actions, e.g. grinding or replace-
components, corrosion retarding additions or corrosion ment, may be waived if it can be documented that the specified
products; safety level for the pipeline system is not impaired.
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108 Defects that affect the safety or reliability of the pipeline E600 Leaks
shall either be removed by cutting out the damaged section of 601 Prior to carrying out a repair of any leak, the mechanism
the pipe as a cylinder, or alternatively, the pipeline may be re- causing the leak shall be established.
qualified to a lower design pressure according to Section 11
and Section 5. 602 The most suitable method for repairing a leak in the pipe
depends upon e.g. the pipe material, pipe dimensions, location
109 Depending upon the condition of the damage, a tempo- of leak, load conditions, pressure, and temperature. The fol-
rary repair may be accepted until the permanent repair can be lowing repair methods may be used:
carried out. If a temporary repair is carried out, it shall be doc-
umented that the pipeline integrity and safety level is main- a) The damaged portion is cut out of the pipe as a cylinder
tained either by the temporary repair itself andor in and a new pipe spool is installed either by welding or
combination with other precautions. by an mechanical connector. For guidance, reference is
made to DNV RP-F104, Mechanical Piyeline Cou-
E 200 Global buckling plings.
b) Clamps are installed, and tightness is obtained by ei-
201 In case of a global buckling (upheaval buckling or lateral ther welding, filler material, friction or other qualified
deflection) resulting in plastic bending strains, the pipeline mechanical means.
may continue operating until the need of repair has been eval-
uated, provided that the operational parameters are kept within 603 Leaking flanges and couplings may be sealed by install-
a range that prevents the accumulation of low-cycle high strain ing a seal clamp covering the leaking flange or coupling, in-
fatigue failure in the buckled section. creasing the bolt pre-load, or replacing gaskets and seals. Prior
to increasing the pre-load in bolts, it shall be documented by
E 300 Grooves, gouges, cracks and notches calculation that no over-stressing occurs in bolts, flange or gas-
ketkeals. In case the pre-load in the bolts is removed, e.g. due
301 Sharp defects like grooves, gouges, and notches should to changing of gasket, new bolts shall be used for the flange
preferably be removed by grinding or other agreed repair connection.
methods. For ground defects where all sharp edges are con- 604 All repair clamps, sleeves, pipe spools, and mechanical
f i i e d as removed, the defect can be regarded as a smooth connectors shall be qualified prior to installation and leak test-
metal loss defect, see E 400. ed after installation. For guidance, reference is made to DNV
RP-F104, Mechanical Pipeline Couplings.
E 400 Metal loss defects
401 Metal loss defects caused by e.g. corrosion, erosion, or E 700 Repair by welding
grind repair shall be checked for capacity. For guidance, refer- 701 Repair welding procedures and welders shall be quali-
ence is made to DNV RP-F101, Corroded Pipelines. fied as described in Appendix C.
702 Repair welding above water shall be carried out as de-
E500 Dents scribed in Appendix C.
501 A dent is defined as a depression which produces a gross 703 Underwater welding shall be carried out in a dry habitat,
disturbance in the curvature of the pipe wall, and which results see Appendix C.
in a diameter variation of more than 2% of the nominal diam- 704 Repair welding may, in special cases, be carried out on
eter (see Section 5 ) . pipelines while operating, depending on pipe material, pipe
502 A dent affecting the longitudinal or circumferential weld wall thickness, product type, pressure and temperature. It shall
can result in cracks, and removal of the damaged portion of the be documented that safety for carrying out the repair is accept-
pipe should be considered. The damaged part can be cut out as able, and a safety procedure shall be established.
a cylinder, or repaired by installing a full encirclement welded 705 All repair welds shall be subject to visual and non-de-
split sleeve which is designed to take the full internal operating structive testing, see Appendix D. Following the repair, pres-
pressure. sure testing may be required for the repaired section.
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SECTION 11
REQUALIFICATION
A. General The reason for requiring use of this standard is in case the origi-
nal standard used for design is less stringent than necessary to
A 100 Objective meet the target safety levels specified in this standard.
101 The purpose of this section is to define re-qualification
and to give requirements for re-qualification of pipeline sys-
tems.
102 Re-qualification is a re-assessment of the design under
changed design conditions. B. Design Criteria
Guidance note:
A re-qualification may be triggered by a change in the original B 100 General
design basis, by not fulfilling the design basis, or by mistakes or 101 A target safety level as defined in Section 2C 600 shall
shortcomingshaving been discovered during normal or abnormal apply for a re-qualification assessment.
operation.
Possible causes may be: 102 Operational experience, e.g. change of operational con-
- preference to use this standard, e.g. due to requirements for
ditions, inspection records and modifications, shall be consid-
higher utilisation for existing pipelines; ered in a re-qualification assessment.
- change of the premises;
B 200 System Pressure Test
- environmental loads,
- deformations, 201 System pressure testing may be required when:
- scour.
- change of operational parameters; ~ the original mill pressure test or system pressure test does
- pressure or temperature, not satissl requirements according to this standard at the
- corrosivity of the medium. new design pressure;
- deterioration mechanisms having exceeded the original as- ~ a significant part of the pipeline has not been system pres-
sumptions; sure tested e.g. new pipeline section. (for omission of sys-
- corrosion velocity, both internal and external, tem pressure test, see Section 5B.203).
- dynamic responses, contributing to fatigue, which may
be caused by lacking supports etc. B 300 Deterioration
- extended design life;
- discovered damage; 301 All relevant deterioration mechanisms shall be evaluat-
ed. Typical deterioration mechanisms are:
- dents,
- damage to pipeline protection,
- weld defects,
corrosion,
- corrosion related defects.
- damage to anodes. ~ external corrosion
~ internal corrosion
erosion,
A 200 Application accidental loads,
201 Within the original design life, and without essential development of free spans,
changes in the manner of employment (repair etc.), the stand- fatigue,
ard under which the pipeline was built shall apply when con- settlement.
sidering incidents, minor modifications or rectification of
design parameters exceeded during operation. 302 Sufficient reliability or safety measures shall be applied
For major modifications or other instances not covered by the to account for the accuracy and uncertainties in the inspection
above paragraph this standard shall apply. result s.
Guidance note: 303 Accumulated damage experienced prior to the re-quali-
The same safety level shall apply for lifetime extensions of an ex- fication shall be included in the evaluation.Commentary (In-
isting pipeline as would apply for the design of a new pipeline. formativeì
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SECTION 12
COMMENTARY (INFORMATIVE)
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I
I \ I , I
Elastic properties
E Young’s modulus X
V Poisson’s ratio X
a Temperature expansion, as function of the
temperature (within the actual temperature X
Plastic properties
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ure during installation, normally considered as safety class the pipeline will/may be necessary.
low, will have a significantly smaller consequence than a fail-
ure during a shut-down period of the pipeline, where both pol- Pipelines subjected to subsidence related horizontal move-
lution and time for repair are significantly more expensive and ments should be kept under observation during their operation-
time consuming. al life. There are normally significant uncertainties involved in
the prediction of the subsidence load effects, and design ac-
However, the total safety may not always be increased by spec- counting for these uncertainties (in order to reflect the accept-
isling a higher safety class. This may be the case when the able probability of failure stated in this standard) may in some
most probable cause of failure would be draught of vessel, cases be unpractical. Monitoring of the subsidence progress
where the emphasis should be put on operating procedures and and pipeline behaviour may in such cases be part of the design
back-up. During such circumstances, it may not be required philosophy.
with a higher safety class.
Pipelines installed on unstable seabed where freespans may
The above clearly illustrates that Table 2-4 is for "normal" occur or grow during their operational life should be subject to
classification only, as stated. regular inspection. In extreme cases, it may be impossible to
consider such events in the original design, and the only design
C 200 Structural reliability analyses option is to prepare a contingency philosophy for monitoring
and intervention of freespans.
Structural reliability methods consider structural analysis
models in conjunction with available information regarding In cases where uncertainties in the operational conditions (me-
the involved variables and their associated uncertainties. The dium chemical composition, water content, temperature, etc.)
reliability as assessed by reliability methods is not an objective impose uncertainties in the prediction of the corrosion rate,
physical property of the pipeline itself in the given operational close monitoring of the medium or corrosion inspection may
and environmental condition, but rather a nominal measure of be part of the design philosophy.
the reliability given a particular physical and probabilistic
modelling and analysis procedure applied. D 200 Air and sea temperatures
Structural reliability analysis is only one part of a total safety In cases where the air or sea temperature at the time of instal-
concept as gross errors are not included. A gross error is de- lation is higher than the minimum ambient temperature de-
f i e d as a human mistake during the design, construction, in- fined in the project design basis, the minimum ambient
stallation or operation of the pipeline that may lead to a safety temperature applicable for the installation period (including
level far below what is normally aimed for by use of a partial sufficient contingency) should be used when applicable. This
safety factor design format or specific reliability analysis. may be relevant in calculations where the temperature differ-
Target reliabilities have to be met in design in order to ensure ence between the ambient installation temperature and the
that certain safety levels are achieved. A probabilistic design minimum or maximum design temperature is governing for the
check can be performed using the following design format: design.
Accident statistics may be used as guidance on relative failure ference relative the reference pressure is the column weight of
probability levels but only limited information about specific the content.
failure probability for SLS, ULS and FLS can be deduced from
failure statistics. Structural failure probability from a SRA is a The following relationship exists:
nominal value and cannot be interpreted as an expected fre- piocai, ref
-
- pref + Pcont ' g h
'
quency of failure.
The following specific local pressures exist:
C 300 Characteristic values Pld = pd+Pcont'g'
In a LRFD format, so called characteristic values are used. pli =pinc+Pcont'g'h=pd' Yinc+Pcont'g'h
These are often lower fractiles for strength and resistance, not
always however, and upper fractiles for loads. Typical exam- Pit = Yt+Pt.g.h
ples of these may be SMYS for the yield stress and 100-year
waves for loads. where
-
The characteristic value in the resistance formulas is a lower pine - pd . Knc=incidentalpressure
fractile and the expected yield stress is typically in the order of
8% higher. On commonly overlooked implication of this is
xnc = 1.10 (normally; maximum), see Section 3B 300,
1.05 (minimum)
that it is not allowed to replace the fy based upon a certificate
or test. Such a replacement requires a thorough evaluation by Pt = 1.05~inc
a reliability specialist. pcont = density of contents
pt = density of test liquid (water) content
g = gravitational acceleration
h = vertical distance from reference point to sea surface
D. Design Premise
An example for a design pressure of 200 bar, 10% incidental
D 100 Monitoring pressure and a content density of approximately 200 kg/m3 is
given in the figure below. The differential pressure which shall
The following includes typical examples where monitoring of be used for pressure containment is also included.
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within the joint industry project SUPERB and the reports may
be bought from Sintef, Norway. Some results have been pub-
lished, e.g. Jiao et al (1996) and Mmk et al (1997).
The SUPERB results were incorporated in DNVRulesf o r Sub-
murine Pipeline Systems, 1996 (DNV'96) and modified in or-
der to allow for additional aspects, not necessarily to be
considered in a research project. Hence, all limit states may not
have identical partial factors as in the SUPERB reports.
In this new standard, the LRFD format has been modified on
the resistance side as described in Section 2 and the limit states
from DNV'96 modified correspondingly. The local buckling
formulation has, further more, included some results from the
Hotpipe project, allowing a higher utilisation of pressurised
pipes. See e.g. Vitali et al (1999).
F 200 Material de-rating
E 200 Conversion of pressures For a pipeline designed for a temperature above 50"C, a corre-
sponding de-rated yield stress shall be determined and used for
The governing pressure for design is the incidental pressure. the conditions where this is the relevant temperature. The de-
The incidental pressure is normally defined as the pressure rated strength applies only to conditions where the elevated
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(12.4)
F. Design Criteria
F 100 General
The basis for most of the given limit states were developed
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The corresponding usage factors for xnc= 1.10 (10% inciden- This third degree polynom has the following analytical solu-
tal pressure) are given in Table 12-2. tion:
1
pc = y - - b (12.10)
Utilisation Safety Class Pressure 3
factor, au Low I Normal I Hiph test where:
1.o0
I 0.8473
(0.843)
I 0.802 I 0.698l I 0.96
0.96
I 0.8133
(0.838)
I 0.77 I 0.672 I 0.96
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propagation may be different; and
~ the stress-strain relationship will correspond to a static o, = the equivalent stress
case while in the real case a much higher value may be ex- oz= longitudinal stress
perienced due to the high strain rate.
y = usage factor as given by Table 12-3.
In the real situation, however, the running buckle will stop &q h == yield stress, see Table 5-2
when it reach a water depth corresponding to a too low pres- tangential shear stress
sure. At this point, the running buckle will change from a dy-
namic condition to a static condition. The very important I Table 12-3 Usage factors for equivalent stress check,
conclusion from this is that the most conservative estimate
from a dynamic and static condition should always be used, 17 1.o0 0.90 0.80
since the buckle will experience both. And, this will not neces-
sarily be as conservative as it may look at the first glance. All Load Factors are to be equal to unity for the stress check.
The safety factors provided on the propagating pressure is Condition load factor shall be applied when relevant and on
based upon a conditioned probability, i.e. including the proba- relevant stress components.
bility for a buckle to occur in addition to the probability of the
pipe failing to resist the pressure. This implies that the failure F 1300 Local buckling - Adding moments
probability of the propagating pressure resistance in itself (iso- For a pipe section exposed to bending moments acting in dif-
lated) is 1-2 decades higher than for other ULS limit states. ferent directions, the factorised load effects should be added,
e.g. a functional moment in the x-direction and a environmen-
F 1100 Local buckling - Buckle arrestors tal moment in the y-directions should be added as in:
The buckle arrestor is usually designed to resist the propagat-
ing pressure. The propagation pressure resistance of a pipe is (12.11)
based upon an "infinite" pipe, and the length has to be consid-
ered when designing the buckle arrestor. A short buckle arres- Load effect factors shall be applied on each individual compo-
tor needs to be thicker than a longer buckle arrestor. nent.
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F 1400 Ovalisation i.e. the ultimate tensile sltrength (in true stress) to yield stress
Pipe ovalisation is mentioned in three different places within ratio.
this standard: The material specific Failure Assessment Diagram (FAD),
which requires knowledge of the material stress strain curve,
~ Section 5D 800, where the maximum allowable ovalisa- must be used to avoid non-conservative or excessively con-
tion fo = 3%. This applies for the pipeline as installed con- servative predictions. For assessing defects located within the
dition. This limitation is due to the given resistance weld metal the FAD should be derived from all-weld metal
formulations which not includes the ovality explicitly, as tensile tests. For assessing defects at the fusion line and within
well as other functional aspects as stated in the paragraph. HAZ the FAD should be derived from parent material tensile
~ Section 5D.503, where the minimum ovalisation fo = 0.5% tests. The respective yield stress values at 0.2% permanent
to be accounted for in the system collapse check; and the strain or at the lower yield point should be derived from the
combined loading. The collapse formula includes the oval- same stress-strain curves.
ity explicitly giving a lower resistance for a larger ovality,
hence a minimum ovality is prescribed. The design strain should be calculated by an elastic-plastic
~ Table 6-14 and Table 6-15, dimensional requirements, analysis considering strain concentrations and safety factors.
where the maximum allowable out of roundness to be de- In lack of a relevant strain concentration factor (SNCF), the
livered from Manufacturer is specified. SNCF may be approximated from elastic stress concentration
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weldments are usually predominately subjected to membrane ~ The J-value vs. the crack mouth displacement or load point
stress and contain weld defects of smaller heights than the displacement can be derived by non-linear elastic-plastic
notch length of standardised specimens. It is therefore justified finite element analysis using the stress-strain curve of the
to use non-standard test specimens that more closely reflects material to be tested.
the crack tip constraint of pipeline weld defects. ~ The CTOD value can be measured by using a double clip
gauge technique . The displacement due to separation of
The formulas given by the test standards for deriving the frac- the crack faces is measured at two different distances from
ture toughness from the load vs. displacement records may not the crack mouth, z1 and z2, e.g. at zero and at 2 mm. The
be valid for non-standard specimen configurations. The frac- CTOD is calculated from the load-displacement curve as
ture toughness shall therefore be derived by one of the tech- 2 2
niques described below or another proven method. (1 - v )' KIr a+z,
SENB test specimens with reduced notch length, but otherwise
6 = ' 2E + VP1- z2 - ( vp2 - Vpl)
in accordance with BS 7448 or equivalent standards, may be
used for deriving the fracture toughness for use in an ECA pro-
vided that the specimen notch length is not chosen shorter than where
the height of the most severe weld defect assessed in the ECA. is the stress intensity factor at the subject
KI
The fracture toughness for SENB test specimens can be de- load
rived from the load vs. clip gauge displacement record accord- Vpl andVp2 are the plastic parts of the clip gauge dis-
ing to the following formulas: placements at z1 and z2 respectively.
2
J=[mxf(g)] + VPAP H. API Material Grades
B w''5 E B(W-U)
H 100 API material grades
qp =
(3 (;I2
3,785-3, 101 - +2,018 -
101 The API requirements to the Grades X42 through X80
are listed in Table 12-4. For full details see the API Specifica-
tion for Line Pipe (API Specification 5L). The SMYS and
where A is the area under the load vs. crack mouth displace- SMTS values given in MPa in the table below are converted
ment (ChOD) curve. For definitions of the other parameters it from the API specification (in ksi), and differ slightly from the
is referred to BS 7448. mechanical properties in Section 6, Table 6-3, which apply for
this standard.
If the total displacement, V,, is measured at a distancez 5 0.2a
from the physical crack mouth then the CMOD can be calcu- Table 12-4 API Material Grades
lated from:
CMOD =
1+
0.8u + 0.2w
1,221 -0,739-
a + 2,751n 1,418n-U
m =
W
-
W
I. Components and assemblies
I100 Bends
It should be noted that the mother pipe shall be subject to hy-
drostatic testing in accordance with Section 6 E1100. This
does however not include the relaxed requirement of Section 6
=
(2;)
OYS
1,724-6.098 - +8.326 - -3.965(-) OYS
(OTS) OT S
E l 108.
For bends made of clad or lined pipe special care should be tak-
en to prevent disbonding andor wrinkling of the cladlining
layer. It may be difficult or impossible to obtain bending radii
of the order of 3D or 5D without disbonding andor wrinkling.
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be used to demonstrate that adequate load transfer will be de- vital importance to have a common understanding between the
veloped and maintained during the life of the structure. The de- disciplines on the choice and requirements of the material. The
sign of the studbolts are to be such that it is possible to monitor sub-section will go through some of the aspects linking design
the remaining bolt tension during the design life time. This can with material and vice versa.
be done by utilising mechanical bolt load indicators in some of An overview of the links between material and design is given
the studbolts in each connection. in Figure 12-2. The different aspects will be discussed in the
The minimum remaining pretension level in the studbolts at following.
which pre-tensioning must be performed is to be determined The design premise will state content, transport requirement,
during the design phase. description of the content etc.
The design is to be such that all the studbolts in one connection The material type and grade will be decided by a life cycle cost
can be pre-tensioned simultaneously by nieans of bolt tension- analyses considering both operational and design aspects.
ing jacks.
All relevant loads are to be considered when calculating the fa-
tigue life of the Riser Supports.
I300 J-tubes
The J-tube system is to be designed to perform satisfactorily
during its entire planned life. It is to be designed against rele-
vant failure modes.
~ The routing is to be based on the following considerations:
~ platform configuration and topsides layout
~ space requirements
~ movements of the J-tube
~ cable/Pipeline approach
~ J-tube protection
~ in-service inspection and maintenance
~ Installation considerations.
The J-tube spools are normally to be joined by welding.
For J-tubes, loads during Installation include:
~ load-out
~ transportation
~ lifting
~ launching
~ upending
~ docking
~ pressure testing
~ temporary supporting.
The effect of deflections due to a connected Pipeline's thermal
expansion or contraction is to be taken into account.
Loads caused by deflections of the J-tube, or the structure to
which the support is attached, are to be considered. Figure 12-2 Overview of links between material and design
Loads on the J-tube and supports as a result of foundation set- J 200 Supplementary requirements
tlements are to be considered. Accidental loads are loads to The supplementary requirements are described in Section 6 0
which the J-tube and support system may be subjected in con-
nection with incorrect operation or technical failure such as Sour service (S) is required if the fluid is defiied as sour ac-
fiie, explosions and impact loads. The relevant accidental cording to the NACE definition, see Section 6D.101.
loads and their magnitude are to be determined on the basis of Fracture arrest (F) is required for pipelines transporting gas or
a risk analysis. mixed gas, see Section 5D. 1103 and 1104, Section 6D 200.
The effect of impact by vessels is to be considered for the J- Supplementary requirement for plastic deformation (P) is re-
tube and support system within the splash zone. Normally the quired if the accumulated plastic strain exceed 2%. The sup-
J-tubes and supports are to be routed inside the structure to plementary requirement also requires testing of strained
avoid vessel impact. material which implies that information about the expected
Consideration is to be given to accidental loads caused by fall- strain cycles should also be given, see Section 5D.1006.
ing objects such as: Supplementary requirement for dimensions (0) is required by
falling cargo from lifting gear supplementary requirement P and else when tight dimensional
control is required.
~
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Figure 12-3 Illustration of when supplementary requirement U and D as well as Linepipe NDT level 1 is required.
Note that it is required in addition to spec@ P, spec@ the an-
ticipated strain cycles.
J 400 Material data sheet
I Certification I I
I Proiect snecific reguirements and/or agreed deviations to/from the Standard are stated below: I
NDT level B100
Designation B300
Design temueratures Max I Min
I Piue diameter I mm I I
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Wall thickness mm
Lengths m
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K. Installation
K 100 Safety class definition
Installation of pipeline and pipeline components is normally
defined as safety class Low. However, if the installation activ-
--```,,`,`,,,`,,````,````,`,```-`-`,,`,,`,`,,`---
(12.13)
should satisfy:
(12.14)
where
R stingerradius =
E,, calculated mean overbend strain =
E,,~ axial strain contribution =
z, 1.O5 safety factor for concrete crushing =
E,, limit mean strain giving crushing of the concrete. =
Positive strain denotes tensile strain.
The mean overbend strain at which concrete crushing first oc-
curs depends on the pipe stiffness, the concrete strength and
thickness, the axial force and the shear resistance of the corro-
sion coating. Crushing occurs at lower mean overbend strains
for lower concrete strength, lower axial force, higher pipe stiff-
ness and higher shear resistance. If no other information is
available, concrete crushing may be assumed to occur when
the strain in the concrete (at the compressive fibre in the mid-
dle of the concrete thickness) reaches 0.2%.
For concrete coating of 40 mm thickness or more, together
with asphalt corrosion coating, a conservative estimate of E,,
is 0.22% for 42" pipelines and 0.24% for 16" pipelines, with
linear interpolation in between.
Reference is made to Endal (1995) or Ness (1995).
K 300 Simplified laying criteria
This simplified laying criteria may be used as a preliminary
simplified criterion of the local buckling check during early
design stages. It does not supersede any of the failure mode
checks as given in the normative part of the standard.
In addition to the simplified stress criteria given below, the
limit states for Concrete Crushing (K200), Fatigue (Sec.5
D700) and Rotation (Sec.5 H203) shall be satisfied. Reference
is further made to Endal et. al. (1995) for guidance on the Ro-
tation limit state.
Overbend
For static loading the calculated strain shall satisfy Criterion I
in Table 12-5. The strain shall include effects of bending, axial
force and local roller loads. Effects due to varying stiffness
(e.g. strain concentration at field joints or buckle arrestors)
need not be included.
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FE analyses have shown that the most important parameters, shore Oil and Gas Pipeline Technology, London, 1987
with respect to stifhess variations are variations, in yield stress Vitali L., Bruschi R., Mmk K., Verley R.(1999); "Hotyiye
and wall thickness. Under disadvantageous circumstances, project - Capacity oj'pipes subjected to internalpressure, axial
variations within normal fabrication tolerances may lead to force and bending moment", Proc. 9th Int. Offshore and Polar
buckling of the pipe cross section. Engineering Conference, Brest 1999.
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Page 118 - A p p A
APPENDIX A
SUPPLEMENTARY REQUIREMENTS TO I S 0
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This hoop stress formula for the I S 0 mill pressure test is dif- identical). Hence, the mill test pressure difference compared to
ferent from the formula in I S 0 13623 and DNV (which are this standard depends on D/t.
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APPENDIX B
MECHANICAL TESTING AND CORROSION TESTING
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~ The weld reinforcement on both faces shall be removed largest possible cross section. The notch shall be perpendicular
flush with the original surfaces, as showed in Fig. B-2. The to the surface.
weld shall be located in the centre of each specimen. Base material
~ The specimens shall be bent to a angle of 180" using a
former with diameter depending on the specified mini- 602 The specimens shall be taken transverse to rolling direc-
mum yield stress SMYS for the parent material. For mate- tion/forging direction/pipe axis whenever possible. However,
rials with SMYS up to 360 MPa, the former diameter shall for pipes with D<300 mm, the specimens shall be taken paral-
be 4x thickness of the test specimen. For materials with lel to pipe axis.
SMYS equal to or exceeding 415 MPa, the former diame- Charpy V-notch testing of welds.
ter shall be 5x thickness of the test specimen.
~ After bending, the welded joint shall be completely within 603 The location of specimens is given in Appendix C Fig.
the tensioned region. C- 1. When the wall thickness exceeds 20 mm for double sided
welds, four additional sets of Charpy-V notch test specimens
Bend test of clad/lined pipes shall be performed on full thick- shall be sampled from the weld metal, FL+ (sampling 50% of
ness of the pipe, including the corrosion resistant alloy. HAZ), FL+2 mm and FL+5 mm in the root area, see Fig. B-6.
Test acceptance criteria are given in Appendix C Part F. Impact testing of clad/lined pipes shall be performed in the car-
bon steel portion of the material.
Longitudinal root bend testing on cladílinedpipes
Charpy V-notch testing of load bearing weld overlay
502 Longitudinal root bend test shall include the corrosion
resistant alloy. 604 When the weld overlay material is designed to transfer
the load across the base materiayweld overlay fusion line, im-
~ The longitudinal axis of the weld shall be parallel to the pact testing of the weld overlay and HAZ shall be performed
specimen, which is bent so that the root surface is in ten- (i.e. when the overlay is a part of a butt joint or acts as a tran-
sion. sition between a corrosion resistant alloy and a carbon steel).
~ The width of the longitudinal root bend specimen shall be The longitudinal axis of the specimen shall be perpendicular to
at least twice the width of the internal weld reinforcement the fusion line and the notch parallel to the fusion line.
or maximum 25 mm. The edges may be rounded to a radi- Test acceptance criteria are given in Appendix C Part F.
us of 1/10 of the thickness.
~ The internal and external weld reinforcement shall be re- A 700 Drop weight tear test (DWTT)
moved flush with the original surfaces. 701 Drop weight tear test shall be carried out in accordance
~ The thickness of the specimen shall be equal to the base with API RP 5L3.
material thickness or a maximum of 10 mm, as shown in
Fig. B-3. Drop weight tear test specimens
~ The specimen shall be bent to an angle of 180" using a 702 Full thickness specimens are preferred. Reduced speci-
former with diameter 90 mm. men may be used subject to Purchaser agreement. If reduced
thickness specimens are used, both surfaces shall be equally
Test acceptance criteria are given in Appendix C Part F. machined to the thickness of 19.0 mm. The testing temperature
Bend testing of weld overlay reduction given in API RP 5L3 shall apply.
503 Side bend test specimens shall be used. The test speci- The specimens shall be taken transverse to the rolling direction
or pipe axis, with the notch perpendicular to the surface.
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mens shall be sampled perpendicular to the welding direction.
Reference is made to Section 6D.204.
~ For pipes the test specimens shall sample the full thickness
of the weld overlay and the base material. For heavy sec- A 800 Fracture toughness testing
tions the thickness of the base material in the specimen
shall be at least equal to 5x the thickness of the overlay. Fracture toughness testing (CTOD or critical J testing and d-R
~ The thickness of side bend specimens shall be 10 mm. The or J-R testing) shall be carried out in general compliance with
edges may be rounded to a radius of 1/10 of the thickness. the latest revisions of the relevant parts of BS 7448 or an equiv-
The central portion of the bend test specimen shall include alent standard.
an overlap area. The number of valid CTOD or critical J tests for each location
~ The specimens shall be bent to an angle of 180". For base shall be minimum 3. The characteristic CTOD or critical J val-
materials with SMYS up to 415 MPa the former diameter ue shall be taken as the lowest from 3 valid tests or selected in
shall be 4x thickness of the test specimen. For base mate- accordance with BS 7910. For testing specimens with notch lo-
rials with SMYS equal to or exceeding 415 MPa the cation in fusion line/HAZ, it is recommended to test at least 6
former diameter shall be 5x thickness of the test specimen. specimens in order to obtain 3 valid specimens. Only speci-
mens that are qualified with respect to crack tip location by
Test acceptance criteria are given in Appendix C Part F. post-test metallographic examination shall be considered val-
id.
A 600 Charpy V-notch impact test
Qualification of linepipe
601 The impact test shall be carried out in accordance with
the requirements of this Appendix and IS0 148. The test pieces 801 The following applies when the requirements to fracture
shall be prepared in accordance with IS0 148 without any prior toughness are set as workmanship criteria with respect to qual-
flattening of the test material. Standard (i.e. full size) speci- ification of linepipes:
mens shall be used whenever possible. Each set shall consist of Testing of weld metal and of base material only.
three specimens taken from the same test coupon. The test tem- The test specimen geometry shall be in accordance with the
perature shall be in accordance with Section 6 Table 6-4 or as test standard using through thickness notched specimens.
relevant..
Testing of parent material shall be conducted on specimens
Test acceptance criteria are given in Section 6 Table 6-3 or Ta- taken both in the longitudinal and the transverse pipe direction.
ble 6-6 as applicable. Either through thickness notched specimens of rectangular
The specimens shall be sampled 2 mm below the surface. A sections (Bx2B) or surface notched specimens of square sec-
smaller distance than 2 mm shall be used if necessary (due to tions (BxB) shall be used. (With the notation used by BS 7448
the dimensions of the material) to make specimens with the assuming axial grain flow the test specimens are to of type X-
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weld metal centre line. tempered forgings and castings in low-alloy steels the require-
ments of Section 7F shall apply in addition.
Testing of fusion line/HAZ shall be conducted on surface
notched specimens of square sections (BxB) with orientation Micro examination of duplex stainless steels shall be per-
transverse to the weld direction. (The corresponding notation formed at a minimum magnification of x400.
used by BS 7448:1991 is NQ). The specimen shall be notched Acceptance criteria are given in Section 6C 300, C 400, C 500
so that the direction of crack extension cross the fusion line as applicable.
from the weld metal side or is parallel with the fusion line. Hardness testing of base material
Following testing of fusion line/HAZ each specimen shall be 1003 Hardness testing of base material shall be carried out
qualified with respect to the location of the fatigue pre-crack according as shown in Fig B-4a. The Vickers HV10 method
tip by post-test metallography as outlined in the test standard. according to IS0 6507.
The specimen is considered qualified if
Hardness testing of welds
a) the pre-crack tip is not more than 0.5 mm from fusion line
1004 Hardness testing shall be performed in accordance with
and IS0 6507-1 on the specimens used for macro examination.
b) grain coarsened heat affected zone (GCHAZ) micro-struc- The Vickers method HV10 shall be used. Indentations shall be
ture is present within a region confined by a line perpendicular made along traverses, each 1.5 mmM.5 mm below the surface
to the crack plane through the crack tip and a parallel line 0.5 at either side of the weld.
mm ahead of the crack tip.
In the weld metal, a minimum of 3 indentations equally spaced
803 The following applies when determination of the frac- along each traverse shall be made. In the HAZ, indentations
ture resistance curve ( 6 R or J-R curve) is carried out in con- shall be made along the traverses for each 0.5 mm into unaf-
junction with an Engineering Critical Assessment (ECA): fected material, and starting as close to the fusion line as pos-
Testing shall be conducted at a temperature representative of sible. A minimum of 3 indentations on either side of the weld
the most severe loading condition. shall be made into the unaffected material spaced approxi-
The geometric configurations of the test specimens shall be as mately 1 mm. Refer to Fig. B-4.
stated in 802. For double sided welds, one additional hardness traverse shall
Following testing of fusion line/HAZ each specimen shall be be made through the root area, see Fig. B-4 b).
qualified with respect to the location of the fatigue pre-crack Hardness testing of cladlined pipes shall have one additional
tip as required in 802. hardness traverse located in the thickness centre of the clad-
804 When CTOD or critical J fracture toughness testing is ding. Refer to Fig. B-5 a) in for longitudinal welds in pipes and
carried out in conjunction with an Engineering Critical Assess- Fig. B-5 b) for girth welds.
ment (ECA), modification of test specimen geometry and load- Acceptance criteria are given in Appendix C Part F..
ing mode in order to reduce unintended conservatism are
acceptable provided that all modifications are well founded on For hardness testing of weld overlay, the Vickers method
generally accepted fracture mechanics theory and experimen- HV10 shall be used. Hardness testing shall be performed at a
minimum of 3 test locations each: in the base material, in the
tal documentation.
HAZ and in each layer of overlay up to a maximum of 2 layers.
Further guidelines for use of such specimens are given in Sec-
tion 12 of this document. Acceptance criteria are given in Appendix C Part F.
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orientation of the coupon shall be transverse to the pipe axis for 206 Rolled surfaces shall be tested "as-received", i.e. with-
pipes with D 2 300 mm. For smaller diameters, the coupon out mechanical preparation. The root and the cap side of the
shall be oriented parallel to pipe axis. The coupon may be welds are only to be prepared with the intention of removing
straightened prior to uniform tension in order to obtain full size "loose material" that will interfere with weighing prior to and
specimens. after testing. Cut faces shall be ground (500 grid) and sharp
The test coupon shall be of either full or reduced wall thick- edges smoothed off. The specimen shall subsequently be pick-
ness. The reduced (parallel) section of the coupon shall have a led to reduce the susceptibility of cut surfaces to end-grain at-
width and thickness sufficient to produce the required number tack. For duplex stainless steels and austenitic grades with
of standard (full size) Charpy V-notch specimens needed for PRE > 30, 20% nitric acid + 5% hydrofluoric acid, 5 minutes
the test. at 60°C is adequate.
After preparation the test coupon shall be aged at 250°C for 207 The test solution shall be prepared according to the ref-
one hour. Thereafter, the specified number of Charpy V-notch erenced standard. For 25 Cr duplex and austenitic CRAs with
specimens shall be machined from the middle of the coupon. a specified PRE value of minimum 40 (see Section 6 Table 6-
The orientation of the specimens shall be longitudinal to the 5) the test temperature shall be:
coupon centreline, with the notch perpendicular to the surface ~ 50°C for base materials (including longitudinal weld, if
of the test coupon. applicable);
Acceptance criteria are given in Section 6D.203. ~ 35°C and 40°C for girth welds in 25 Cr duplex and auste-
nitic CRAs respectively.
The test period shall be 24 hours.
B. Corrosion Testing
Corrosion testing of weld overlay
B 100 General 208 Specimens for corrosion testing of the weld overlay
101 For certain linepipe material and fluid combinations shall be machined from the base material side. The remaining
where improper manufacture or fabrication can cause suscep- surface of the specimen shall be representative for the weld
tibility to corrosion related damage, the need for corrosion test- overlay at the minimum distance from the fusion line (equal to
ing during qualification andor production shall be assessed. 3 mm or the minimum weld overlay thickness specified for the
Certain corrosion tests are applicable to c o n f i adequate finished machined component, whichever is the lesser). The
manufacturing and fabrication procedures affecting the micro- opposite surface of the specimen shall be machined such that
structure. the thickness of the specimen is 2 mm. The size of the speci-
men shall be 25 x 25 mm in length and width.
This subsection describes test requirements and methods for
corrosion te sting. B 300 Hydrogen Pressure Induced Cracking test
Test laboratories shall meet the requirements in A. 102 above. 301 Hydrogen Pressure Induced Cracking (HPIC) testing
shall be carried out based on NACE TM0284 "Evaluation of
B 200 Pitting corrosion test
Pipeline Steels for Resistance to Stepwise Cracking" modified
201 This test is applicable to ver@ CRA resistance to pitting according to EFC Publication Number 16 Iv2Guidelineson Ma-
and crevice corrosion by oxidising and chloride containing flu- terials Requirementsfor Carbon Steel and Low Alloy Steels for
ids, e.g. raw seawater and other water containing fluids (in- HS-containing Environments in Oil and Gas Production".
cluding treated seawater) with high residual contents of
302 Evaluation and acceptance criteria shall comply with
oxygen andor active chlorine. For duplex stainless steels, this
EFC Publication Number 16.
test is further applicable to ver@ adequate microstructure re-
lated to manufacturing and fabrication procedures affecting B 400 Sulphide Stress Cracking test
e.g. toughness and weldability in addition to corrosion resist-
ance. 401 Linepipe materials to be used for sour service and not
meeting the general requirements in Section 6D 100, shall be
202 The test shall be carried out according to ASTM G48 qualified by testing for resistance to Sulphide Stress Cracking
"Standard Test Methods for Pitting and Crevice Corrosion Re- (SSC) as specified in Section 6D.102.
sistance of Stainless steels and Related Alloys by the Use of
Ferric Chloride solutions", Method A. 402 For qualification of new materials (i.e. not listed for sour
service in the latest edition ofNACE MR0175), testing shall be
203 Requirements for frequency and extent of testing during conducted on specimens from at least 3 heats of material. If
manufacture and installation are defined in Section 6E 800 and qualification is to be performed for a material listed for sour
Section 9A 800, respectively. Location of specimens is given service in NACE MRO175 but not meeting the requirements
in Fig. B-2. for a specific property in Section 6D 100, e.g. maximum hard-
204 Test specimens from cladlined pipe shall be machined ness or contents of alloying or impurity elements, then testing
to remove the carbon steel portion and are to contain the full shall be carried out on material representing the worst case
weld and any heat affected zone in the corrosion resistant al- conditions to be qualified.
loy. 403 Qualification testing shall include testing of simulated
205 The minimumrecommended size of test specimens is 25 girth welds and for welded pipe also seam welds. Specimen
mm wide by 50 mm long by full material thickness. For welds, preparation, testing procedures and acceptance criteria shall
at least 15 mm of the base material on each side of the weld comply with either EFC publication No. 16 and 17 for C-Mn
shall be included in the test specimen. and CRA linepipe respectively, or NACE TM0177-96.
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Figure B-5Hardness locations cladded materials
Figure B-6 Charpy V-notch specimen location for testing The "FL" specimen shall sample 50% WM and 50% HAZ. The
in the root area of double sided welds FL+2mm and FL+5mm specimens shall be sampled 2 and 5
mm from the fusion line nose formed where the two fusion
lines come together.
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APPENDIX C
WELDING
A. Application calibration and testing of all tools and welding equipment used
during qualification/production welding.
A100 General
B 200 Personnel
101 This appendix applies to all fabrication involving shop-
, site- or field welding including post weld heat treatment. 201 All personnel involved in welding related tasks shall
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have adequate qualifications and understanding of welding
102 The materials covered by this appendix are: technology. The qualification level shall reflect the tasks and
~ C-Mn steel; responsibilities of each person in order to obtain the specified
~ cladlined steel; and quality level.
~ corrosion resistant alloys ( C U ) including ferritic auste- Welding Co-ordinator
nitic (duplex) steel, austenitic stainless steels, martensitic 202 The Manufacturer organisation shall nominate at least
stainless steels ("13% Cr"), other stainless steels and nick- one authorised welding Co-ordinator in accordance with EN
el based alloys. 719.
The materials are addressed with and without requirements for Welding operators, welders and air-arc gaugers
sour service. The material requirements are specified in Sec- 203 Through training and practise prior to qualification test-
tion 6 and Section 7. ing, the welding personnel shall have a understanding of;
A 200 Welding processes ~ fundamental welding techniques,
201 Welding may be performed with the following processes ~ welding procedure specifications,
unless otherwise specified: ~ relevant methods for non-destructive testing, and
acceptance criteria.
Shielded Metal Arc Welding (SMAW / 11i),
~
~ Flux Cored Arc Welding without gas shield (FCAW /114), 204 Welders and welding operators shall be certified in ac-
~ Flux Cored Arc Welding with external gas shield (G- cordance with EN 287, IS0 9606 or other relevant and recog-
FCAW / 136), nised standards, for the respective positions, material grades
~ Gas Metal Arc Welding (GMAW / 135), and welding processes.
~ Gas Tungsten Arc Welding (GTAW / 141),
~ Submerged Arc Welding (SAW / 12), and 205 Qualification testing according to EN 1418 or equivalent
Plasma Arc Welding (PAW / 15). is required for welding operators where their tasks are to pre-
set, adjust, start, guide and stop the welding operation.
~
Guidance note: 206 Welders shall be qualified for single side butt welding of
GMAW and FCAW are regarded as methods with high potential pipes in the required principal position. Welders may be qual-
for non-fusing type defects ified for part of the weld, root, fillers or cap by agreement. Re-
pair welders may be qualified for partial thickness repair on a
representative test configuration provided only such weld re-
202 Pre-qualification shall be performed to document that pairs are made.
welds meeting all specified requirements under realistic field 207 The qualification test shall be carried out with the same
conditions can be consistently produced. or equivalent equipment to be used during production welding,
Pre-qualification testing is considered necessary for the fol- and should be at the actual premises, i.e. work shop, yard, and
lowing welding process: vessel. Use of other premises shall be specially agreed.
~ resistance welding (high frequency welding), 208 Qualification testing shall be based on 100% visual ex-
amination, 100% radiographic or ultrasonic testing, and 100%
~ flash butt welding, magnetic particle or liquid penetrant testing. Test requirements
~ friction welding, shall be in accordance with Appendix D, H.
~ radial friction welding,
~ electron beam welding, and 209 When using processes which have high potential for
~ laser welding non-fusing type defects, bend testing shall be performed. The
number of bend tests is specified in Table C-l.
203 Prior to qualification testing, general information of the
welding procedure and possibly reference to practical experi-
ence and joint quality shall be documented. The extent and the
content of the pre-qualification program shall be agreed before Pipe diame- Wall Face- Root- Side-
start up. ter(mm) Thickness bendtests bendtests bendtests
(m.1)
A 300 Quality Assurance
D < 100 O 2 O
Requirements for Quality Assurance are given in Section 2B 100 < D < 300 t<O O 2 O
500. D > 300 2 2 O
D < 100 O O 2
100 < D < 300 t t 20 O O 2
D > 300 O O 4
B. Welding Equipment, Tools and Personnel
B 100 Welding equipment and tools
101 Inspection of the workshop, site or vessel prior to start of
production shall be required. This shall include verification of
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plete and acceptable welding procedure qualification is there- welding consumables in order to meet the any guaranteed max-
by qualified. imum value for hydrogen in the weld metal. Recommendations
211 When a qualification testing of recent date is transferred for post weld heat treatment (maximum temperature, holding
to a new project, the welding personnel shall be informed time, etc.) should also be provided.
about particular project requirements for which their welding Guidance note:
performance will be especially important. The Contractor responsible for the welding and the welding con-
212 Personnel to perform air-arc gouging shall be trained sumable Manufacturer should agree on the content and the spec-
ified limits in the data sheets
and experienced with the actual equipment. Qualification test-
ing may be required.
Hyperbaric welding
C 200 Chemical composition
213 Prior to qualification testing for underwater (hyperbaric)
welding, welders shall have passed a surface welding test as 201 All welding consumables shall be delivered in accord-
specified above and shall have received relevant training for ance with Manufacturer's data sheets, which shall state the
hyperbaric welding. minimum and maximum levels of C, Mn, Si, P, S, micro-alloy-
214 Qualification for underwater welding shall, as a mini- ing elements and any other intentionally added elements.
mum, consist of one test in the habitat (or at a testing facility 202 When sour service is specified, the chemical composi-
under representative conditions for the work in question), and tion of the welding consumables shall comply with NACE
shall be in accordance with the qualified underwater welding MR-0175. The Ni-content may be increased up to 2.2% in
procedure. The test weld shall be visually examined and non- welding consumables for girth welds, provided that other re-
destructively tested. Mechanical testing shall be in accordance quirements in EFC 16 are fulfilled, and that the welding proce-
with Table C- 1. dure has been tested for resistance to SSC.
215 Renewal of the qualification (214 above) may be re- 203 The selection of welding consumables shall be given
quired if welding has been interrupted for a period more than 6 special attention in order to avoid any types of preferential
months. The retest shall as a minimum consist of one test cou- weld corrosion. This applies particularly to material with en-
pon with an approximate length of 300 - 400 mm. The welding hanced corrosion properties, and for selection of welding con-
shall be performed in an agreed welding position under repre- sumable for the root pass in systems for seawater service.
sentative conditions, followed by visual examination and non-
destructive testing. 204 The chemical composition of the weld overlay materials
shall comply with the material requirements specified for the
applicable type of overlay material or with a project specifica-
tion.
C. Welding Consumables C 300 Mechanical properties
C 100 General 301 The weld metal shall, as a minimum, have strength, duc-
101 Welding consumables shall be suitable for their intended tility and toughness meeting the requirements of the base ma-
application, giving a weld with the required properties and cor- terial. The yield stress (Rt0.5) of welding consumables should
rosion resistance in the finally installed condition. be within the range 80 - 250 MPa above the SMYS of the re-
spective base material.
102 Welding consumables for arc welding shall be classified
according to recognised classification schemes. 302 For girth welds, all batches of consumables used in pro-
duction including possible wire / flux combinations shall be
103 Low hydrogen consumables and processes shall be used qualified by testing according to C 400.
for welding of all C-Mn steels. However, cellulose coated elec-
trodes may be used for welding C-Mn steels with SMYS 5 415 303 Welding consumables for welds in pipelines exposed to
provided special welding procedures preventing hydrogen in- accumulated plastic strain from the installation method andor
duced cracking are established. operational loads requires special attention for selection of
yield stress, see E 600 and Section 6D 300. The yield stress
104 Low hydrogen consumables shall give a diffusible hy- (Rt0.5) of welding consumables should be within the range 80
drogen content of maximum 5 mV100g weld metal. Hydrogen - 200 MPa above the SMYS of the respective base material.
testing shall be performed in accordance with I S 0 3690 or BS Response to straining and ageing shall meet the requirements
6693-5. of the base material when tested in accordance with E 600.
105 Welding steels with SMYS 2 415 MPa shall be given
special consideration in order to ensure safety against cold C 400 Batch testing - Girth welds
cracking in the HAZ andor the weld metal. Attention shall 401 The purpose of batch testing is to ver@ that the consum-
also be given to the requirements for the relationship between ables used for girth welds remain nominally equivalent to that
the yield and tensile strength of weld metal and base material. used for welding procedure qualification, with respect to
106 Welding consumables for processes other than manual chemistry and mechanical properties.
or mechanised arc welding may require special consideration 402 Batch testing shall be conducted when ECA is per-
with respect to certification, handling and storage. formed and always for steels with SMYS 2 415MPa for all
107 All welding consumables shall be individually marked welding consumables, including possible wire/flux combina-
and supplied with an inspection certificate type 3.1B according tions when new batches other than the one used for welding
to EN 10204 or equivalent. Certificate type 2.2 is sufficient for procedure qualification is to be used for installation welding.
SAW flux. 403 For this standard a batch is defiied as the volume of
Data Sheet product identified by the supplier under one unique batch
108 Each welding consumables or combination of welding number, manufactured in one continuous run from batch con-
consumables shall be delivered in accordance with a data trolled raw materials.
sheet. The data sheet shall give guaranteed limits andor mini- 404 Each individual product (brand name and dimensions)
mum values for composition and mechanical properties, deter- shall be tested once per batch, except for solid wire originating
mined under defined reference conditions. The data sheet from the same heat, where one diameter may represent all.
should give recommendations for handling/recycling of the SAW fluxes do not require individual testing, however, SAW
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wires shall be tested in combination with a selected, nominal may be based on previously qualified welding procedures pro-
batch of flux. vided that all the specified requirements can be fulfilled.
405 The testing shall be performed on samples taken from 102 All welding shall be based on welding consumables and
girth welds welded according to the welding procedure to be welding techniques proven to be suitable for the type of mate-
used in production. Three samples shall be removed from the rial and type of fabrication in question. A welding procedure
12 and 6 o'clock position and from the 3 or 9 o'clock position. specification shall as a minimum contain the following infor-
The testing of each sample shall include: mation:
~ 1 all-weld metal tensile test. Hardness testing (HV10) of material standard, quality level, grade and project specifi-
the centre at the end of each grip; cation;
~ 1 macro section taken adjacent to the all-weld metal ten- diameter and wall thickness (or range);
sile test. The macro section shall be hardness tested groove preparation and design, including tolerances;
(HV10) vertically through the weld centre line with inden- welding process;
tations spaced 1.5mm apart; number and location of welders;
~ 1 set of Charpy V-notch test at weld centre line in half welding consumable, trade name and recognised classifi-
thickness. Test temperature shall be the same as for quali- cation;
fication of the relevant procedure; and gas mixture and flow rate;
~ If required due to ECA, fracture toughness testing shall be welding rod I wire diameter;
performed of the weld metal at the minimum design tem- quantity of added metal powder or wire;
perature. welding parameters: current, voltage, type of current, po-
larity, travel speed, wire stick out and wire angle for each
arc (or range);
Chemical analysis number of welding arcs as well as cold and hot wire addi-
tion;
406 For solid wire and metal powders the analysis shall rep- welding position(s) and direction;
resent the product itself. For coated electrodes and cored wires, stringer or weaving;
the analysis shall represent the weld metal, deposited accord- nozzle size;
ing to EN 26847 (IS0 6847). The analysis shall include: number of passes;
~ all elements specified in the relevant classification stand- number of passes before barge move-up;
ard and the relevant data sheet, see 201; and clamping (internal or external);
the N content. maximum time laps between passes;
minimum preheat and interpass temperature range; and
~
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D>300mm. 1G (PA)
~
I 2~ ( p c j I 1&2G’(PA+PC) I
Thickness: A change outside the thickness interval 0.75 t to 1.5 5G (PF/PG) I G + ~ G + ~(PA+PF/PG)
G
2G + 5G @C+PF/PG) All
t for t 5 30 mm, where t is the nominal thickness of the test 6G (H-L045) All
joint, excluding the thickness of any corrosion resistant clad-
ding. For t > 30 mm a change outside the thickness interval Note 1 qualification welding on butt joints may also be applicable for weld-
ing of fillet welds, e.g. 1G and 5G may also be applicable for 1F and
0.75 t to 1.25 t. 5F respectively.
Groove configuration: Any change in groove dimensions out-
side the tolerances specified in the agreed WPS. 604 The essential parameters for underwater welding are
those specified above plus the following:
Line-up clamps: Change from external to internal or vice ver-
sa. Pressure inside the chamber: Any change.
Weldingprocess: Any change. Gas composition inside the chamber: Any change.
Number of wires: Change from single-wire to multiple-wire Humidity: Any increase beyond + 10% Rh of the maximum
system or vice versa. level during qualification.
Welding equipment:
Any change in equipment type and model for mechanised
E. Qualification of Welding Procedures
~
welding;
~ Any change in equipment type and model when semi- E 100 General
mechanised welding equipment (equipment with wire
feeding for manual welding) is used for installation weld- 101 Qualification welding shall be performed basedupon the
ing (including underwater welding). accepted pWPS, using the type of welding equipment to be
used during production welding, and under conditions that are
Arc characteristics: Any changes affecting the transfer mode
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shop, site, vessel or the habitat where the production welding 203 When a heat treated pipe or component is repaired by
will be performed (see D 200, D 300, D 400). welding, a new suitable heat treatment may be required to be
102 The number of test joints shall be sufficient to obtain the included in the qualification of the weld repair procedure, de-
required number of specimens for the destructive tests speci- pending on the effect of the weld repair on the properties and
fied. Allowance for re-testing should be considered when de- microstructure of the existing weld and base material.
ciding the number of test joints to be welded. 204 Extent of NDT, mechanical testing and corrosion testing
103 The test joints for qualification welding shall be of suf- (if applicable) shall be as for the production welding procedure
ficient size to give realistic restraint during welding. qualification, but with additional impact testing in the HAZ be-
tween existing weld metal and repair weld. The number and lo-
104 The welding qualification test shall be representative for cation of the additional impact test sets shall be agreed on a
the production welding with respect to angle of pipe axis, in- case by case basis. Repair welding procedures shall meet the
terpass temperature, application of preheat, heat conduction, same requirements as the original weld. Full and half thickness
time between each layer, etc. The base material selected for the repair shall be tested as a main procedure. For other repairs:
qualification testing should be representative of the upper macro, bend and hardness.
range of the specified chemical composition for C-Mn steel,
and of the nominal range of the specified chemical composi- 205 The qualification test shall be made on pipe nipples or
tion for corrosion resistant alloys. If tack welds are to be fused pipe components in a manner realistically simulating the repair
into the final joint during production welding, they shall be in- situation to be qualified, e.g.
cluded when welding the test piece. ~ full and 1/2 thickness repair,
105 For qualification welding of procedures for linepipe or ~ shallow surface repair of the weld seam, and
linepipe components containing longitudinal welds, attention ~ single pass repair.
should be paid to the requirement for obtaining a macro and
hardness test specimen from the longitudinal weld, see note 2 The length of the pipe nipple or test material shall be sufficient
in Fig. C-2 and note 8 in Table C-3. For all welding positions, to give realistic restraint.
except 1G (PA) and 2G (PC), it is recommended that one of the 206 Weld repairs performed from the inside of a single-sided
pipes used for the welding procedure qualification test be fixed joint shall be qualified separately, when internal weld repairs
with the longitudinal weld in the 6 or 12 o'clock position. are agreed.
106 Fillet welds to pressure containing pipes or components
E 300 Qualification of longitudinal and spiral welds in
may be qualified by a full penetration butt joint, provided that
linepipe and linepipe components
the essential variables in D 600 are applied.
301 Pre-qualification testing is required for manufacturers
107 Qualification of weld overlay shall be performed on a
with limited experience of fabrication of linepipe and linepipe
test sample which is representative for the size and thickness
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1) For HFW pipes, the tensile specimen shall be located along the weld seam within the heat-treated area
2) Two additional side bend specimens shall be tested for cladlined pipe
3) Each Charpy V-notch set consist of 3 specimens Impact testing shall be carried out with the V-notch in the weld metal, in the fusion line (FL), in FL+2
mm and FL+5 mm Impact testing is not required for t i6 mm
4) Where several welding processes or welding consumables are used, impact testing shall be carried out in the corresponding weld regions, if the region
tested cannot be considered representative for the complete weld
5) For double sided welds on C-Mn steels with S M Y S > 415 MPa, four additional sets of Charpy V-notch test specimens shall be sampled from the weld
metal, FL (sampling 50% of HAZ), FL + 2 mm and FL + 5 mm in the root area, refer Fig B-6 in Appendix B
6) When the wall thickness exceeds 20 mm for single sided welds, two additional sets of Charpy V-notch test specimens shall be sampled from the weld
metal root and FL in the root area
7) For HFW pipes, impact testing shall be conducted with the Charpy V-notch located in the FL, FL+2 mm and in the Transformation Line (TL) (TL which
has been formed during the local heat treatment subsequent to welding)
8) Requirements for corrosion tests and microstructure examination are specified in F and depend on service and the type of material
9) Three base material and three weld metal specimens Fracture toughness testing is not required for t i13 mm
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3) For girth welds in welded pipe, one macro and hardness shall include a longitudinal pipe weld.
9) Requirements for corrosion tests and microstructure examination are specified in F, and depend on the service and type of material, see Section 6.
10) Bend tests on cladllined pipes shall be performed as side bend tests.
I l ) Longitudinal bend tests are only applicable for cladllined pipe.
12) Fracture toughness testin shall only be performed when required for Engineering Critical Assessment (ECA), see F.314. Extent of testing shall be in
accordance with Auuenfix BA 800. unless soecified otherwise.
E 500 Qualification of girth welds for installation and performed by any of the arc welding processes specified in
tie-in A200.
501 Installation, general 504 The WPS shall be qualified by NDT, mechanical testing
502 Pre-qualification testing is required for Contractors hav- and corrosion testing (if applicable) prior to start of any pro-
inp limited exnerience with installation and tie-in weldinp duction
" to
thë agreed spekfication. 505 The type and number of destructive tests for welding
503 Qualification of welding for installation and procedure qualification are given in Table C-4 with method
tie-in of pipelines systems and pipeline components may be and acceptance criteria as specified in F below. For welding in
position 1G (PAI and 2G (PCI. the number of mechanical tests
may be red&ed'to half of what is specified in Table C-4 sub-
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formed as a "buttering" test providing considerations are made C-3 to Table C-6. Sampling of test specimens is shown in Fig.
to start/stop and that access limitations for the actual produc- C-1 and Fig. C-2 for longitudinal welds in linepipes and line-
tion welding is simulated. pipe components and girth welds respectively.
703 The qualification program may be extended in cases 302 Test specimen dimensions and methods for testing are
where the underwater welding will occur under conditions given in Appendix B.
where previous experience is limited, or will be undertaken by
a company with limited experience in this field. 303 If test results are influenced by improper sampling, ma-
chining, preparation, treatment or testing, then the test sample
704 If a welding procedure is to be used over a large range of and specimen (as relevant) shall be replaced by a correctly pre-
depths, it may, subject to special evaluation in each case, re- pared sample or specimen and a re-test may be performed.
quire qualification testing at one or several pressures.
304 A test failing to meet the specified requirements may be
705 Voltage and amperage of the welding circuits should re-tested. The reason for the failure shall be investigated and
preferably be continuously monitored at the arc. If voltage is
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Note 1: The indicated location of the test specimensare not required for qualification ofwelding in the 1G @A) and 2G @C) positions, where
sampling positions are optional.
Note 2: For welded pipe, one macro and hardness shall include a longitudinal pipe weld.
Figure C-2 Welding procedure qualification test - girth wleds, sampling of test specimens
All-weld tensile testing not be less than those specified for the weld metal (see C 300)
306 The upper yield or the R ~and~the,tensile
~ strength shall and the elongation shall not be less than that specified for the
base material. When different material grades are joined, the
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acceptance level of the weld metal shall be at least equal to the the corrosion resistant portion of the weld examined in accord-
minimum specified strength of the lower grade. ance with Section 6C 500.
Bend testing 504 Other C u ' s shall have the microstructure examined in
307 The guided bend tests shall not disclose any open defects accordance with Section 6C 400.
in any direction exceeding 3 mm. Minor ductile tears less than F 600 Testing of weld overlay
6 mm, originating at the specimen edge may be disregarded if
not associated with obvious defects. 601 When the weld overlay is not contributing to strength,
tensile testing and Charpy V-notch testing of the weld overlay
Longitudinal root bend testing on cladílinedpipes material are not required. When the weld overlay strength is
308 The guided bend tests shall not disclose any open defects considered as a part of the design, such mechanical testing of
in any direction exceeding 3 mm. Minor ductile tears less than the weld overlay material is required.
6 mm, originating at the specimen edge may be disregarded if 602 The base material shall retain the minimum specified
not associated with obvious defects.
mechanical properties after any post weld heat treatment. The
Charpy V-notch impact testing base material properties in the post weld heat treated condition
309 The average and single Charpy V-notch toughness at shall then be documented by additional testing and recorded as
each position shall not be less than specified for the base ma- a part of the welding procedure qualification.
terial in the transverse direction (KVT values), see Table 6-3, 603 The testing in 604 through 607 shall, as a minimum, be
Table 6-4, Table 6-6. Any requirement for fracture arrest prop- performed when the overlay material is not considered as part
erties as listed in shall not apply for the weld and HAZ. of the design and when the base material has not been affected
310 When different steel grades are joined, a series of impact by any post weld heat treatment.
tests shall be performed in the HAZ on each side of the joint. Bend testing of weld overlay
The weld metal shall meet the more stringent energy require-
ment. 604 The bend testing shall be performed in accordance with
Appendix B A 500. The guided bend tests shall disclose no de-
Macro section fects exceeding 3 mm. Minor ductile tears less than 6 mm,
311 The macro section shall be documented by photographs originating at the specimen edge may be disregarded if not as-
(magnification of at least 5x). sociated with obvious defects.
312 The macro section shall show a sound weld merging Macro examination of weld overlay
smoothly into the base material without weld defects accord- 605 The macro sections shall be documented by mac-
ing to the visual examination and NDT acceptance criteria in rographs. The macro section shall show a sound weld merging
Appendix D. smoothly into the base material without weld defects accord-
Hardness testing ing to the visual examination and NDT acceptance criteria in
Appendix D.
313 The maximum hardness shall not exceed the limits given
in Section 6C 200, Section 6C 300, and Section 6D 100 as ap- Hardness testing of weld overlay
plicable for the intended service and type of material tested. 606 The maximum hardness for base material and HAZ shall
Fracture toughness testing not exceed the limits given in Section 6 C 200, Section 6 C
300, Section 6 C500, Section 6 D 100 as applicable for the in-
314 Fracture toughness shall not be less than specified for tended service and type of material. The maximum hardness
the base material and weld in Section 6 C. For girth welds frac- for the overlay material shall not exceed the limits given in
ture toughness testing shall only be performed when required NACE MR-O175 for sour service, unless otherwise specified.
for Engineering Critical Assessment (ECA), see Section 9E.
Extent of testing shall be in accordance with Appendix BA Chemical analysis of weld overlay
800. 607 The chemical composition shall be obtained in accord-
Testing of girth welds exposed to accumulatedplastic strain ance with Appendix B A 300. The location for the chemical
analysis shall be considered as the minimum qualified thick-
315 The girth weld shall be plastically deformed and aged in ness to be left after any machining of the corrosion resistant
accordance with E 600. The mechanical testing specified by weld overlay. The chemical composition of the weld deposit
Table C-5 shall meet the requirements in Section 6D 300. The metal shall comply with the applicable specification for the
difference in values obtained for the yield stress of base mate- type of alloy specified for the overlay material.
rial and weld metal should be within a range of 100 MPa.
All-weld tensile testing of load bearing weld overlay
F 400 Sulphide stress cracking test
608 All-weld tensile testing shall be performed in accord-
401 Sulphide stress cracking testing is to be performed to ance with Appendix B A400.
qual@ materials not meeting the requirements for sour service
according to Section 6D 100. Testing procedures are specified 609 The yield stress and ultimate tensile strength of the weld
in Appendix BB 400 deposit shall be at least equal to the material strength used in
the design.
F 500 Corrosion Testing and Microstructure Examina- Charpy V-notch impact testing of load bearing weld overlay
tion
610 When the weld overlay material is designed to transfer
Corrosion test the load across the base materiayweld overlay fusion line, im-
501 25 Cr duplex stainless steel shall be subject to pitting pact testing of the weld overlay and HAZ shall be performed
corrosion test. Testing procedures are specified in Appendix (i.e. when the overlay is a part of a butt joint or acts as a tran-
BB 200, and the acceptance criteria are given in Section 6C sition between a corrosion resistant alloy and a carbon steel).
300. 611 The average and single Charpy V-notch toughness at
Microstructure examination. each position shall not be less than specified for the base ma-
terial. When different steel grades are joined, a series of impact
502 Welds in duplex stainless steel shall have the micro- tests shall be considered in the HAZ on each side of the joint.
structure examined in accordance with Section 6C 300. The weld metal shall meet the more stringent energy require-
503 Cladlined steel pipes shall have the microstructure of ment.
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Corrosion testing and microstructure examination of weld minimum interpass temperature of the pass in question shall be
overlay applied.
612 Requirements for corrosion testing and microstructure 210 Supports, attachments, lifting devices etc. used for per-
examination of stainless steel and nickel base weld overlay manent positioning of risers and pipelines shall be welded to a
materials used in seawater service shall be specially consid- doubler ring or plate. Doubler rings for temporary use should
ered and agreed. be clamped. Welding of temporary attachments shall be sub-
613 The surface to be used for microstructure examination ject to agreements.
shall be representative of a weld overlay thickness of 3 mm or 211 Permanent doubler rings and plates shall be made of ma-
the minimum overlay thickness specified for the fiiished ma- terials satisSling the requirements for pressure containing
chined component, whichever is less. parts. Doubler rings shall be made as fully encircling sleeves
with the longitudinal welds made with backing strips, and
avoiding penetration into the main pipe material. Other welds
shall be continuous, and made in a manner minimising the risk
G. Fabrication and Welding Requirements of root cracking and lamellar tearing.
G100 General 212 Transitions where the material thickness or yield stress
is unequal shall be in accordance with ASME B 3 1.8 Appendix
101 All welding shall be performed using the type of weld- I or equally recognised codes.
ing equipment and under the conditions that are representative
for the working environment during procedure qualification 213 Field bevelling shall preferably be by means of bevel-
welding (see E.lO1). Pre-qualification testing shall be per- ling machines.
formed for welding systems where the Contractor has limited 214 After cutting of linepipe or plate material for new bevel
previous experience, or where the system will be used under preparation, a new lamination check by ultrasonic and magnet-
new conditions. All welding equipment shall be maintained in ic particle/dye penetrant testing shall be performed.
good condition in order to ensure the quality of the weldment. 215 Maximum root gap for fillet welds should be 2 mm.
102 All welding shall be performed under controlled condi- Where the root gap is > 2 mm but 5 5 mm, this shall be com-
tions with adequate protection from detrimental environmental pensated by increasing the throat thickness on the fillet weld by
influence such as humidity, dust, draught and large tempera- 0.7 mm for each mm beyond 2 mm gap. Welding of fillet welds
ture variations. with root gap > 5 mm is subject to repair based on an agreed
103 All instruments shall have valid calibration certificates procedure.
and the adequacy of any control software shall be documented. G 300 Repair welding
G 200 Production welding 301 Defective welds that cannot be repaired with grinding
201 All welding shall be carried out strictly in accordance only may be locally repaired by welding. Repair welding shall
with the accepted welding procedure specification and the re- be performed in accordance with a repair welding procedure.
quirements in this subsection. If any parameter is changed out- For welding processes applying large weld pools, e.g. multi-
side the limits of the essential variables, the welding procedure arc welding systems, any unintended arc-stop is to be consid-
shall be re-specified and re-qualified. Essential variables and ered as a repair.
variation limits are specified in D 600. 302 Weld seams may only be repaired twice in the same ar-
202 The weld bevel shall be free from moisture, oil, grease, ea. Repeated repairs of the root in single sided welds are not
rust, carbonised material, coating etc., which may affect the permitted, unless specifically qualified and accepted by Pur-
weld quality. Welding of CRAs or cladlined materials require chaser in each case. Weld repairs shall be ground to merge
cleaning of internal and external surface of the pipe up to a dis- smoothly into the original weld contour.
tance of at least 20 mm from the bevels. 303 Repairs of the root pass in a single-sided joint for mate-
203 Longitudinal welds shall be staggered at least 50 mm rial meeting sour service requirements shall be carried out un-
and should be located in the upper half of the linepipe if possi- der constant supervision.
ble. 304 A local weld repair shall be at least 50 mm long.
204 The minimum preheat temperature shall be measured at 305 The excavated portion of the weld shall be large enough
a distance of minimum 75 mm from the edges of the groove at to ensure complete removal of the defect, and the ends and
the opposite side of the heating source when practically possi- sides of the excavation shall have a gradual taper from the bot-
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ble. If not possible. The adequacy of the measuring at the out- tom of the excavation to the surface. Defects can be removed
side only shall be demonstrated. by grinding, machining or air-arc gouging. If air-arc gouging
205 The interpass temperature shall be measured at the edge is used, the last 3 mm through the root of the weld shall be re-
of the groove immediately prior to starting the following pass. moved by mechanical means and the whole excavated area
shall be ground to remove any carbon enriched zones. The
206 Number of welders and the weld sequence shall be se- width and the profile of the excavation shall be sufficient to en-
lected in order to cause minimum distortion of the pipeline or sure adequate access for re-welding.
the components.
Complete removal of the defect shall be c o n f i i e d by magnet-
207 Line-up clamps should not be removed before the first ic particle testing, or dye penetrant testing for non ferromag-
two passes are completed. The release of line-up clamp shall netic materials. Residuals from the NDT shall be removed
be qualified and simulated during WPQ. When tack welds are prior to re-welding.
necessary for alignment, these shall only be made in the weld
groove if qualified in the welding procedures. Defective tack 306 If the area of repair is subject to large bending andor ax-
welds shall be completely removed. ial stresses, e.g. at a laybarge repair station or similar situa-
tions, the weld repair length shall be determined by
208 Start and stop points shall be distributed over a length of calculations, see Section 9A 700.
weld and not "stacked" in the same area.
209 Welding shall not be interrupted before the joint has suf- G 400 Post weld heat treatment
ficient strength to avoid plastic yielding and cracking during 401 Post weld heat treatment should be performed for weld-
handling. Prior to restart after an interruption, preheating to the ed joints of C-Mn steel having a nominal wall thickness above
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50 mm, unless CTOD testing shows acceptable values in the as yielding and cracking of pipes in tension. The maximum
welded condition. In cases where the minimum design temper- length of allowable repair steps shall be calculated based on the
ature is less than -1O"C, the thickness limit shall be specially maximum stresses present in the joint during the repair opera-
determined. tion, see Section 9A 700.
402 If post weld heat treatment is used to obtain adequate re- 703 Full penetration repairs are only to be implemented un-
sistance of welded joints against sulphide stress cracking, this der constant supervision, otherwise the weld shall be cut out.
shall be performed for all thicknesses. 704 Production tests (See Section 9A 900) shall be per-
403 Post weld heat treatment shall be carried out at 580°C to formed in a manner which, as far as possible, reproduces the
620°C unless otherwise recommended by the steel Manufac- actual welding, and covers the welding of a sufficient large
turer or the welding consumables Manufacturer. For quenched pipe section in the relevant position. Production welds cut out
and tempered material, the post weld heat treatment tempera- due to NDT failure may be used.
ture shall as a minimum be 25°C below the tempering temper- 705 For production testing, the same number of tests as spec-
ature of the base material. ified in E 500 (and Table C-5 when applicable) shall be carried
404 Heating, soaking and cooling shall be performed in a out.
controlled manner according to an approved procedure. The Underwater welding
soaking time shall be 2 minutedmm, but with minimum soak-
ing time 1 hour. Where local heat treatment is performed, the 706 Underwater welding shall be carried out utilising a low
specified temperature shall be maintained in a band extending hydrogen process, in a chamber (habitat) where the water has
at least 3 times the wall thickness on each side of the weld. The been displaced. Other methods are subject to special accept-
temperature at the edge of the insulation band shall be maxi- ance by Purchaser.
mum half the soaking temperature. When the temperature at all 707 A c o n f i a t i o n test should be carried out at the location
parts has dropped below 300"C, the joint may be cooled in still prior to starting the welding. The test weld shall be made on
air. pipe or components in the habitat under actual conditions. The
405 The heat treatment temperature cycle shall be available coupons shall cover welding from the 6 o'clock to 9 o'clock re-
for verification if requested. gion. Subject to acceptable visual examination and NDT, the
welding may commence. NDT requirements shall be in ac-
G 500 Welding of linepipe and linepipe components cordance with acceptance criteria as for the production welds.
501 The Manufacturer shall be capable of producing welded Mechanical testing of the test weld shall be performed imme-
linepipe and linepipe components of the required quality. diately after welding. The number of mechanical tests is half
that required for welding procedure qualification. Provided
502 Welds containing defects may be locally repaired by that the same welding habitat, equipment and welding proce-
welding. Weld deposit having unacceptable mechanical prop- dure are used consecutively on the same pipeline under com-
erties shall be completely removed before re-welding. parative conditions, further c o n f i a t i o n test welds are not
503 Testing during production of linepipe shall be performed required.
according to Section 6E 800. 708 Welding cables shall be of the same dimension and ap-
504 Production tests should be required during the produc- proximately the same length (e.g. I 5 % ) as those used during
tion of linepipe components. The tests shall be performed in a the welding procedure qualification test. Use of artificial re-
manner which, as far as possible, reproduces the actual weld- sistance to simulate the actual cable dimension and length may
ing, and covers the welding of a sufficient large test piece in be used, if this is agreed.
the relevant position. Production welds, cut out due to NDT 709 All relevant welding parameters shall be monitored and
failure, may be used. recorded at the surface control station under supervision by a
welding Co-ordinator. The welding area shall have continuous
G 600 Fabrication of risers, expansion loops, pipe communication with the control station. All operations includ-
strings for towing. ing welding shall be monitored by a video system that can be
601 The Contractor shall be capable of producing welded remotely controlled from the control station.
joints meeting the required quality. This may include welding
of girth welds, overlay welding and post weld heat treatment of
the components. Relevant documentation of the Contractor's
capabilities shall be available if requested by the Purchaser. H. Material and Process Specific Requirements
602 Production tests should be required during the produc- H 100 Internally cladhined carbon steel
tion Section 9A 900. The tests shall be performed in a manner
which, as far as possible, reproduces the actual welding and Production welding
covers the welding of a sufficient large test piece in the rele- 101 Welding of the corrosion resistant cladding portion may
vant position. Production welds cut out due to NDT failure be performed by the welding processes listed in A 200, except
may be used. Flux Cored Arc Welding without gas shield (FCAW / 114).
603 When production testing is required, the same number of The welding shall be double sided whenever possible. Welding
tests as specified in E 400 (and Table C-5 when applicable) of the root pass in single sided (field) joints will generally re-
shall be carried out. Impact test samples shall be located in the quire welding with Gas Tungsten Arc Welding (GTAW / 141)
weld metal and in the HAZ at the position that showed the low- or Gas Metal Arc Welding (GMAW / 135).
est average energy absorption during the procedure qualifica- 102 The f i a 1 weld bevel preparation shall be made by ma-
tion test. chining or grinding. The grinding wheels used for the corro-
sion resistant cladding material shall not have previously been
G 700 Installation and tie-in welding used for carbon steel. Thermal cutting shall be limited to plas-
Installation ma arc cutting.
701 Installation welding shall be carried out by qualified per- 103 Stainless steel wire brushes shall be used for interpass
sonnel. The type of welding equipment and the welding proce- cleaning of the corrosion resistant weld metal and cladlined
dure shall be qualified prior to installation welding. material.
702 Long defects may require repair in several steps to avoid 104 All operations during welding of the pipeline system
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shall be carried out with adequate equipment andor in a pro- 204 The heat input should be kept within the range 0.5 - 1.5
tected environment to avoid carbon steel contamination of the kJ/mm, avoiding the highest heat input for smaller wall thick-
corrosion resistant material. Procedures for examination of nesse s.
surfaces and removal of any contamination shall be prepared.
205 In case of a second weld repair, a separate welding pro-
Welding consumables cedure qualification shall be performed.
105 Welding consumables for corrosion resistant materials Welding consumables
shall be selected to suit the cladding/lining material. The cor-
rosion resistance of the welding consumable shall be better 206 Welding consumables with enhanced nickel and nitro-
than that of the claddinghing material. For single sided gen content shall be used unless full heat treatment after weld-
(field) joints, the same type of welding consumable should be ing is performed. Sufficient addition of material from the
used for all passes needed to complete the joint. Alternative welding consumables is essential for welding of the root pass
welding consumables may be considered for fill and capping and the two subsequent passes.
passes after depositing a weld thickness not less than 2 times Backing or shielding gases shall not contain hydrogen. The ox-
thickness of the claddinghing. The alternative welding con- ygen content of the backing gas shall be less than O. 1% during
sumables must be documented to be compatible with the weld- welding of the root pass.
ing consumables used for the root area, the base material and
the applicable service. Any effect on the probability for detect- H 300 Martensitic (13% Cr) stainless steel
ing weld defects by the applicable NDT procedures is also to
be considered. Extent of testing and documentation shall be Production welding
agreed before commence of qualification testing. 301 Welding of martensitic stainless steel may be performed
by the welding processes listed in A 200, except for Flux Cored
H 200 Duplex stainless steel
Arc Welding without gas shield (FCAW / 114). Welding of
Production welding root pass in single sided joints will normally require welding
201 Welding of 22 Cr / 25 Cr duplex stainless steel may be with Gas Tungsten Arc Welding (GTAW / 141).
performed by the welding processes listed in A 200, except for 302 Thermal cutting shall be limited to plasma arc cutting.
Flux Cored Arc Welding without gas shield (FCAW / 114).
Welding of root pass in single sided joints will generally re- 303 Fabrication of martensitic stainless steel shall be per-
quire welding with Gas Tungsten Arc Welding (GTAW / 141). formed in a workshop or part thereof, which is reserved exclu-
sively for this type of material. Grinding wheels and steel
202 Thermal cutting shall be limited to plasma arc cutting. brushes shall be suitable for martensitic stainless steels and
203 Fabrication of duplex stainless steel shall be performed shall not previously have been used on carbon steel materials.
in a workshop, or part thereof, which is reserved exclusively Post weld heat treatment
for this type of material. Grinding wheels and steel brushes
shall be suitable for working on duplex stainless steel and not 304 A suitable post weld heat treatment may be performed if
previously used for carbon steel. sour service is required.
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APPENDIX D
NON-DESTRUCTIVE TESTING (NDT)
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I S 0 5580 Non-destructive testing - Industrial radio-
be read and interpreted in conjunction with this Appendix. graphic illuminators - Minimum require-
103 Requirements for NDT and visual examination of other ments.
materials shall be specified and shall be in general agreement I S 0 9002 Quality Systems, Model for Quality Assur-
with the requirements of this Appendix. ance in Production, Installation and Servic-
ing.
A 200 Codes and standards I S 0 9303 Seamless and welded (except submerged
201 The following codes and standards are referred to in this arc-welded) steel tubes for pressure purposes
Appendix: - Full peripheral ultrasonic testing for the de-
tection of longitudinal imperfections
ASME Boiler and Pressure Vessel Code, Section V, I S 0 9304 Seamless and welded (except submerged
Article 2 and Article 5. arc-welded) steel tubes for pressure purposes
ASTM - Eddy current testing for the detection of im-
A578/578M Standard Specification for Straight-Beam perfections
Ultrasonic Examination of Plain and Clad I S 0 9305 Seamless tubes for pressure purposes - Full
Steel Plates for Special Applications peripheral ultrasonic testing for the detection
ASTM of transverse imperfections
A577/577M Standard specification for Ultrasonic Angle- I S 0 9402 Seamless and welded (except submerged arc
Beam Examination of Steel Plates welded) steel tubes for pressure purposes -
ASTM Full peripheral magnetic transducer/ flux
leakage testing of ferromagnetic steel tubes
E 709 Standard Guide for Magnetic Particle Exam- for the detection of longitudinal imperfec-
ination tions
ASTM I S 0 9598 Seamless steel tubes for pressure purposes-
E 797 Standard Practice for Measuring Thickness Full peripheral magnetic transducer/flux
by Manual Ultrasonic Pulse-Echo Contact leakage testing of ferromagnetic steel tubes
Method for the detection of transverse imperfections
ASTM I S 0 9765 Submerged arc-welded steel tubes for pres-
E 1212 Standard Practice for Establishment and sure purposes - Ultrasonic testing of the weld
Maintenance of Quality Control Systems for seam for the detection of longitudinal andor
Non-destructive Testing Agencies transverse imperfections)
ASTM E 1444 Standard Practice for Magnetic Particle Ex- I S 0 10124 Seamless and welded (except submerged
amination arc-welded) steel tubes for pressure purposes
ASTM E 1417 Standard Practice for Liquid Penetrant Ex- - Ultrasonic testing for the detection of lam-
amination inar imperfections
DNV Classification Note No. 7 - Ultrasonic In- I S 0 10543 Seamless and hot-stretch reduced welded
spection of Welded Joints steel tubes for pressure purposes - Full pe-
EN 473 Qualification and certification of NDT per- ripheral ultrasonic thickness testing
sonnel - General principles I S 0 11484 Steel tubes for pressure purposes - Qualifica-
EN 1711* Non-Destructive Examination of Welds: tion and certification of non-destructive test-
Eddy Current Examination by Complex ing (NDT) personnel
Plane Analysis I S 0 11496 Seamless and welded steel tubes for pressure
EN 12084* Eddy Current testing - General Principles of purposes - Ultrasonic testing of tube ends for
the Method the detection of laminar imperfections
IS0 1027 Radiographic image quality indicators for I S 0 12094 Welded steel tubes for pressure purposes -
non-destructive testing - Principles and iden- Ultrasonic testing for the detection of lami-
tification nar imperfections in strips or plates used in
IS0 1106-1 Recommended practice for radiographic ex- manufacture of welded tubes
amination of welded joints Part 1: Fusion I S 0 12095 Seamless and welded steel tubes for pressure
welded butt joints in steel plates up to 50 mm purposes - Liquid penetrant testing
thick I S 0 13663 Welded steel tubes for pressure purposes-U1-
IS0 1106-2 Recommended practice for radiographic ex- trasonic testing of the area adjacent to the
amination of welded joints Part 2: Fusion weld seam body for detection of laminar im-
welded butt joints in steel plates thicker than perfections
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IS0 13664 Seamless and welded steel tubes for pressure acceptance criteria.
purposes - Magnetic particle inspection of
tube ends for the detection of laminar imper- 502 If alternative methods or combinations of methods are
fections used for detection of imperfections, the procedures shall be
IS0 13665 Seamless and welded steel tubes for pressure prepared in accordance with an agreed code or standard. The
purposes - Magnetic particle inspection of need for procedure qualification shall be considered in each
tube body for the detection of surface imper- case based on the method's sensitivity in detecting and charac-
fections terising imperfections and the size and type of defects to be de-
tected.
*Until final approval of the EN'S, reference is made to the cor-
responding prEN's. 503 Non-destructive testing procedures shall be signed by
the responsible Level 3 person.
A 300 Quality Assurance
A 600 Personnel qualifications
301 NDT Contractors shall as a minimum have an imple-
mented quality assurance system meeting the general require- 601 Personnel performing manual or semi-automatic NDT
ments of IS0 9002 and supplemented with the requirements and interpretation of test results shall be certified according to
given in ASTM E 1212. a certification scheme which meets the requirements of EN
473 (Qualification and certification of NDT personnel-General
302 Further requirements for quality assurance are given in principles) and shall possess a valid certificate of proficiency.
Section 2B 500. The certificate shall state the qualification level and categories
A 400 Non-destructive testing methods for which the operator is certified.
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401 Methods of NDT shall be chosen with due regard to the 602 Personnel calibrating and interpreting results from auto-
conditions influencing the sensitivity of the methods. The mated equipment for NDT shall be certified to an appropriate
methods' ability to detect imperfections shall be considered for level according to a certification scheme meeting the require-
the material, joint geometry and welding process used. ments of EN 473. In addition, they shall be able to document
adequate training and experience with the equipment in ques-
402 As the NDT methods differ in their limitations andor tion, and shall be able to demonstrate their capabilities with re-
sensitivities, combination of two or more methods may be re- gard to calibrating the equipment, performing an operational
quired in order to ensure optimum probability of detection of test under productiodsite/field conditions, and evaluating size
harmfùl defects. and location of imperfections.
403 For detection of surface imperfections in ferromagnetic 603 Personnel operating automated equipment for NDT dur-
materials, magnetic particle or eddy current testing shall be ing manufacture of linepipe shall be certified according to IS0
preferred. For detection of surface imperfections in non-mag- 11484 or equivalent certification scheme.
netic materials, either dye penetrant testing or eddy current
testing shall be preferred. 604 Preparation of NDT procedures and execution of all
NDT shall be carried out under the responsibility of Level 3
404 For detection of internal imperfections either ultrasonic personnel and shall be performed by personnel holding at least
andor radiographic testing shall be used. It may be necessary Level 2 qualifications. Personnel holding Level 1 qualifica-
to supplement ultrasonic testing by radiographic testing or vice tions may carry out NDT under the direct supervision of Level
versa, in order to enhance the probability of detection or char- 2 personnel.
acterisationhizing of flaws.
605 Personnel performing visual examination shall have
Radiographic testing is preferred for detection of volumetric documented training and qualifications according to NS477,
imperfections. For material thicknesses above 25 mm radio- EWE Welding Inspector, or equivalent.
graphic testing should be supplemented by ultrasonic testing.
606 Personnel interpreting radiographs, performing ultra-
Ultrasonic testing is preferred for detection of planar imperfec- sonic testing, interpreting results of magnetic particle and liq-
tions. Whenever determination of the imperfection height and uid penetrant testing and performing visual examination shall
depth is necessary, e.g. as aresult of an ECA, ultrasonic testing have passed a visual acuity test , such as Jaeger J-2, within the
is required. previous 12 months.
405 Alternative methods or combination of methods for de-
tection of imperfections may be used provided that the meth- A 700 Reporting
ods are demonstrated as capable of detecting imperfections 701 All NDT shall be documented such that the tested areas
with an acceptable equivalence to the preferred methods. may be easily identified and such that the performed testing
can be duplicated. The reports shall identiSl the defects present
A 500 Non-destructive testing procedures in the weld area and state if the weld satisfies the acceptance
501 Non-destructive testing shall be performed in accord- criteria or not.
ance with written procedures that, as a minimum, give infor-
mation on the following aspects: A 800 Timing of NDT
801 Whenever possible, NDT of welds shall not be per-
applicable code(s) or standard(s), formed until 24 hours has elapsed since completion of weld-
welding method (when relevant), ing.
joint geometry and dimensions,
material(s), 802 If welding processes ensuring a diffusible hydrogen con-
method, tent of maximum 5ml/lOOg of weld metal are used, adequate
technique, handling of welding consumables is verified, shielding gas
equipment, main and auxiliary, content of H, is controlled, or measures (such as post heating
consumables (including brand name), of the weldments) are taken to reduce the contents of hydro-
sensitivity, gen, the time in 801 above can be reduced.
calibration techniques and calibration references, 803 Cellulose electrodes may be used for the root and hot
testing parameters and variables, pass of C-Mn steel with SMYS less than 415 MPa provided the
assessment of imperfections, heat input from subsequent welding passes reduces the hydro-
reporting and documentation of results, gen content sufficiently to prevent hydrogen induced cracking.
reference to applicable welding procedure(s), and See Appendix C 103.
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804 Provided the requirements of 802 and 803 above are side IQI is at least to meet the requirement shown in Fig. D-l.
complied with, NDT of pipeline installation girth welds and
longitudinal welds in linepipe may be performed as soon as the
welds have cooled sufficiently to allow the NDT to be per-
formed.
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101 Manual non-destructive testing of welds shall be per-
formed as required in the following and in general compliance
with these standards:
Radiography IS0 1106-1, IS0 1106-2, IS0 1106-3,
IS0 5579.
Ultrasonic ASME Boiler and Pressure Vessel Code,
Section V, Article 5 Figure D-1 Source side IQI sensitivity curve (sensitivity in
YO)
DNV Classification Note No. 7- Ultra-
sonic Inspection of Welded joints (Sensitivity requirements for material thickness < 10 mm shall
Magnetic Particle ASTM E 709, ASTM E 1444 be agreed in each case)
Dye Penetrant ASTM E 1417 207 IQIs shall whenever possible be placed on the source
Eddy Current ASTM E 309 side during exposure. If the IQIs must be placed on the film
side during production radiography this shall be indicated by
B 200 Radiographic testing projecting the letter F onto the film. The sensitivity of the film
201 Radiographic testing shall be performed by use of X-ray side IQI from the procedure qualification shall be used as ac-
according to agreed procedures. Use of radiographic isotopes ceptance criterion.
(gammarays) may be required in some situations and is subject 208 Exposed radiographs shall have an average H & D den-
to agreement in each case. sity at the sound weld metal image of minimum 2.0. The max-
202 Radiographic testing procedures shall contain the infor- imum density allowed shall be according to the capabilities of
mation in A 500 and: the available viewing equipment, but not more than 4.0.
209 Evaluation of radiographs shall be performed under con-
radiation source; ditions satisfiing the requirements of IS0 2504 and IS0 5580.
technique; Radiographs from the radiographic procedure qualification
geometric relationships; shall be available as reference at the place where evaluation of
film type; production radiography is performed.
intensifiing screens;
exposure conditions; 210 Processing and storage shall be such that the films main-
processing; tain their quality for a minimum of 5 years without deteriora-
Image Quality Indicator sensitivities in percent of the wall tion. Thiosulphate tests shall be performed at regular intervals.
thickness, based on source and film side indicators respec- If film storage time in excess of 5 years is required, the radio-
tively; graphs should be digitised using methods giving adequate res-
backscatter detection method; olution and stored in electronic media in an agreed manner.
density;
film side Image Quality Indicator identification method; B 300 Manual ultrasonic testing
film coverage; and 301 Ultrasonic testing shall be performed according to
weld identification system. agreed procedures.
203 Film and intensifiing screen classification shall be ac- 302 Ultrasonic testing procedures shall contain the informa-
cording to IS0 5579. tion in A 500 and:
For X-ray exposure, fine-grained film in combination with type of instrument;
lead screens shall be preferred. For gamma ray exposure, ultra type and dimensions of probes;
fiie grained film and lead intensifiing screens shall be used. range of probe frequencies;
204 Image Quality Indicators (IQI) according to document description of reference block;
IS0 1027 and of required number shall be used. The IQIs shall calibration details, range and sensitivity;
be clearly identifiable. surface requirements, including maximum temperature;
type of coupling medium;
Subject to agreement, other types of IQIs providing the same scanning techniques supplemented with sketches, show-
accuracy of information regarding sensitivity of radiographs, ing the probes used and area covered; and
may be used. re cording details.
205 Each radiographic procedure and the consumables used
shall be qualified by making radiographic exposures of a weld- 303 No special procedure qualification test should be re-
ed joint with the same or typical configuration and dimensions, quired when manual methods are used. The procedure shall be
and of material equivalent to that which shall be used. subject to agreement.
The IQIs shall for radiographic procedure qualification pur- 304 Manual ultrasonic testing equipment shall:
poses be placed on both the film side and the source side. ~ be applicable for the pulse echo technique and for the dou-
206 The sensitivities obtained by both IQIs during procedure ble probe technique;
qualification shall be recorded and the sensitivity of the source ~ cover as a minimum the frequency range from 2 to 6 MHz;
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have a calibrated gain regulator with maximum 2 dB per ometries the reference block shall in addition to the features re-
step over a range of at least 60 dB; quired in 308, have a curvature equal to the pipe to be tested.
have a flat screen accessible from the front for direct plot- The reference reflectors shall be radially drilled holes as de-
ting of reference curves or be capable of displaying user- tailed in G 800.
defiied curves;
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shall be checked prior to start of any testing and at regular in- ~ scanning details, and
tervals during testing. ~ recording details.
407 Use of permanent magnets is not permitted. DC yokes 603 In general no special procedure qualification test is re-
may only be used for specific applications if required by na- quired when manual methods are used. The procedure is con-
tional regulations.
sidered qualified based on agreed testing procedure
408 The surface to be tested shall be clean and dry, free from specifications.
dirt i.e. paint, grease, oil, lint, scale, welding flux etc. which
may interfere with the testing. 604 Manual eddy current testing equipment shall have:
409 Testing using fluorescent wet magnetic particles should ~ single or dual frequency,
be the preferred method. ~ frequency range to include 1000Hz to lMHz,
410 If non-fluorescent wet or dry particles are used they shall ~ gadnoise, a lmm deep artificial defect shall be indicated
provide adequate contrast with the background or the surface as a full screen deflection through a coating thickness cor-
being tested. responding to the maximum expected on the structure to
be tested. Further, a 0.5 mm deep artificial defect shall be
411 To ensure detection of discontinuities having axes in any indicated through the same coating thickness with a mini-
direction, the testing of each area shall be performed with the mum noisehignal ratio of 1 to 3;
direction of the magnetic field in at least two directions ap- ~ the evaluation mode shall be a complex plane display,
proximately perpendicular to each other, and with sufficient ~ as a minimum, the signal display shall be in the x-y mode
overlap to cover the area to be tested. with storage facility. The trace shall be clearly visible as
412 Testing with fluorescent magnetic particles shall be con- well under daylight as under dark conditions, and
ducted in a darkened area with maximum 20 lux background ~ the phase control shall be able to give complete rotation in
light, using filtered ultraviolet light with wave lengths in the steps of no more than 10" each.
range of 3200 to 3800 A. Operatorshterpreters shall allow
sufficient time for eyesight to adjust to the dark surroundings. 605 Eddy current probes for measuring thickness of coating
Interpreters shall not wear photo-chromatic viewing aids. shall be capable of providing a full screen deflection lift-off
signal on the instrument when moved from an uncoated spot
413 Magnetic particle testing shall not be performed on parts on the reference block to a stop covered with the maximum
with surface temperatures exceeding 300°C. Between 60°C coating thickness expected on the structure to be tested. The
and 300"C, only dry magnetic particle testing shall be used. probe shall be clearly marked with its operating frequency
B 500 Manual liquid penetrant testing range.
501 Liquid penetrant testing shall be performed according to 606 Eddy current probes for weld examination shall be opti-
agreed procedures and shall only be used on non-ferromagnet- mised for examination of welds of the actual type to be tested.
ic materials or materials with great variation in magnetic per- Such probes shall be able to operate when covered by a thin
meability, unless otherwise agreed. layer of non-metallic wear-resistant material over the active
face. If used with such a cover, it shall always be mounted dur-
502 Liquid penetrant testing procedures shall contain the in- ing calibration as well.
formation in A 500 and:
607 A standard reference block of the same material as the
surface preparation; test component shall be used. It shall have narrow slots of 0.5,
make and type of penetrant, remover, emulsifier and de- 1.O and 2.0 mm depth. Tolerance of the slot depth shall be +O,
veloper; -0.1 mm. Recommended width of slots shall be O. lmm but ac-
details of pre-testing cleaning and drying, including mate- ceptable up to 20% of the maximum depth (= 0.4 mm). All
rials used and time allowed for drying; slots shall have the same width in the same block.
details of penetrant application: the time the penetrant re- The standard reference block shall have length, width and
mains on the surface, the temperature of the surface and thickness dimensions and slot positions, distances and lengths
penetrant during the testing (ifnot within the 15°C to 35°C depending on probes to be used such that calibrations can be
range); made without interference between slots or with edges.
details of developer application, and developing time be-
fore evaluation; and 608 Eddy current equipment, including probes and cables,
method for post-test cleaning. shall have calibration certification pertaining to the character-
istics of the equipment.
503 When the temperature of the surface and the penetrant is 609 Calibration of the eddy current equipment shall be car-
within the range 15°C to 35"C, no special procedure qualifica- ried out whenever it has been out of function for any reason in-
tion tests should be required. The procedure shall be subject to cluding on/off, and whenever there is any doubt concerning
agreement. proper functioning of the equipment.
Outside the temperature range 15°C to 35"C, the procedure
shall be qualified and a suitable comparator block shall be used 610 Surface conditions - excess weld spatter, scale, rust and
to compare indications from surface defects tested within and loose paint can influence sensitivity by separating the probe
outside the range during the procedure qualification. from the test object and shall be removed before the inspection.
611 The weld surface and the heat-affected zones shall be
B 600 Manual eddy current testing scanned with the chosen probe(s) in a raster like scan. As far as
601 Eddy current testing shall be performed according to EN the geometry of the test object permits it, the probe shall be
12084 and EN 1711 and accepted procedures. moved in a direction perpendicular to the main direction of the
expected defect. As least two probe runs shall be carried out
602 Eddy current testing procedures shall contain the infor- perpendicular to each other. For differential coil types, the sen-
mation in A 500 and: sitivity for defect detection is also dependent on the coil orien-
type of instrument, tation. Therefore care shall be taken that this is also controlled
during examination.
~
~ type of probe,
~ frequency setting, 612 All indications exceeding 50% signal amplitude from a
~ calibration details, 2.0mm deep slot in the reference block and all crack like indi-
~ surface condition requirements, cations shall be reported with information about the location of
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the defect, approximate length of the defect and maximum sig- 305 Manual magnetic particle testing of forgings shall be
nal amplitudes unless otherwise agreed with Purchaser. done in accordance with ASTM E 709, ASTM E1444 or equiv-
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alent standard
B 700 Visual examination
306 Manual liquid penetrant testing of forgings shall be done
701 Visual examination shall be carried out in a sufficiently in accordance with ASTM E 1417 or equivalent standard.
illuminated area, (approximately 500 lx). A sufficient amount
of tools, gauges, measuring equipment and other devices shall C 400 Castings
be available at the place of examination. 401 Manual ultrasonic testing of castings shall be done ac-
cording to ASTM A 609 using the flat bottom hole calibration
procedure with 3 mm 0 flat bottom holes and the supplemen-
C. Manual Non-destructive testing of Base tary requirement S1 with basic reference hole of 3 mm 0.
Equivalent standard may be used.
Materials and Weld Overlay
Straight beam examination
C 100 General The flat bottom holes shall be 3 mm 0 flat bottom holes at 3
101 All non-destructive testing of base materials shall be depths through the thickness. One hole shall have a metal
done according to agreed procedures as required in A 500, B depth of lOmm, one hole shall be at mid thickness and one hole
200, B 300, B 400, B 500 and B 600. shall have a metal depth of the thickness 10 mm. ~
102 Manual non-destructive testing of base material, welds 402 Radiographic testing of castings shall be done accord-
and weld overlay shall be done on general compliance with the ing to ASME, section 5, article 2 or equivalent standard.
requirements given in subsection B and the referenced stand- 403 Radiographic procedures shall in addition to the require-
ards. ments of B.202 give the following information:
103 Acceptance criteria for manual non-destructive testing
of base material and weld overlay are given in subsection I. ~ shooting sketches,
~ coverage,
C 200 Plate and pipe ~ source location,
201 These requirements are not applicable for plate and strip ~ location of IQI, and
covered by subsection F or linepipe covered by subsection G. ~ acceptance criteria
202 Manual ultrasonic thickness measurements shall be 404 Manual magnetic particle testing of castings shall be
done on accordance with ASTM E797 or equivalent standard. done in accordance with ASTM E 709, ASTM E1444 or equiv-
203 Manual ultrasonic testing for detection of laminar flaws alent standard.
in C-Mn, ferritic-austenitic (duplex), other stainless steels and 405 Manual liquid penetrant testing of castings shall be done
nickel based corrosion resistant alloys ( C U ) shall be done in in accordance with ASTM E 1417 or equivalent standard.
accordance with IS0 12094 or equivalent standard.
204 Manual ultrasonic testing for detection of laminar flaws C 500 Weld overlay
in cladlined steel shall be done in accordance with ASTM 501 NDT and visual examination on magnetic weld overlay
A578/578M or equivalent standard. deposits shall be performed as 100% visual examination and
205 Manual ultrasonic testing for detection of flaws other 100% magnetic particle testing
than laminar, shall be done on accordance with ASTM A577/ 502 NDT and visual examination on non-magnetic weld
577M or equivalent standard using a rectangular notch. overlay deposits shall be performed as 100% visual examina-
206 Manual magnetic particle testing of plate, strip and pipe tion and as 100% liquid penetrant or eddy current testing on
edges shall be done in accordance with ASTM E 709, ASTM non-magnetic weld deposits.
El444 or equivalent standard.
207 Manual liquid penetrant testing of plate, strip and pipe
edges shall be done in accordance with ASTM E 1417 or D. Automated Non-Destructive Testing
equivalent standard.
208 Manual eddy current testing of plate, strip and pipe edg- D 100 General
es shall be done in accordance with ASTM E309 or equivalent 101 These requirements are applicable to all automatedNDT
standard. processes except automated ultrasonic testing of girth welds
where specific requirements are given in Appendix E. The re-
C 300 Forgings quirements given in this subsection are additional to the re-
301 Manual ultrasonic testing of forgings shall be done ac- quirements of any code or standard where automated NDT
cording to ASTM A 388/ASTM A 388M or equivalent stand- methods are prescribed or optional.
ard. For angle beam testing of duplex or austenitic steel 102 The performance automated NDT equipment shall be
forgings longitudinal wave angle beam probes should be used. documented by statistical records. Items subject to documenta-
Straight beam examination tion include:
302 The flat bottom holes shall be 3 mm 0 flat bottom holes ~ brief functional description of the equipment;
at 3 depths through the thickness. One hole shall have a metal ~ detailed equipment description;
depth of 5 mm, one hole shall be at mid thickness and one hole ~ operation manual including type and frequency of func-
shall have a metal depth equal to the thickness 5mm. A DAC ~
tional checks;
curve shall be established using the different holes. ~ calibration;
Angle beam examination ~ limitations of the equipment with regard to material or
303 The DAC curve shall be established using rectangular weld features including size, geometry, type of flaws, sur-
OD and ID notches with a depth of 3% of the thickness. face finish, material composition etc.; and
~ repeatability.
304 Reference blocks shall be material from the actual forg-
ings and in the same heat treatment condition. 103 Equipment shall have documentation of calibration per-
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formed within the previous 6 months. 207 For calibration of the equipment, one or more special
reference blocks shall be prepared and used. These blocks shall
D 200 Automated ultrasonic testing be identical to the pipe or part of pipe to be tested with regard
201 Specific requirements for automated ultrasonic testing to material, acoustic properties, surface finish, diameter and
(AUT) of girth welds are given in Appendix E. thickness. For welded pipe the reference block shall contain a
typical production weld.
202 The requirements herein are additional to D 100 above
and are applicable to all automated ultrasonic testing other than 208 The reference block shall contain artificial reflectors
automated ultrasonic testing of girth welds. representing potential defects, and to ver@ positioning accu-
racy.
203 Requirements to the calibration of equipment, reference
blocks and equipment Set-ups are given in subsections F and G 209 Other types of reflectors may be necessary for determin-
for each specific application. ing the detection capabilities of the equipment and for specific
applications.
The configuration of automated ultrasonic testing equipment
shall be described and documented with regard to: 210 The reference block shall be of a size allowing dynamic
checks with the same velocity and under the same conditions
reference to code, standard or guideline used for design as during production testing.
and operation of the equipment, 211 The dimensional accuracy of the reference block shall
number and type of probes with description, be documented.
function of scanning device,
ultrasonic instrument, number of channels and data acqui- 212 Reference blocks and calibration of the equipment shall
sition, be as required in subsections F and G.
recording and processing of data, 213 Procedures for automated ultrasonic testing shall as a
reference blocks, minimum contain the following information:
couplant,
couplant monitoring method, ~ functional description of equipment;
temperature range for testing and limitations, ~ reference standards and guidelines;
coverage achieved, ~ instructions for scanning device, ultrasonic electronics,
maximum scanning velocity and direction, hardware and software for recording, processing, display
documentation of method for calibration and sensitivity or presentation and storage of indications;
settings, and ~ equipment configuration: number of probes, types, cover-
reporting of recordable indications. age;
~ déscription of the probe operating mode(s), probe angles
204 The equipment shall incorporate continuously operating and probe firing sequence;
--```,,`,`,,,`,,````,````,`,```-`-`,,`,,`,`,,`---
systems for: ~ sketches showing the area covered by each probe indicated
weld seam centring (if annlicablel
alarm for loss ofreut;m ;&na1 <io&of coupling),
1-
by the beam centre and lines showing - 2dB, - 3dB and - 6
UD;
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Page 148 - App.D
accumulated strain resulting from installation and operation is F. Non-Destructive Testing of Plate and Strip at
above 0.3% but will not exceed 2.0%, shall be established by Mill
an ECA (see E 200).
The ECA shall determine the fracture toughness values re- F 100 General
quired to tolerate the defects permitted in subsection H. 101 The type and extent of non-destructive testing during
Alternatively can "fitness for purpose" type acceptance criteria manufacture of plate and strip shall be:
be established based on fracture toughness values actually
achieved. ~ 100% ultrasonic testing of plate and strip for laminar im-
perfections,
103 Acceptance criteria for pipeline girth welds where the 100% ultrasonic testing of clad plate for laminar imperfec-
accumulated strain resulting from installation and operation is
~
above 2.0%, shall be established based on an ECA (see E 200), tions and lack of bonding.
and validated by testing according to the requirements of Sec-
tion 9E. 102 The ultrasonic testing shall include testing of the four
edges of platehtrip over a width extending at least 50mm in-
104 For some welding methods an unambiguous correlation side the location of future welding preparations. A suitable al-
can be established between variation in welding parameters lowance in the area width shall be made to cover possible
and occurrence of defects. oversized plates and later edge milling and end bevelling.
For such methods the acceptance criteria given in this Appen- 103 If NDT of the body of line pipe is performed at the pipe
dix may, subject to special consideration and agreement, in mill, ultrasonic testing of plate and strip for laminar imperfec-
part be substituted by welding parameter records showing a tions may, subject to agreement, be omitted at the plate and
variation within acceptable limits. Such substitution shall be strip mill.
based on a comprehensive documentation of the correlation.
104 The acceptance criteria given in this subsection are gen-
Verification of the validity of the correlation by conventional, erally valid unless other acceptance criteria are specified in ac-
relevant NDT methods shall be performed during the entire pe- cordance with relevant clauses of subsection E.
riod the method is in use. The extent and type of NDT used for
the verification and the associated acceptance criteria, shall be 105 Equipment and procedures used for the ultrasonic test-
agreed in each case. ing shall comply with the requirements of subsection D. The
requirements for automated NDT processes given in subsec-
105 The method(s) ofNDT and acceptance criteria for mate- tion D are additional to the requirements of any code or stand-
rials other than steel shall be agreed in each case. ard referred to in this subsection where automated NDT
E 200 Acceptance criteria based on Engineering Criti-
methods are prescribed or optional.
cal Assessment @CA)
F 200 Ultrasonic testing of C-Mn and duplex steel plate
201 Whenever acceptance criteria for NDT are established and strip
by an ECA, the ECA shall be performed in accordance with the
requirements given in 202 through 206. 201 Ultrasonic testing of the plate or strip body for laminar
imperfections shall be in accordance with IS0 12094 amended
202 The ECA shall be performed as required in Section 5D as follows:
1100.
~ the distance between adjacent scanning tracks shall ensure
203 If acceptance criteria for weld defects are based on an 100% coverage of the plate body and all four edges and be
ECA, ultrasonic testing or automated ultrasonic testing shall be sufficiently small to ensure detection of the minimum al-
performed.
lowed imperfection size, and
204 The ultrasonic testing uncertainty data used in the ECA ~ for plate nominal thicknesses 2 40 mm the recess depth in
shall be appropriate for the applied ultrasonic testing equip- the reference standardítest piece shall be increased in order
ment and procedures used for the detection and assessment of to place the bottom of the recess between '/4 and %of the
flaws of concern in the material and weld geometries in ques- nominal plate thickness.
tion.
205 If automated ultrasonic testing (AUT) is used for testing 202 Acceptance criteria for ultrasonic testing of C-Mn and
of or pipeline girth welds, the data used in the ECA shall be de- duplex steel plate and strip are given in Table D-2.
rived from the qualification testing of the automated ultrasonic 203 Subject to agreement the acceptance criteria for the body
testing system required in Appendix E. of plate and strip can limited to an allowed permitted area
The uncertainty data from this qualification testing shall be sta- of100 mm2 and a population density of 5 with the minimum
tistically treated to establish the flaw sizing error that gives a imperfection size area 30 mm2, length and width 5mm. All
95% confidence level against undersizing of flaws. other requirements in Table D-2 shall apply.
The maximum allowable flaw sizes from the ECA shall be re- Table D-2 Ultrasonic testing of C-Mn and duplex steel plate
duced in length and height with a flaw sizing error, that based and strip, acceptance criteria
on the data from the qualification testing will give a 95% con-
fidence against under sizing of flaws.
Service Maximumal- Minimum size Maximumpop-
206 For manual ultrasonic testing the data used in the ECA lowedimperfec- ojìmperfection ulationdinsity
for quantitative estimates of ultrasonic testing uncertainty, per- tion tobe consid-
formance and reliability are preferably be of the "measured re- ered
sponse versus actual flaw size" type. The estimates shall be Non- Area: Area: 300 mm2 10
based on published results from comprehensive studies into sour 1000 mm2 Length: 35 mm within the
the reliability of manual ultrasonic testing. Width: 8 mm reference area
Sour Area: 500 mm2 Area: 150 mm2 5
207 The approach outlined above may also be used to justi@ Length: 15 mm within the
exceeding the acceptance criteria referred to in 101.
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Width: 8 reference area
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App.D - Page 149
ïable D-2 Ultrasonic testing of C-Mn and duplex steel plate 105 All NDT for final acceptance of pipe shall be performed
after completion of cold straightening, forming, and expan-
sion. NDT for "in-house" purposes may be performed at any
time at the Manufacturer's discretion.
106 If NDT of plate and strip in accordance with subsection
tion tobe consid- F is performed at the plate or strip mill, ultrasonic testing for
ered laminar imperfections in the body of the pipe may be omitted.
All Area: 100 mm2 Length: 10 mm 3
Width 6 mm within the G 200 Untested pipe ends
reference area
201 When automated non-destructive testing equipment is
Notes:
Two or more adjacent imperfections shall be considered as one imper-
I used, a short area at both pipe ends cannot normally be tested.
The untested ends may either be cut off or the ends subjected
1)
fection if they are separated by less than the largest dimension of the to manual or semi-automatic NDT by the same or alternative
smallest indication method with an appropriate technique and using test parame-
2) The population density shall be the number of imperfections smaller ters that will achieve at least the same sensitivity.
than the maximum and greater than the mimmum imperfection size
3) The reference area shall be G 300 Suspect pipe
1000mm x 1000mm for non-sour service 301 In all cases when a pipe inspection results in automated
500mm x 500mm for sour service non-destructive testing equipment signals equal to or greater
The reference area for plate/strip when the plate/strip width is less than than the trigger or alarm level, the pipe shall be deemed sus-
one side of the square reference area, shall be 1 00m2 for non-sour and pect.
O 25m2 for sour service
1000mm length for the edge areas
Suspect pipe can be dealt with according to one of the follow-
ing options:
4) The width of an imperfection is the dimension transverse to the edge of
the plateístrip ~ the pipe can be scrapped,
F 300 Ultrasonic testing of clad plate and strip ~ the suspect area can be cropped off.
301 For ultrasonic testing of the base material the require- If the suspect area is cropped, then all NDT requirements per-
ments of F 100 and F 200 shall apply. taining to pipe ends shall be performed on the new pipe end.
302 Ultrasonic testing for the detection of lack of bond be- 302 Alternatively, the suspect area of the pipe may be re-
tween the base material and cladding material in the body of tested by a different and appropriate test method supplemented
plate and strip, shall be performed in accordance with ASTM by the original method, with a different technique using test
A578, S7. parameters which give the same sensitivity as used during the
original test, and using the same acceptance level.
303 Acceptance criteria are:
Pipes passing these tests are deemed acceptable.
ASTM A578, S7. In addition, no areas with laminations or 303 Pipes may be repaired provided the provisions of Sec-
lack of bond are allowed in the plate edge areas. tion 6 E 1000 are fulfilled.
F 400 Visual examination of plate and strip 304 Re-inspection of repair welds shall be 100% visual ex-
amination and 100% manual radiographic and ultrasonic test-
401 Visual examination and acceptance criteria shall be ac- ing.
cording to Section 6 E 504.
Testing shall be performed in accordance with G 800.
Acceptance criteria shall be in accordance with G 800.
G. Non-Destructive Testing of Linepipe at Pipe G 400 Non-destructive testing applicable to all pipe
Mills 401 Ultrasonic testing of the ultimate 50 mm from each pipe
end for detection of laminar imperfections in C-Mn and duplex
G100 General steel shall be in accordance with IS0 11496. The 50mm band
101 The extent of non-destructive testing during manufac- shall be measured from the fùture weld preparation and an al-
ture of linepipe shall be as required in Section 6,Table 6-13. lowance shall be made for later end bevelling. Manual ultra-
sonic testing, semi-automated or automated equipment may be
102 The types of testing required in Section 6, Table 6-13 are used. For welded pipe the reinforcement of the longitudinal
defined as: weld shall be removed so that it does not interfere with the test-
ing.
~ Ultrasonic testing The acceptance criterion is:
~ Surface imperfection testing
~ Radiographic testing According to requirements to plate and strip edges in Ta-
ble D-2 for non-sour or sour service.
Whenever the choice of methods for non-destructive testing is
optional, this is indicated in this subsection. 402 Ultrasonic testing of the ultimate 50 mm from each pipe
end for detection of laminar imperfections in of cladlined pipe
103 The requirements for automatedNDT processes given in shall be in accordance with ASTM A578/578M, S7. The
subsection D are additional to the requirements of any code or 50mm shall be measured from the future weld preparation and
standard referred to in this subsection where automated NDT an allowance shall be made for later end bevelling.
methods are prescribed or optional.
The acceptance criterion is:
104 The acceptance criteria given in this subsection are valid
unless other acceptance criteria are specified in accordance no areas with laminations or lack of bond are allowed in
with relevant clauses of subsection E. the plate edge areas.
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P a g e l 5 0 - App.D
Guidance note: 504 Full peripheral ultrasonic thickness testing shall be per-
The ultimate length from each pipe end may, subject to agree- formed in accordance with I S 0 10543. The minimum area
ment be increased to 1OOmm to allow field re-bevelling of pipe. coverage shall be not less than 25% of the pipe surface.
The acceptance criterion is:
403 Magnetic particle testing or eddy current testing of the The specified minimum and maximum thickness shall be
end face or bevel of each pipe in ferromagnetic steel for the de- met.
tection of laminar imperfections shall be performed in accord-
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ance with: Ultrasonic testing for longitudinal imperfections in p@e body
505 Ultrasonic testing for the detection of longitudinal im-
~ I S 0 13664 and B 400 for magnetic particle testing perfections in the pipe body shall be performed in accordance
~ B 600 for eddy current testing with I S 0 9303.
The acceptance criterion is: The acceptance criterion is:
imperfections longer than 6 mm in the circumferential di- Acceptance level L2K.
rection are not permitted.
Ultrasonic testing for transverse imperfections in p@e body
404 Liquid penetrant or eddy current testing of the end face 506 Ultrasonic testing for the detection of transverse imper-
or bevel of each pipe in non-ferromagnetic steel for the detec- fections in pipe body shall be performed in accordance with
tion of laminar imperfections shall be performed in accordance I S 0 9305
with
The acceptance criterion is:
~ I S 0 12095 and B500 for liquid penetrant testing
~ B 600 for eddy current testing Acceptance level L2K.
The acceptance criterion is: Surface testing for longitudinal and transverse indications in
pipe body
imperfections longer than 6 mm in the circumferential di- 507 Testing of ferromagnetic seamless pipe for the detection
rection are not permitted. of longitudinal and transverse surface imperfections shall be
405 Residual magnetism at pipe ends in the direction parallel performed in accordance with one of the following standards:
to the pipe axis shall be measured with a calibrated Hall effect ~ I S 0 9304 (eddy current testing)
gauss meter or equivalent equipment. The residual magnetism ~ I S 0 9402 (flux leakage testing)
is not to exceed 3mT (30 Gauss). Some welding methods may ~ I S 0 9598 (flux leakage testing)
require a more stringent acceptance criterion. ~ I S 0 13665 (magnetic particle testing)
G 500 Non-destructive testing of seamless pipe Guidance note:
501 The extent of NDT shall be according to Section 6, Ta- If detection of defects on the internal surface of the pipe is
ble 6-13. deemed important, IS0 9402 or IS0 9598 should be preferred.
502 For pipes in duplex steel, it shall be demonstrated that
the presence of any possible coarse, anisotropic zones will not
impede the testing. The acceptance criteria are:
Ultrasonic testing for laminar imperfections in p@e body ~ I S 0 9304 : Acceptance level L2
503 Ultrasonic testing for the detection of laminar imperfec- ~ I S 0 9402: Acceptance level L2
tions in pipe body shall be performed in accordance with I S 0 ~ I S 0 9598: Acceptance level L2
10124 amended as follows: ~ I S 0 13665: Acceptance level M1
~ the distance between adjacent scanning tracks shall ensure 508 Testing of non-ferromagnetic seamless pipe for the de-
100% coverage of the pipe body and be sufficiently small tection of longitudinal and transverse surface imperfections
to ensure detection of the minimum allowed imperfection shall be performed in accordance with one of the following
size; standards:
a sample pipe shall be fitted with one 3.0 mm 0 through
I S 0 9304 (eddy current testing)
~
drilled hole at each end. The distance from the pipe end to
~
trasonic testing equipment during production testing. Prior The acceptance criteria are:
to start of production the pipe shall be passed through the
ultrasonic testing equipment at the operational scanning ~ I S 0 9304 : Acceptance level L2
velocity. For acceptance of the equipment both holes need ~ I S 0 12095: Acceptance level P1
to be detected by all probes. At the manufactures option
these holes may be included in the reference block. G 600 Non-destructive testing of HFW, LBW and EBW
Pipe
The acceptance criteria are:
601 The extent of NDT shall be according to Section 6, Ta-
According to requirements to plate and strip body in Table ble 6-13.
D-2 for non-sour or sour service. 602 For pipes in duplex steel, it shall be demonstrated that
Guidance note:
the presence of any possible coarse, anisotropic zones will not
impede the ultrasonic testing.
Acceptance cntena for laminations in the pipe body according to
F.203 may apply, subject to agreement Ultrasonic testing for longitudinal imperfections in the weld
seam
603 Ultrasonic testing of the full length of the weld seam of
Ultrasonic thickness testing HFW, LBW and EBW pipe for the detection of longitudinal
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imperfections shall be in accordance with I S 0 9303 and the ~ indications exceeding the alarm level set for N5 notches
following amendments: and 1.6 mm 0 holes are not acceptable; and
for TOFD probes, indications exceeding the length or the
Equipment
~
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quency. 708 The equipment shall include devices for weld tracking
The acceptance criteria are: and provide checks of adequate coupling for each individual
probe.
~ IS0 9304 :Acceptance level L2 709 The total automated ultrasonic system shall have a doc-
~ IS0 13665:Acceptance level M1 umentation of calibration not older than 6 months at the start
of production.
Testing of non-ferromagnetic pipe for the detection of imper-
fections in the weld area 710 The reference block shall contain:
613 Testing of non-ferromagnetic HFW, LBW and EBW A 1.6 mm 0 through drilled holes at the weld centreline.
pipe for the detection of surface imperfections in the weld area B 1.6 mm 0 through drilled holes in the base material at
shall be performed in accordance with one of the following both sides at the weld toe edge, or drilled to half thick-
standards: ness from the outside and inside.
~ IS0 9304 (eddy current) C N5 notches in the base material and parallel to the weld
~ IS0 12095 (dye penetrant testing) at both sides of the weld toe edge externally.
D N5 notches in the base material and parallel to the weld
Eddy current testing performed in accordance with IS0 9304 at both sides of the weld toe edge internally.
shall use the segment coil technique, reference hole diameter E N5 notches in the weld, centred on and transverse to
of maximum 3.20 mm and the lowest possible excitation fre- the weld externally.
quency. F N5 notches in the weld, centred on and transverse to
The acceptance criteria are: the weld internally.
G 3.0 mm 0 through drilled holes in the pipe material 10
~ IS0 9304 :Acceptance level L2 mm outside the weld toe edge.
~ IS0 12095:Acceptance level PI
The length of the N5 notches shall be 1.5 times the probe (crys-
Radiographic testing tal) element size or 20 mm, whichever is the shorter. The
length does not include any rounded corners. The width of the
614 Radiographic testing of the extreme 300 mm of weld at N5 notches shall not exceed 1 mm.
each pipe end shall be performed in accordance with the re-
quirements of B 200. The number of notches and holes may be increased above the
numbers given above at the Manufacturer's option.
The acceptance criteria are:
Pipe wall thickness in excess of approximately 20 mm may re-
Table D-4 and lack of fusion and lack of penetration are quire that specific probes are used to detect longitudinal imper-
not permitted. fections in the mid thickness area of the weld. In such cases the
reference block shall contain a reflector to indicate the target
G 700 Non-destructive testing of SAW pipe position for these probes in order to ver@ correct positioning
701 The extent of NDT shall be according to Section 6, Ta- of the probes. The reflector may by used for setting of the
ble 6-13. aladrecording level if it provides a return signal equal to a
702 For pipes in duplex steel, it shall be demonstrated that N5 notch. The Manufacturer shall propose a type of reflector
the presence of any possible coarse, anisotropic zones will not suitable for the purpose, and the type of reflector used is sub-
impede the ultrasonic testing. ject to agreement.
Ultrasonic testing for longitudinal and transverse imperfec- 711 A sample pipe shall be fitted with one 3.0 mm 0 through
tions in the weld seam drilled hole at the weld centreline at each end. The distance
from the pipe end to the hole shall be equal to the length not
703 Ultrasonic testing of the weld seam of SAW pipe for the covered by the ultrasonic testing equipment during production
detection of longitudinal and transverse imperfections shall be testing. Prior to start of production the pipe shall be passed
in accordance with IS0 9765, and the requirements given in through the ultrasonic testing equipment at the operational
the following. scanning velocity. For acceptance of the equipment, both holes
704 The equipment arrangement shall be suitable for detec- need to be detected by all probes. At the Manufacturer's option,
tion of defects oriented predominantly parallel to andor at these holes may be included in the reference block.
right angles to the weld seam. In both cases testing shall be car- 712 The initial calibration shall be performed in the static
ried out in two opposing directions of beam travel. mode.
705 A description of the equipment shall be provided for re- A separate calibration shall be performed for each probe
view and agreement. The description shall include all docu- against the reference reflectors located in the area of the weld
mentation required by D 100 and D 200. that shall be covered by that probe.
706 The description of the equipment shall include: For detection of transverse imperfections, readily distinguish-
the number and position of probes dedicated for detection able signals shall be obtained from the (A) 1.6 mm 0 hole. The
response from the opposite side (B) 1.6 mm 0 hole and the (E)
~
of longitudinal defects and their operational mode (pulse- and (F) transverse N5 notches shall be recorded.
echo andor through transmission);
~ the number of probes dedicated for detection of transverse For detection of longitudinal imperfections, the probe shall be
defects, their orientation given in degrees relative to the targeted at the (A) 1.6 0 hole. The response from the (C) or (D)
weld axis and their operational mode (pulse-echo andor N5 notch that is applicable for the specific probe shall be re-
through transmission); and corded.
~ a sketch showing the probe angle, the chosen number of 713 If the wall thickness require specific probes to cover the
skips, the distance from the weld centreline to the probe mid thickness area of the weld, they shall be adjusted to obtain
index point and the angle between the ultrasound beam di- a peak signal from the mid thickness reflector.
rection and the weld axis for each probe.
714 The calibration shall be optimised until each primary re-
707 The probe angle shall be chosen to obtain the best test re- flector (A), (B), (C) and (D) is detected by at least two different
sult for the wall thicknesddiameter ratio of the pipe to be test- probes with different angles andor sound paths andor sensi-
ed. tivities.
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715 The signal amplitude percentage of full screen height re-calibrated as required in 712 to 719 and all pipes tested since
from reflectors (A) through (F) shall be recorded without any the last successful dynamic check shall be re-tested.
alterations to the amplification, position and angle relative to 723 Insufficient coupling shall be deemed to occur if the
the weld axis or sound path length used to optimise the calibra- transmission signal from any probe is more than 1OdB lower
tion of the probes. than lowest the a l d r e c o r d i n g level for the probe pair.
716 The detection gates shall be set using the (G) 3mm 0 724 For production testing the total gain shall be increased
holes. Gates shall start at the (G) reflector on the near side and with a minimum of + 3dB. This increased gain shall be re-
end at the (G) reflector at the opposite side. Only if geometrical moved during the dynamic check.
echoes from the weld reinforcement can exceed the echo from
the opposite (G) reflectors, may the gates end immediately be- 725 Indications exceeding the aladrecording level or re-
fore the appropriate (C) or (D) reflector. The gate start and end corded shall be investigated by radiographic testing according
shall be set reflecting the tolerances of the weld tracking de- to 803. If the presence of a defect is not confirmed by radiog-
vice. raphy, manual ultrasonic testing according to 809 and 810
shall be performed. If this additional NDT does not confirm the
717 After completing the static calibration all settings, gate presence of defects, the pipe shall be re-scanned by the auto-
positions, angle relative to the weld axis and offsets from the matic ultrasonic equipment. If the rescanning the first 5 times
weld centre line to the probe index point shall be recorded for the alarm system has been triggered does confirm the absence
each probe. of defects, further re-scanning may be omitted.
718 The aladrecording level for each probe shall set as fol- Ultrasonic testing of the piye bodyfor detection of laminar im-
lows: perfections
~ For transverse imperfections: 80% of the signal amplitude 726 Ultrasonic testing of the pipe body for detection of lam-
from the opposite side (B) 1.6mm hole, but not less than inar imperfections need not be performed at the pipemill if test-
the lowest signal amplitude from the either of the (E) or (F) ing according to subsection F is performed at the plate/strip
transverse N5 notches. mill.
For longitudinal imperfections: 100% of the signal ampli-
727 The testing, if performed at the pipemill, shall be in ac-
~
tude from the applicable (C) or (D) N5 notch giving the cordance with IS0 12094 amended as follows:
lowest signal amplitude.
~ If the use of a mid thickness notch has been agreed for set- the distance between adjacent scanning tracks shall ensure
ting of the a l d r e c o r d i n g level (signal response equal to 100% coverage of the plate body and all four edges and be
a N5 notch): 100% of the signal amplitude. sufficiently small to ensure detection of the minimum al-
Guidance note:
lowed imperfection size, and
for plate nominal thicknesses 2 40 mm the recess depth in
Provided equal coverage and sensitivity is obtained other equip- the reference standardhest piece shall be increased in order
ment configurations, reference reflectors and calibration meth-
ods may be used, subject to agreement. to place the bottom of the recess between %and Yi of the
nominal plate thickness.
The acceptance criteria are:
Guidance note:
As an alternative to the N5 notches and 1.6mm 0 holes the "two- According to requirements to plate and strip body in Table
lambda method" may be used. This method uses fixed depth in- D-2 for non-sour or sour service.
ternal and external notches and the test sensitivity is increased by
electronic means i.e. by an increase in dB. The depth of the Guidance note:
notches shall be twice the wavelength at the ultrasonic frequency Acceptance criteria for laminations in the pipe body according to
used. The method is specified in SEP 1916. Use of this method F.203 may apply, subject to agreement
requires that the ultrasonic velocity and the ultrasonic frequency
for the particular application are documented. The method may
be used subject to agreement.
Ultrasonic testing of the area adjacent to the weld seam body
for detection of laminar imperfections
719 A check on the calibration shall be performed in the dy- 728 Ultrasonic testing of the area adjacent to the weld seam
namic mode. The change in gain required to maintain the re- body for detection of laminar imperfections need not be per-
corded percentage of full screen height for each probe shall be formed at the pipemill if testing according to subsection F has
recorded as an average of the 3 dynamic check results. All been performed at the plate/strip mill.
probes shall be verified as indicating the recorded signal am- 729 The testing if performed at the pipemill shall be in ac-
plitude from the probes dedicated to the respective holes and cordance with IS0 12094 amended as follows:
notches. Gate settings shall not deviate more than 2.5 mm from
the reference position. The width of the tested band shall be 50 mm;
720 The dynamic check shall be performed at time intervals the distance between adjacent scanning tracks shall ensure
according to I S 0 9765. 100% coverage of the area adjacent to the weld and be suf-
ficiently small to ensure detection of the minimum al-
721 The equipment shall be deemed to be out of calibration lowed imperfection size; and
if: for plate nominal thicknesses 240mm the recess depth in
the response from any reflector during the dynamic check the reference standardhest piece shall be increased in order
to place the bottom of the recess between % and Yi of the
~
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730 Testing of ferromagnetic SAW pipe for the detection of band at each pipe end of C-Mn and duplex steel shall be per-
surface imperfections in the weld area shall be performed in formed manually unless performed with automated equipment.
accordance with one of the following standards: The provisions of IS0 11496 shall apply. Probes meeting the
requirements of IS0 12094, Annex A shall be used.
~ IS0 9304 (eddy current)
~ IS0 13665 (magnetic particle Acceptance criterion is:
Eddy current testing performed in accordance with IS0 9304 The requirements to plate and strip edges in Table D-2 for
shall use the segment coil technique, reference hole diameter non-sour or sour service.
of maximum 3.20 mm and the lowest possible excitation fre-
quency. 808 Ultrasonic testing for laminations over a 50mm wide
band at each pipe end of cladlined pipe shall be performed
The acceptance criteria are: manually unless performed with automated equipment.. The
provisions of ASTM A578/578M, S7 shall apply.
~ IS0 9304:Acceptance level L2
~ IS0 13665:Acceptance level M1 Acceptance criterion is:
Testing of non-ferromagnetic pipe for the detection of imper- ASTM A578, S7. In addition, no areas with laminations
fections in the weld area or lack of bond are allowed in the plate edge areas. Manual
ultrasonic testing of seamless pipe
731 Testing of non-ferromagnetic SAW pipe for the detec-
tion of surface imperfections in the weld area shall be per- Manual ultrasonic testing of SAW welds
formed in accordance with one of the following standards:
809 Manual ultrasonic testing of SAW welds shall be per-
~ IS0 9304 (eddy current) formed in general accordance with B 300.
~ IS0 12095 (dye penetrant testing) Probes with beam angles of O", 35", 45", 60" and 70" shall be
available.
Eddy current testing performed in accordance with IS0 9304
shall use the segment coil technique, reference hole diameter Calibration shall be against a reference block with a 1.6 mm 0
of maximum 3.20 mm and the lowest possible excitation fre- through drilled hole using a 45" probe. A DAC curve consist-
quency. ing of 3 points shall be established.
The acceptance criteria are: Scanning for longitudinal defects shall be performed trans-
verse to the longitudinal axis of the weld with 100% overlap on
~ IS0 9304 : Acceptance level L2 scan lines. The scanning shall include a check along the weld
~ IS0 12095: Acceptance level P1 with a Oo probe for laminar defects that may interfere with the
testing. Scanning for transverse defects shall be included as de-
Radiographic testing tailed in 810.
732 Radiographic testing of the extreme 300 mm of weld at Indications exceeding 20% of DAC shall be further investigat-
each pipe end and shall include the area not covered by the au- ed and the amplitude maximised using probes with a smaller
tomatic ultrasonic. The testing shall be performed in accord- and larger angle. All maximised indications exceeding 50% of
ance with the requirements of B 200. DAC shall be reported.
The acceptance criteria are: Acceptance criterion is:
Table D-5 and lack of fusion and lack of penetration are
not permitted. no maximised indications between 50% and 100% of
DAC are acceptable unless the presence of a defect is con-
G 800 Manual NDT firmed and found acceptable with radiographic testing and
no maximised indications exceeding 100% of DAC are ac-
801 Manual NDT shall be performed as given below and in ceptable.
general compliance with the requirements of subsection B.
802 The requirements in this subsection are applicable for 810 Scanning for transverse defects shall be performed at an
manual NDT performed at pipemills only. angle to the weld and "on bead"
Radiographic testing Probes with beam angles of 45", 60" and 70" and frequencies
of 2 and 4 MHz shall be available. Use of 4 MHz probes shall
803 Radiographic testing shall be performed according to B be preferred.
200.
The reference block shall contain 1. mm 0 through drilled
Acceptance criteria are: holes at the weld centreline.
Table D-5 and lack of fusion and lack of penetration are For "on bead" scanning a DAC curve shall be established
not permitted. against the 1.6 mm 0 weld centreline hole using 3 points (e.g.
1/2, full and 11/2 skip).
Manual ultrasonic testing
For scanning at an angle of 45" to the weld a DAC curve shall
804 Manual ultrasonic testing shall be performed at each be established against the 1.6mm 0 weld centreline hole using
pipe end over the area not covered by the automatic ultrasonic 3 points (e.g. %, full and 1% skip).
testing. In addition manual ultrasonic testing shall be per-
formed whenever required to confirm the presence of defects "On bead" scanning shall be performed in both directions and
and all weld repairs. a number of 100% overlapping scans shall be performed.
805 Manual ultrasonic testing shall be performed in general Scanning at an angle of 45" to the weld shall be performed
accordance with B 300. from both sides and in both directions with 100% overlap on
scan lines.
806 Reference blocks shall be made from a section of project
pipe. Indications found to be acceptable with radiographic testing,
and where their dimension and type are c o n f i i e d by ultrason-
Manual ultrasonic testingpipe ends ic testing, are acceptable. Other indications are not acceptable
807 Ultrasonic testing for laminations over a 50mm wide if their maximised amplitude exceeds 50% of DAC.
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App.D - Page 155
Indications exceeding 20% of DAC shall be further investigat- H. Testing of Installation Girth Welds, Compo-
ed and the amplitude maximised using probes with a larger and nent Welds and other Pressure Containing
smaller angle. All maximised indications exceeding 50% of
DAC shall be reported. Welds
The acceptance criterion is: H100 General
no maximised indications between 50% and 100% of 101 These requirements are applicable to NDT and visual
examination of installation girth welds and welds in bends, ris-
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P a g e l 5 6 - App.D
ceeds 0.2 t or the height of a welding pass, whichever is small- inspection requirements as the original weld.
er, the defect is not acceptable.
305 For welds in duplex steel, other stainless steels and clad Table D-3 Acceptance criteria for visual examination and sur-
face method testing
steel, the requirements in 301 to 304 are applicable except that
lack of fusion and lack of penetration are not permitted in the Extemal profile Welds shall have a regular finish and merge
root of single sided welds. smoothly into the base material and shall not
extend beyond the original joint preparation
H 400 Repair of welds by more than 3 mm (6mm for SAW welds).
Fillet welds shall be of specified dimensions
401 Welds that do not comply with the requirements shall be and regular in form.
repaired locally or the whole weld zone shall be removed. Re- Cap reinforcement/ Cap reinforcement:
welding shall be performed with qualified repair welding pro- root penetration Height less than 0.2 t, maximum 4 mm.
cedures and by qualified welders, see Appendix C. Root penetration:
height less than 0.2 t. maximum 3 mm.
402 Complete removal of the defect shall be confirmed by
magnetic particle testing, or liquid penetrant testing for non- Cap concavity/root Cap concavity: not permitted.
ferromagnetic materials, before re-welding. concavity Root concavity shall merge smoothly into
base material and at no point shall the weld
403 A repaired weld shall be subject to the same testing and thickness be less than t.
Misalignment of Less than O. 15 t and maximum 3 mm.
adjoining ends
(High/low)
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Cracks Not acceutable.
Lack of Individual length :
penetrationílack of < t, maximum 25 mm.
fusion Accumulated length in any 300 mm length of
weld
< t. maximum 50 mm.
Undercut, if Individual
measured by Depth d Permitted length
mechanical means d>l.Omrn Not permitted
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App.D - Page 157
1) Volumetric defects separated by less than the length of the smallest defect or defect group shall be considered as one defect
2) Elongated defects situated on line and separated by less than the length of the shortest defect shall be considered as one defect
3) Refer to the additional requirements in 303 for welding methods that produce welding passes exceeding O 2 t
4) Maximum 10% porosity in cluster area
5) "Isolated" pores are separated by more than 5 times the diameter of the largest pore
6) Pores are "On-line" if not "Isolated" and if 4 or more pores are touched by a line drawn through the outer pores and parallel to the weld "On-line" pores
shall be checked by ultrasonic testing If ultrasonic testing indicates a continuous defect, the criteria for lack of fusion defect shall to apply
7) Detectable imperfections are not permitted in any intersection of welds
8) Applicable to double sided welding where the root is within the middle t/3 only
9) Acceptance criteria of Table D-3 shall also be satisfied
not exceed 3 t, maximum 100 mm in any weld length of 300 mm nor more than 12% of total weld length. Any accumulation of defects in any
cross section of weld that may constitute a leak uath or reduce the effective thickness of weld more than t/3 is not acceutable.
If onlv one side of the weld is accessible for testinn 6 dB shall be subtracted from the maximum echo uermitted above
Notes:
a) Reference level is defined as the echo amplitude corresponding to the echo from the side drilled hole in the reference block described in Fig D-2 of this
appendix, or equivalent reflector
b) All indications exceeding 20% of the reference level shall be investigated to the extent that the operator determines the shape, length and location of the
imperfection
c) Indications that cannot be established with certainty shall whenever possible be tested with radiography Indications that are type determined in this way
shall meet the acceptance criteria of Table D-4
d) Longitudinal imperfections where the echo height intermittently is below and above the acceptance level, shall if possible be investigated with radiogra-
phy Indications that are determined in this way shall meet the acceptance criteria of Table D-4 If radiography cannot be performed, the length shall not
exceed 3 t, maximum 100 mm in any weld length of 300 mm
e) Length, height and depth shall be determined by an appropriate method, see B 3 15
f> Detectable imuerfections are not uermitted in anv intersection of welds
I. Acceptance Criteria for Pipeline Components, 101 NDT and visual examination of pipeline components
Equipment, Structural Items, Base Materials and equipment shall be performed in accordance with and
and Weld Overlay meeting the acceptance criteria of the code or standard used for
the design of the item in question, see Section 7.
I100 General 102 For forgings and castings used in pipeline components
and equipment, the acceptance criteria given in this subsection
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P a g e l 5 8 - App.D
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flaws in C-Mn, duplex, other stainless steels and nickel based
corrosion resistant alloys ( C U ) performed according to I S 0
12094 are given in Table D-2.
203 Acceptance criteria for manual ultrasonic testing for de-
tection of laminar flaws in cladlined steel performed accord-
ing to ASTM A578/578M, S7 shall be ASTM A578, S7. In
addition, no areas with laminations or lack of bond are allowed
over a width extending at least 50 mm inside the location of fù-
hue weld preparations.
204 For manual ultrasonic testing for detection of flaws oth- Table D-7 Radiographic acceptance criteria for castings
er than laminar, performed according to ASTM A577/577M or Type of defect I Acceptance criteria
equivalent standard, the acceptance criteria shall be that no in- Cracks I ASTM E 186. E280. E446 I Not acceutable
dications exceed the DAC curve established against the rectan- I
Gas porosity I ASTM E 186, E280, E446 I Level A2
gular notch with depth 3% of the thickness. Inclusions I ASTM E 186, E280, E446 I Level B2
205 Acceptance criteria for manual magnetic particle testing Shrinkage I ASTM E 186. E280. E446 I Level C2
of plate and pipe edges performed according to ASTM E 709,
ASTM E1444 or equivalent standard shall be: 403 Acceptance criteria for manual magnetic particle testing
of castings done in accordance with ASTM E709, ASTM
No indications longer than 6mm in the circumferential/ El444 or equivalent standard shall be according to Table D-6.
longitudinal direction are permitted
Acceptance criteria for manual liquid penetrant testing of cast-
206 Acceptance criteria for manual liquid penetrant testing ings done in accordance with ASTM E1417 or equivalent
of plate and pipe edges performed according to ASTM E 1417 standard shall be according to Table D-6.
or equivalent standard shall be:
I500 Acceptance criteria for weld overlay
No indications longer than 6mm in the longitudinal direc- 501 Acceptance criteria for as-welded surfaces of magnetic
tion are permitted and non magnetic weld overlay for visual examination, mag-
207 Acceptance criteria for manual eddy current testing of netic particle testing and liquid penetrant testing are:
pipe and pipe edges performed according to ASTM E 309 or no round indications with diameter above 2 mm and no
~
equivalent standard shall be: elongated indications with length above 3 mm,
No indications longer than 6mm in the circumferential/ indications separated by a distance less than the diameter
~
longitudinal direction are permitted or length of the smallest indication, shall be considered as
one indication, and
I300 Acceptance criteria for forgings accumulated diameters of round indications and the length
~
301 Acceptance criteria for manual ultrasonic testing of of elongated indications in any 100 x 100 mm shall not to
forgings performed according to ASTM A 388/ASTM A 388/ exceed 10 mm.
M or equivalent standard shall be: For machined surfaces acceptance criteria shall be especially
Straight beam examination agreed upon.
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App.E - Page 159
APPENDIX E
AUTOMATED ULTRASONIC GIRTH WELD TESTING
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405 The instrument shall provide an adequate number of in- system for field inspection and to monitor the ongoing system
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spection channels to ensure the examination of the complete performance. Calibration blocks shall be manufactured from a
weld through thickness in one circumferential scan. Each in- section of pipeline specific linepipe.
spection channel shall provide 413 Acoustic velocity and attenuation measurements shall
~ Pulse echo or through transmission modes be performed on material from all sources of pipe material sup-
~ One or more gates, each adjustable for start position and ply to be used. These measurements shall be performed ac-
length cording to Annex B unless an equivalent method is agreed. If
Gain adjustment differences in acoustic velocity for the same nominal wall
thickness from any source of supply results in a beam angle
~
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App.E - Page 161
der field conditions and evaluating size, nature and location of ToFD technique
imperfections. 803 The recording threshold for ToFD is normally not rec-
425 Operators whom are not accepted shall not be used, and ommended to be changed from the calibration threshold. How-
operators shall not be substituted without prior approval. In ever, a change of threshold may be prescribed in the procedure.
case additional operators are required, details of these shall be Threshold level
accepted before they start to work.
804 It shall be verified that the threshold level is set low
426 One individual shall be designated to be responsible for enough to detect the minimum height critical defect identified
the conduct of the ultrasonic personnel, the performance of in the acceptance criteria.
equipment, spare part availability, and inspection work, in-
cluding reports and records. B 900 Power supply
427 The operators shall have access to technical support 901 The ultrasonic system shall have a dedicated power sup-
from one individual qualified to Level 3 at any time during ex- ply. There shall be provisions for alternative power supply in
ecution of the examination work. case of failure in the main power supply. There shall be no loss
of inspection data as a result of a possible power failure.
B 500 Recorder Set-up
501 Channel output signals shall be arranged on the record- B 1000 Software
ing media in an agreed order. The function of each channel 1001 All recording, data handling and presenting software
shall be clearly identified. The hard copy recording shall be shall be covered by the Quality Assurance system and all soft-
corrected to account for any difference introduced due to dif- ware versions be identifiable by a unique version number.
ferent circumferential positions of the transducers.
1002 This version number shall be clearly observable on all
display and printout presentations of examination results.
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B 600 Circumferential scanning velocity
601 The maximum allowable circumferential scanning ve- B 1100 System Log Book
locity (V,), shall be determined according to 1101 The operator shall keep a Log Book detailing the per-
formance/characteristics data and identification for instru-
ments and transducers. The Log Book shall be updated as
V, 5 W, PRF/3 changes are made, or, as additional information is gathered.
The Log Book shall be kept at the place of inspection, and be
where W, is the narrowest -6 dB beam width at the appropriate made available for review upon request.
operating distance of all transducers within the array, and PRF
is the effective pulse repetition frequency per transducer. B 1200 Spares
1201 There shall be a sufficient number of spare parts avail-
B 700 Gate settings able at the place of examination to ensure that the work can
Pulse echo, tandem and through transmission techniques proceed without interruptions. The type and number of spares
shall be agreed.
701 With each transducer positioned for the peak signal re-
sponse from the calibration reflector the detection gates are to B 1300 Slave monitors
be set. The gate shall start before the theoretical weld prepara-
tion and a suitable allowance shall be included to allow for the 1301 The system shall include the possibility to provide
width of the heat affected zone, so that complete coverage of slave monitors for use by supervising personnel, if agreed.
the heat affected zone is achieved. The gate ends shall be after
the theoretical weld centreline, including a suitable allowance
for offset of the weld centreline after welding. For porosity
mapping channels the gates shall also be set to cover the total C. Procedure
weld volume dedicated to the transducer.
C 100 General
ToFD technique 101 A detailed Automated Ultrasonic Examination Proce-
702 Ideally the time gate start should be at least 1 ?s prior to dure shall be prepared for each wall thickness and joint geom-
the time of arrival of the lateral wave, and should at least ex- etry to be examined prior to the start of any welding. The
tend up to the first back wall echo. Because mode converted procedure is as a minimum to include
echoes can be of use in identiSling defects, it is recommended
that the time gate also includes the time of arrival of the first functional description of equipment;
mode converted back wall echo. reference standards and guidelines controlling equipment
maintenance;
703 As a minimum requirement the time gate shall at least instructions for scanning device, ultrasonic instrument, ul-
cover the depth region of interest. trasonic electronics, hard- and software for recording,
704 Where a smaller time gate is appropriate, it will be nec- processing, display, presentation and storage of inspection
essary to demonstrate that the defect detection capabilities are data;
not impaired. transducer configuration(s), characteristics, types, cover-
age;
B 800 Recording Threshold number of examination zones for each wall thickness to be
Pulse echo, tandem and through transmission techniques examined;
gate settings;
801 The recording threshold for planar detection channels equipment settings;
shall be at least 6 dB more sensitive than the reference reflec- description of calibration block(s), including type, size
tor, and shall be such that the smallest non-allowable imperfec- and location of all calibration reflectors;
tions are detected. calibration intervals;
802 The recording threshold for porosity detection channels calibration records;
shall be at least 14 dB more sensitive than the reference reflec- identification of inspection starting point, scanning direc-
tor. tion, and indication of length inspected;
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method for scanner alignment and maintenance of align- of the complete system, a weld shall be scanned followed by
ment; re-calibration with the inspection band removed between each
allowed temperature range; scan. If any of the echo amplitudes from the reflectors of the
couplant, coupling and coupling control; calibration block deviate more than 2 dB from the initial cali-
transducer and overall functional checks; bration, the system shall not be used until acceptable correc-
height and length sizing methodology; tions have been made. For an acceptable test, 3 satisfactory
surface condition and preparation; scans and re-calibrations are required. In addition, a power
description of inspection work; failure shall be simulated and operation of the system on the al-
acceptance criteria; and ternative power source with no loss of examination data shall
instructions for reporting including example of recorder be verified.
chart and forms to be used. Reference line
103 Prior to welding a reference line shall be scribed on the
pipe surface at a distance from the centreline of the weld prep-
D. Calibration aration on the inspection band side. This reference line shall be
used to ensure that the band is adjusted to the same distance
D 100 Initial static calibration from the weld centreline as to that of the calibration block.
Transducerpositioning and Primary Reference Sensitivity Guiding band positioning
101 The system shall be optimised for field inspection using 104 The tolerance for inspection band positioning is I 1 mm
the relevant calibration block(s). relative to the weld centreline. The template used to align the
102 Pulse echo and tandem transducers shall in turn be posi- scanning band to the reference line shall be adjusted to account
tioned at its operating (stand-off) position and adjusted to pro- for weld shrinkage. Shrinkage is determined by marking the
vide a peak signal from its calibration reflector, this signal reference line on both pipe ends for the first 25 welds, then
shall be adjusted to the specified percentage of full screen measuring the distance between them after welding.
height (FSH). Surface condition
103 The gain level required to produce this peak signal re- 105 The scanning area shall be free of spatter and other irreg-
sponse is the Primary Reference Level (PRE). The PRE, the ularities which may interfere with the movement of the trans-
signal to noise (S/N) ratio, and the transducers stand-off dis- ducers, the coupling or the transmission of acoustic energy into
tance shall be recorded. the material. The longitudinal seam welds shall be ground
Gate settings flush and smooth for a specified distance, normally in the
range of 150 mm from the factory bevel face to ensure that no
104 With each transducer positioned for a peak signal re- transducers are lifted from the pipe surface. The pipe coating
sponse from the calibration reflector the detection gates shall shall be cut back from the original factory bevel face for a
be set as detailed in the agreed Automated Ultrasonic Exami- specified distance, normally around 350 mm for concrete coat-
nation Procedure and according to B.701. ing and 150 mm for corrosion coating.
105 The settings for gate start and gate length for each chan- 106 The actual cut back dimension requirements shall be ad-
nel shall be recorded. vised and confirmed by the inspection body conducting the
testing.
D 200 Dynamic calibration
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Transducer wear baseline measurements
Detection channels
107 Transducer case height measurements shall be provided
201 With the system optimised, the calibration block shall be for prior to the start of field weld examinations. An accurate
scanned. The position accuracy of the recorded reflectors rela- (I0.1 mm) measurement shall be made of the case height at
tive to each other shall be within I 2 mm, and with respect to each corner of each transducer. These measurements shall be
the zero start within I 10 mm. Gate settings shall not deviate recorded and provide a comparison for the periodic measure-
more than 0.25 mm from the reference positions. ments taken throughout the examination period to assess for
202 For all transducers the recording media shall indicate the transducer wear.
required percentage of FSH and locate signals from each cali- Calibrationfrequency
bration reflector in its correctly assigned position.
108 The system shall be calibrated by scanning the calibra-
203 A calibration qualification chart shall be used as the in- tion block before and after inspection of each weld:
spection quality standard to which subsequently produced cal-
ibration charts may be judged for acceptability. This recording ~ for the first 20 welds.
shall be kept with the system Log Book. ~ at any change of calibration block
Coupling monitor channels ~ at any change of nominal wall thickness
at any change of components
204 The coupling monitor channels shall indicate no loss of
~
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pipe tracking system. perfections shall be evaluated. Their nature shall be clearly
113 The starting point for each scan shall be clearly marked identified on the examination report.
on the pipe and the scan direction shall be clearly marked using 103 All evaluations shall be completed immediately after ex-
an arrow. amination of the weld.
Replacement of components G 200 Examination reports
114 Following replacement of any component, the system 201 The examination results shall be recorded on a standard
shall be re-calibrated according to D. ultrasonic report form. The reports shall be made available on
E 200 Operational checks a daily basis or on demand.
Circumferential position accuracy G 300 Inspection records
201 As a minimum the position accuracy of the chart dis- 301 The following inspection records shall be provided:
tance markers shall be validated twice during each shift. Chart
accuracy shall be I 1 cm or better. The result shall be recorded. ~ a hard copy record of each weld examined,
~ an assessment of the weld quality according to the accept-
Transducer performance ance criteria,
202 Transducers shall be examined for wear against the ~ hard copy records of all calibration scans, and
baseline measurements performed according to 107 whenever ~ examination data in electronic form.
a change in gain of more than 6 dB is necessary to maintain the
required percentage of FSH (PRE). The transducer shall be re- 302 In lieu of hard copy records an alternative recording me-
placed or the contact face shall be re-surfaced to correct any of dia is acceptable. Where weld interpretation has been per-
the following: formed using digitally processed signals, the data files shall be
stored and backed up immediately following the examination
~ Beam angle changes of I 1.0" for angles less than 45" or I of each weld. The stored data shall be in the same format as
1.5" for angles greater than 45". used by the operator to assess the acceptability of welds at the
~ Squint angles exceeding 1.5" for single crystal transducers time of examination.
and 2" for twin crystal transducers. 303 It agreed, a software package and one set of compatible
~ For all transducers except creeping wave transducers the hardware shall be provided in order to allow the weld data file
noise shall be at least 20 dB weaker than the signal from to be retrieved in the same manner as the operator viewed the
the reference reflector at the target distance. data at the time of inspection.
~ For creeping wave transducers the noise shall be at least 16
dB weaker than the signal from the reference reflector at
the target distance.
~ Scores in the transducer wearface which may cause local H. Qualification
loss of contact or which exceed 0.5 mm.
H100 General
203 Following either replacement or resurfacing of a trans-
ducer a new calibration shall be performed as described in Ap- 101 Ultrasonic systems shall be qualified and the perform-
pendix E, subsection D. ance of the system shall be documented.
102 A qualification is AUT system, weld method and groove
geometry specific. Qualification done for one type of welds or
an earlier version of the AUT system will not automatically
F. Re-examination qualiSl the system for a new application. This does, however
not mean, that earlier experience and qualification shall be dis-
F 100 General regarded, but be actively used for qualification for related ap-
101 Welds shall be re-examined whenever any of the follow- plications.
ing occur: 103 Qualification involves a technical evaluation of the AUT
Sensitivity system and application in question combined with any re-
quired practical tests .
102 Welds examined at a sensitivity lower than 3 dB from
the PRE shall be re-examined. 104 The qualification shall be based on a detailed and agreed
qualification programme.
Coupling loss
103 Welds exhibiting a loss of acoustic coupling, i.e. a drop H200 Scope
in echo amplitude of more than 10 dB from the level through a 201 A qualification programme shall document the follow-
clean weld for a circumferential distance which exceeds the ing:
minimum allowable defect length for the affected channel
shall be re-examined. ~ Fulfilment of the requirements to AUT systems according
to this Appendix
Out of calibration ~ The ability of the AUT system to detect defects of relevant
104 If a calibration scan shows that the system is in any way types and sizes in relevant locations
"out of calibration", all welds examined since the last success- ~ The accuracy in sizing and locating defects.
ful calibration shall be re-examined.
H 300 Requirements
Detection
G. Evaluation and Reporting 301 The detection ability of an AUT system shall be deemed
sufficient if the probability of detecting a defect of the smallest
G 100 Evaluation of indications allowable height determined during an Engineering Critical
Assessment (see Appendix D, E 200) is 90% at a 95% confi-
101 Indications from weld imperfections shall be evaluated dence level. This requirement will, after technical justification,
according to the defect acceptance criteria provided. in most cases be regarded fulfilled, when the smallest allowa-
102 Indications recorded from sources other than weld im- ble defect height is 3 mm or more and the AUT sensitivity level
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is set at 50% of the echo from a 3 mm 0 flatbottom hole. shall be minimum 10 for each welding methodjoint geometry
302 An alternative route to showing sufficient sensitivity and to be used. For small diameter pipelines a number of test welds
detection ability is to show that detection rates are higher, with may be required.
95% confidence, than those for an accepted workmanship 604 In order to show sufficient detection ability at a required
NDT technique, as given in Appendix D. confidence level, it will be necessary to increase the number of
Sizing accuracy included defect s.
303 No specific requirements apply to defect sizing accura- 605 The presence and sizes of the induced defects in the test
cy. However, if the determined accuracy is to be used for de- welds shall be confirmed. For this purpose the test welds shall
termination of acceptable defect sizes based on the allowable subject to radiography, manual ultrasonic testing and magnetic
sizes calculated according to an Engineering Critical Assess- particle or eddy current testing. The reference point for all test-
ment (see Appendix D E 200), then high inaccuracies in sizing ing shall be the same and shall be indicated by hardstamping
(especially undersizing) can cause problems in defining the ac- on the test welds. The techniques used for this testing shall be
ceptance criteria. The requirements are thus indirectly set. optimised for the weld geometries in question. The interpreta-
tion of radiographs and other test results should at least be per-
H 400 Qualification programme formed two individuals, initially working independently of
each other and later reporting their findings jointly.
General
606 The report shall identiSl the identified defects in the test
401 A full qualification programme for a specific application welds with respect to circumferential position, length, height
of an AUT system will in general comprise the following stag- and depth. The report shall be kept confidential.
H 700 Qualification testing
Collection of available background material, including
technical description of the AUT system and its perform- 701 The test welds shall be subjected to testing by the AUT
ance system.
Initial evaluation and conclusions based on available in- 702 For the testing a low echo amplitude recording threshold
formation shall be used. This threshold should be selected somewhat
above the noise level and the recording of echo amplitudes
Identification and evaluation of significant parameters and may be used for possible later determination of the examina-
their variability tion threshold setting to achieve sufficient detectability.
Planning and execution of a capability test programme 703 The reference point for circumferential positioning shall
Planning and execution of a reliability test programme be a hardstamped reference point on the test welds.
Reference investigations 704 The testing shall include repeatability tests with several
Evaluation of results from capability and reliability trials scans with guiding band removed and re-attached between
scans.
402 The extent of each of these stages will be dependent on 705 At least one test shall be done at the elevated tempera-
the prior available information and documentation, and may be ture expected during field work.
totally omitted if the prior knowledge is sufficient.
706 The AUT test results shall be reported. The report shall
403 As a minimum a qualification will involve an assess- give the identified defects in the test welds with respect to cir-
ment of the AUT system technical documentation, including cumferential position, length, height and depth. In addition the
the quality assurance system, and available information on de- defect height and amplitude around the highest and lowest part
tection abilities and defect sizing accuracy. Limited practical of the defects shall be reported for each 2 mm circumferential
tests, must, however, in many cases be executed, on which in- length over a length of 15 to 20mm.
formation is given below.
H 800 Validation testing
H 500 Variables
801 The reports from the AUT qualification testing shall be
501 Variables, which must be taken into account during a validated for accuracy in the determination of defect circum-
qualification, include, but are not necessarily limited to: ferential position, length, height and depth
~ Welding method and groove geometry; 802 The validation testing shall be by cross-sectioning ("sa-
~ Root and cap probe Set-up; lami method"). The defects as reported in the AUT reports
~ Probe set-up for other channels (the number of these chan- shall be used when selecting the areas for cross sectioning. The
nels may be increased or decreased provided there are no extent of cross sectioning shall be sufficient to ensure that the
set-up changes); defect height sizing accuracy determination will be based on a
~ Reference reflectors; minimum of 29 measurements on different defects and / or 'ul-
~ System, data acquisition and data treatment; trasonically independent' parts of defects (i.e. at locations
~ Software version (except changes affecting viewing or many beam widths apart) for each welding method and joint
display only). configuration.
803 The cross sections shall be referenced to and validated
H 600 Test welds against the recording chart positions.
601 Qualification testing shall be performed using test welds 804 For determination of defect height sizing accuracy two
containing intentionally induced defects typical of those ex- parts of each defect, 10 - 20 mm long and corresponding to the
pected to be present in welds produced with the welding meth- highest and lowest part of the defect recorded by AUT, see
ods to be used. 706, shall be selected and the "salami method" applied on these
602 The material and the weld geometry shall be as for the parts to determine its height and location.
actual use of the equipment, including a sufficient number of 805 The weld sections containing defects shall be machined
repair welds with a representative variations in groove shape. in increments of 2.0 mm. Each machined cross section of the
603 The intentionally introduced defects shall vary in length, weld shall be etched and the defect location, height and depth
height and location. Too close spacing of the defects shall be measured with an accuracy better than I 0.1 mm. Each cross
avoided. The number of defects in simulated production welds
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section shall be documented by a photograph with 5 - 10xmag-
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nification. new or modified system to detect and accurately size and posi-
806 In addition a few randomly selected defect parts shall be tion weld imperfections.
subject to such cross-sectioning. For determination of detec-
tion abilities and adjustment of required threshold levels addi-
tional cross-sectioning, or detailed ultrasonic mapping of
specimens cut out from the test weld pipes, is required. These Annex A. Transducer requirements
cross-section should be selected randomly, at locations where A.l Identification
one or more of the applied NDT techniques have found indica-
tions. The transducer shall be identified with the following: the man-
ufacturer, type, beam angle, nominal frequency, crystal size
H 900 Analysis and shape, and a unique identification number.
901 The data recorded during the tests and reference investi- A.2 Beam angle
gations shall be analysed with respect to:
For beam angles less than 45" the measured angle shall not dif-
Accuracy in height sizing (random and systematic devia- fer by more than 1.0".
tion);
Accuracy in length sizing; For beam angles greater than 45" the measured angle shall not
Accuracy in circumferential positioning / location; differ by more than 1.5".
AUT defect characterisation abilities compared to the re- Evaluation shall be made according to BS 4331, Clause 5. The
sults of the destructive tests and the other NDT performed; beam angles shall be determined using the same homogeneous
Repeatability when repositioning guide band and at ele- material for all probes.
vated temperature;
If relevant, determination of probability of detection val- A.3 Beam size
ues or curves for different assumed echo amplitude thresh- The vertical dimension of the beam at the target shall be within
old settings to determine the threshold to be used during 20% of the design height specified. The horizontal dimension
examination, or, alternatively or supplementary, an analy- of the beam at the target shall not be greater than two times the
sis of the relationship between echo amplitude and defect vertical dimension of the beam. The target is defined as the
height. point along the beam axis where the inspection is to be per-
formed. In the case of a focused element the target shall fall
H 1000 Reporting within the -6 dB working range distributed across the focus.
1001 A qualification report shall as a minimum contain: Beam height measurements shall be taken at 5 points along the
-6 dB working range.
~ Outcome of the technical evaluation of the AUT system
according to this Appendix; Evaluation shall be according to BS 433 1 Clause 6.
Description of the specimens and tests performed, includ-
A.4 Overall gain
~
The squint angle shall not exceed 1.5" for single crystal trans-
ducers or 2" for twin crystal transducers.
I. Validity of Qualification Evaluation shall be according to ES1 Clause 8.8.
I100 Validity A.7 Longitudinal angle beam
101 A qualification is AUT system, weld method and groove
geometry specific. The longitudinal angle beam shall be at least 35 dB weaker
than the shear wave beam measured at a range of 100 mm.
A qualification of an AUT system will remain valid on the con-
dition that no changes are made in the essential variables de- Evaluation shall be according to ES1 Clause 8.10.
fiied in I 200. A.8 Surface waves
I200 Essential variables Surface waves shall be at least 34 dB weaker than the shear
201 The following essential variables apply: wave, for beam angles less than 64". For angles grater than 64"
they shall be at least 24 dB weaker measured at 100 mm range.
Welding method and groove geometry (including repair Evaluation shall be according to ES1 Clause 8.11,
welds);
Root and cap probe Set-up; A.9 Side lobes
Probe set-up for other channels (the number of these chan-
nels may be increased or decreased to accommodate Side lobes shall be at least 20 dB weaker than the main beam,
changes in wall thickness provided there are no set-up except for angles greater than 64" where they shall be at least
changes); 15 dB weaker.
Reference reflectors; Evaluation shall be according to ES1 Clause 8.13.
System, data acquisition and data treatment;
Software version (except changes affecting viewing or A.10 Subsidiary maxima
display only). Any fluctuations in the echo amplitude shall not exceed that
caused by interference caused with grass.
202 Changes in the essential variables for an existing quali-
fied system will require a demonstration of the ability of the Evaluation shall be according to ES1 Clause 8.14.
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A . l l Pulse shape
The pulse shape shall be single peaked with any secondary
peaks in the tail of the pulse at least 20 dB less than the peak.
Evaluation shall be according to ES1 Clause 8.16.
A.12 Frequency
The operating frequency shall be within I10% of the nominal
frequency.
Evaluation shall be according to ES1 Clause 8.18,
A.13 Pulse length
The pulse length shall not exceed 2.5 microseconds between
points on the rectified pulse at 10% of peak amplitude.
Evaluation shall be according to ES1 Clause 8.19.
A.14 Signal to noise
For all transducers except creeping wave transducers the noise
shall be at least 20 dB weaker than the signal from the refer-
ence reflector at the target distance.
For creeping wave transducers the noise shall be at least 16 dB Figure 1. Test specimen and transducer placement
weaker than the signal from the reference reflector at the target
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distance.
A minimum of two parallel surfaces are machined for the plane
Evaluation shall be according to BS 4331, Clause 11. Note:
This evaluation shall be performed using the system instru- to be evaluated; one pair of surfaces is made in the radial direc-
mentation in multiplex mode with all cabling in place, and all tion (perpendicular to the OD surface) and the other pair made
relevant electrical systems operating. 20" from the perpendicular to the OD surface. See Figurel.
Additional pairs of parallel surfaces may be machined at other
angles in the plane to be evaluated if more data points are de-
sired.
Annex B. Determination of shear wave velocity
in pipe steels The machined surfaces should be smooth to a 20 pm finish or
better. Minimum width of the specimen surface to be measured
B.l General should be 20 mm and the minimum thickness between the par-
allel surfaces to be measured should be 10 mm. Vertical extent
The procedure defined in this Annex covers methods that may
be used to determine acoustic velocity of shear waves in line- of the test surface will be limited by the pipe wall thickness.
pipe steels. Equivalent methods may be used subject to agree-
ment. B.4 Test method
Linepipe used in oil and natural gas transmission exhibit vary- Using the machined slots as reflectors for the shear wave puls-
ing degrees of anisotropy with varying acoustic velocities de- es with the transducer in the appropriate positions and measur-
pending on the propagation direction with resultant changes in ing the pulse transit times determines together with the
the refracted angle of the sound in the steel. This is especially mechanically measured pulse travelling distances the shear
critical where focused beams are used for zonal discrimination. wave velocities in the axial and 20" direction (Figure 1).
It is thus required to determine the ultrasonic shear wave ve-
locity for propagation in different directions. A similar measurement in the through thickness direction de-
termines the radial velocity. Pulse transit times shall be meas-
B.2 Equipment ured between the forefront parts of lStand 2nd backwall echo,
To determine the shear wave velocity directional dependency or, alternatively, using more multiple echoes.
an ultrasonic shear wave transducer of 5 MHz frequency with A minimum of three readings shall be made for each plane in
a crystal diameter of 6 - 10 mm should be used in combination which testing shall be done.
with an ultrasonic apparatus with bandwidth at least up to 10
MHz and a recommended capability of measuring ultrasonic B.5 Accuracy
pulse transit times with a resolution of 10 ns and an accuracy
of f25ns. Devices for measuring mechanical dimension of the Errors in velocity determination shall not be greater than I
specimens should have a recommended accuracy of I O . Imm. 20ds.
As couplant an easily removable glue or special high viscosity
shear wave couplant is recommended. B.6 Recording
B.3 Specimens Values for the velocities determined can be tabulated and
graphed. By plotting velocities on a two dimensional polar
A specimen is cut from a section of pipe to be tested and the
corresponding results are specific for a particular pipe diame- graph for a single plane, velocities at angles other than those
ter, wall thickness and manufacturer. Specimen dimensions made directly can be estimated.
should be a minimum of 50 mm x 50 mm. The effect of temperature on velocity can be significant under
A similar arrangement can also be used for measuring veloci- extreme test conditions, therefore the temperature at which
ties in a plane normal to pipe axis. these readings have been made should also be recorded.
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