ENGINEER’S STAMP: CONTRACTOR’S STAMP:

5 Minor modifications Lozano Zhao 27.03.2019

4 Minor modifications Kaim Pölzer 07.06.2017
3 General update Proetzl Kloos 06.03.2015
2 General update Geiger / Schutter Rupietta 05.08.2010
1 General update Neumann Casalini 28.04.2006
0 Issue for Tender Documents Kosikova Bangert August 2004
B Issue for Draft Tender Kosikova Bangert August 2004
A For approval Rupietta Bangert July 2003
REV DESCRIPTION PREPARED CHECKED DATE

SALINE WATER CONVERSION CORPORATION

KINGDOM OF SAUDI ARABIA

SWCC WATER TRANSMISSION SYSTEMS

ILF CONSULTING ENGINEERS

LOCATION: TITLE:

Specification M01
STEEL PIPES FOR MAINLINES

SCALE: DOCUMENT No.: REV:

Q C 1 0 - H - 0 4 1 5
SUBCONTRACTOR:
Sheet 1 of 17
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LIST OF CONTENTS

1 SCOPE 3
2 CODES AND STANDARDS 3
3 GENERAL 3
3.1 Environmental Conditions 3
3.2 Definitions 4
3.3 Abbreviations 4
3.4 Conflicting Requirements, Exceptions 4
4 TECHNICAL REQUIREMENTS 5
4.1 Specification of Material 5
4.2 Manufacture of Pipes 6
5 INSPECTION, TESTING AND CERTIFICATION 8
5.1 General 8
5.2 Visual Inspection 9
5.3 Material Tests 9
5.4 Repairing Defects 15
5.5 Test and Production Records 15
6 PRESERVATION, MARKING AND SHIPPING 16
6.1 Preservation 16
6.2 Marking 16
6.3 Shipping and Loading 17
7 DOCUMENTATION 17
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1 SCOPE

This Specification covers the minimum technical requirements for the

manufacture and testing of uncoated longitudinal and helical welded steel line
pipes with plain ends as per API 5L for the use in mainlines.
All work has to fulfil the requirements for non-sour service as per API 5L, meeting
the amended and supplementary requirements of this Specification.

2 CODES AND STANDARDS

The latest edition of the following codes and standards shall establish the
minimum standards for the work.
API 5L Specification for Line Pipe
API 1104 Welding of Pipelines and Related Facilities
EN 10204 Metallic products – Types of inspection documents
ISO 10893-9 Non-destructive testing of steel tubes – Part 9: Automated
ultrasonic testing for the detection of laminar imperfections in
strip/plate used for the manufacture of welded steel tubes
ISO 9001 Quality management systems – Requirements

Besides the above mentioned codes and standards the Contractor shall observe
the following specifications:
G02 General Description of Project and Works
G03 Project Execution
M18 Handling, Storage and Transportation of Line Pipe Material

3 GENERAL

3.1 Environmental Conditions

The environmental conditions, operating conditions, product data, etc. under

which the pipes shall operate are defined in the relevant project description and
pipe laying specifications.
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3.2 Definitions

The terms “Pipe Supplier”, “Engineer”, “Inspector”, etc. used in this Specification
shall have the meaning as defined in the General and Special Conditions of
Contract.

3.3 Abbreviations

API American Petroleum Institute

CE Carbon equivalent
EN European Standard
HB Brinell Hardness
ISO International Organization for Standardization
nom nominal
OD Outer Diameter
PSL Product Specification Level
RT Radiographic Testing
SMYS Specified Minimum Yield Strength
UT Ultrasonic Testing
WT Wall Thickness

3.4 Conflicting Requirements, Exceptions

The Pipe Supplier shall notify the Engineer of any conflict between this
Specification, the codes and standards and any other requirements included as
part of the Contract Documents referring to the line pipes.
Any exceptions to this Specification and referenced documentation shall be
raised by the Pipe Supplier to and approved by the Engineer in writing.
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4 TECHNICAL REQUIREMENTS

4.1 Specification of Material

4.1.1 Type and Quality of Plates and Hot Rolled Coils

The steel shall be fully conforming to API 5L, PSL 2. The coils and plates must
be as-rolled (R), normalised (N), quenched and tempered (Q) or
thermomechanical rolled/formed under controlled temperature conditions (M).
The particular heat treating process shall therefore be specified, recorded and
certified on the Material Test Certificates for plates, coils and pipes.
The surface of plates and coils shall be checked for laminations by means of
ultrasonic testing (UT) in accordance with ISO 10893-9 applying Acceptance
Level U1 for body. A 25 mm wide zone along the edges shall be checked for
laminations following the requirements as per Annex E.3.2.3 of API 5L. UT may
be carried out during the manufacture of the pipe. In case such a defect is
detected by UT after the pipe has been welded, the pipe must be rejected. The
defective part of the pipe may be cut off, if the remaining length of the pipe is
within the permissible limits as per section 5.3.3, item 7, of this Specification.

4.1.2 Yield Strength Ratio

The yield strength shall be either the upper yield strength or the stress at 0.5 %
total elongation of the gauge length.
The proportion between yield strength and tensile strength of any specimen shall
not exceed the following for each steel grade at a temperature of + 20°C:
X 65 and above: 0.90
X 60: 0.87
X 52 and below: 0.85

4.1.3 Chemical Composition

The ladle analysis (including all trace elements) shall be recorded and submitted
to the Engineer.
The carbon-content shall meet the requirements as per Table 5 of API 5L, though
shall not exceed 0.20 %.
The sulphur content shall not exceed 0.010 %.
In compliance with the API 5L, Section 9.2, the maximum carbon equivalent,
calculated to the CE (IIW) formula, shall not exceed 0.43%.
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For the other elements, the maximum contents according to API 5L are valid. The
specified values are also applicable for wall thickness exceeding 25 mm.
4.1.4 Other Requirements
1. Secondary refining shall be used for ladle treatment; vacuum degassing or
chemical treating if necessary for clean steel production. Material shall be fully
killed and fine grain.
2. Continuous casting with suitable casting parameters shall be applied in order
not to cause segregation or slivers defects on the surface of the plates and rolled
coils.
3. Also slag free tapping is necessary for all above casting processes not to
cause slag entrapment, which probably results in bad surface conditions in slabs,
plates and coils.
4. Certificate: Material test certificates shall be according to EN 10204 Type 3.1
showing all chemical analysis required, results of mechanical tests with reference
to coil / plate numbers and corresponding heat numbers.
5. Marking: Adhesive tags shall be attached showing material grade, plate or coil
size, weight, plate or coil number, heat number and Employer’s name.
6. Packing of coils: The method of packing will be min. 4 straps equidistant
through eye of each coil and 3 straps along the circumference.

4.2 Manufacture of Pipes

4.2.1 General
Pipe shall be manufactured from plate or strip according to API 5L, Level PSL 2.
As welding process either submerged-arc welding (SAW) or high-frequency
electric resistance welding (HFW) shall be used. The quality of the weld shall be
such as to guarantee a joint efficiency factor of 1.0.
Continuous tack-welding (COW) performed by the GMAW process shall meet the
requirements as per Section 8.4 of API 5L, and is only then allowed, when the
tack-weld constitutes the backing for the subsequent SAW process and is
completely re-melted to coalesce into the final weld seam.
The minimum number of weld passes (beads) inside and outside is one.

4.2.2 Longitudinal Welded Pipes

The pipe shall be cold mechanically expanded. Expansion between 0.8 % and
1.5 % shall be applied.
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The presence jointers shall not be permitted in the finished longitudinally welded
pipe. The delivery of pipe containing two longitudinal welds shall not be permitted,
either.
In case HFW is used as welding process, the completed weld seam and heat
affected zones shall be normalised following a qualified and approved heat
treatment procedure.

4.2.3 Helical Welded Pipes

The distance of the transverse skelp end weld from the end of the pipe shall not
be less than 500 mm. The inclusion of transverse skelp welds in the pipe is
limited to no more than one joint in each pipe.
Circumferential welds/jointers are not permitted.

4.2.4 Manufacturing Procedure

Before commencing any production work, the Pipe Supplier shall submit a
Manufacturing Procedure Specification (MPS), including an Inspection and Test
Plan (ITP) for approval by Employer.
The Pipe Supplier shall provide the data required as per Annex B.3 of API 5L with
respect to the general characteristics of the manufacturing procedure.
All procedures for testing and measuring shall be subject to approval of
Employer.
By means of the Manufacturing Procedure Qualification Test (MPQT) the Pipe
Supplier shall prove that the production of the pipes is in full accordance with this
Specification.
The Engineer shall be given a four weeks’ notice prior to the MPQT, of when and
where it will take place.

4.2.5 Manufacturing Procedure Qualification Test Report

Within four weeks after the performance of each Procedure Qualification Test, the
Pipe Supplier shall submit a Procedure Qualification Report in triplicate, written in
English language.
This report shall as a minimum provide the information as per Annex B.5 of
API 5L, including:
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 Material Test Certificates for the starting materials (type, quality, properties
and source of steel) in accordance with EN 10204 Type 3.1.
 Test results of all the mandatory tests specified in Table 18 of API 5L.
 In case HFW is used:
o CVN impact testing results of the seam weld
o Metallographic and hardness testing of the seam weld

5 INSPECTION, TESTING AND CERTIFICATION

5.1 General

The Pipe Supplier shall operate a Quality Management System in compliance

with the requirements of ISO 9001.
The pipes shall be inspected and tested in accordance with this Specification and
shall meet the requirements of API 5L.
The Pipe Supplier shall submit a Manufacturing Procedure Specification, a quality
plan and a detailed Inspection and Test Plan before start of production for
approval by the Engineer.
All procedures for testing shall also be subject to the approval of the Engineer or
its representative prior to fabrication of the pipes.
All procedures for testing shall be available for review by an inspector approved
by the Engineer.
Measuring and test equipment, as well as qualification of inspection and test
personnel, shall be in accordance with the requirements of the applicable Codes
and Standards.
The extent of inspection and testing is different for manufacturing procedure
qualification and regular pipe production as outlined in the following sections.
The finished pipes shall be furnished with material test certificates according to
EN 10204 Type 3.2 showing all chemical analysis required as well as the results
of mechanical tests, etc.
Employer or its nominated representative reserve the right to inspect
workmanship at all stages of manufacturing and reserve the right to witness any
of the testing.
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5.2 Visual Inspection

Each pipe shall be visually inspected regarding dimensions, materials and

workmanship by an inspector approved by the Engineer. The results of this
inspection shall be fully in accordance with this Specification.

5.3 Material Tests

5.3.1 Manufacturing Procedure Qualification Tests

The Manufacturing Procedure Qualification Tests are to be performed by the Pipe
Supplier in order to prepare the Procedure Qualification Report.
One completely finished pipe for each wall thickness and steel grade at the
beginning of the normal production or after any change in welding or
manufacturing procedures shall be inspected for compliance with dimensional
tolerances of diameter, wall thickness, out-of-roundness, straightness, weld
contour, surface imperfections, etc. The other tests required in Table 18 of API 5L
for this subject shall also be performed.
After visual and dimensional inspection and acceptance, the pipe shall be subject
to the following tests:
1. Hydrostatic Test
2. Ultrasonic test of the seam weld including a distance of 25 mm from the
edges and radiographic test along the entire length of the weld.
3. Guided Bend Test
One full section specimen of the base material shall be taken according to
API 5L.
4. Tensile Test
Specimen and test values shall be in accordance to API 5L. Base metal and
weld metal shall be tested.
5. Charpy Impact Tests
The Charpy impact test shall be performed as specified in API 5L. Pipe
material and weld metal shall be tested.
Charpy V-Notch Impact tests shall be conducted on all welds made.
Qualification testing shall provide impact transition curve, including base
metal, heat affected zone and weld metal and recording percentage (%) of
shear area for each. At the minimum 5 (five) sets of 3 (three) Charpy V-
Notch impact specimens shall be taken from the base material transverse to
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the pipe axis. Each set is to be tested at a temperature of 60 °C, 20 °C, 0

°C, -20 °C and -40 °C. Using the test values obtained a diagram is to be
drawn showing temperature versus notch impact tenacity.
For both, the base material and the welds the minimum average of
absorbed energy at 0 °C shall be according to API 5L, Table 8. The
minimum value of a single specimen within a set shall be not less than 75%
of the minimum average of absorbed energy required by API 5L.
Samples will be selected by the Pipe Supplier except that Engineer reserves
the right to select additional samples.

5.3.2 Production Tests

During production two types of tests are to be performed in accordance with
API 5L.
A. Non – Destructive Testing (each pipe)
The Pipe Supplier shall carry out the following tests on each finished pipe
and record the results in the Pipe Book for approval by the Engineer.
A.1 Visual Inspection
A.2 Hydrostatic Tests
Hydrostatic test shall be carried out at a pressure providing a hoop
stress equivalent to 95 % of the Specified Minimum Yield Strength.
A.3 Ultrasonic Testing
Non-destructive testing of weld seams shall be carried out by means
of ultrasonic inspection in accordance with the requirements of
API 5L. The area to be inspected shall include the weld of each pipe
and the entire pipe body. All suspected discontinuities shall be
manually re-checked, supplemented by radiological inspection.
As a mandatory requirement each bevelled end of the pipe must be
tested for laminations in accordance with Annex E.3.2.3 of API 5L.
A.4 The weld of each finished pipe shall be radiographed at both ends
along a length of at least 250 mm.
A.5 Additional Tests for Helical Welded Pipes
The intersection of the skelp end weld and the helical seam weld
shall be radiographed to an extent of 150 mm in each direction.
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The remaining part of the skelp weld shall be subject to non-

destructive inspection in accordance with API 5L.
A.6 Check of Dimensions and Inspection
The following points must be checked:
1. Internal diameter
2. External and internal surface and welding seam in respect of
any defects
3. Length
4. Misalignment and off-set
5. Wall thickness of each pipe end
6. Roundness (Ovality)
7. Straightness
8. Welding edge at each end (bevel)
B. Destructive Testing
The Inspector reserves the right to personally select the pipe to be tested
from the entire test unit. A test unit shall be taken maximum as 50 pipes.
The test pipes shall be tested and inspected in the extent and frequency as
defined in the Table 18 of API 5L, unless amended in the following sections.
Test pieces shall be removed from the pipe as indicated in Table 20 of
API 5L.
B.1 Tensile Tests - Base Material
Once per heat and once per test unit, a tensile specimen shall be
taken from the base material in transverse direction.
B.2 Tensile Tests - Welding Seam
Once per heat and once per test unit, the tensile strength of a
specimen taken transverse to the welding seam shall be tested.
B.3 Guided Bend Test - Welding Seam
Once per test unit, two bending specimens shall be taken transverse
to the welding seam. One specimen shall be bent over the face, the
other over the root.
B.4 Charpy Impact Test for Base Material and Welding Seam
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Once per test unit, three V-notch impact specimens (one set) shall be
taken from the base material and the same number from the welding
seams, i.e. base metal, weld metal, fusion line, fusion line + 2 mm.
B.5 Chemical Analysis
Chemical Analysis shall be executed as defined in API 5L, section
10.2.4.1
A ladle analysis per steel charge and a check analysis are to be
performed on one pipe per steel charge.
C. Retesting of Mechanical Properties
Retesting shall be performed for each test in accordance with API 5L,
section 10.2.12.
D. Hardness Tests
The maximum allowable hardness shall be 300 HB.
One (1) specimen / piece of each test unit is required for testing.
5.3.3 Standards of Acceptability
For acceptability the requirements as per API 5L must be fulfilled completely. In
addition the following standards of acceptability for all inspections and tests given
in this Specification are valid.
Dimensional Tolerances:
1. Diameter
The nominal outside diameter of the pipe shall be in accordance with API
Standard 5L, Level PSL 2.
2. Diameter of Pipe Ends:
The internal diameter measured with an internal steel tape at any place
within 100 mm from either end shall not vary more than the specified values
in Table 10 of API 5L.
For pipes with outer diameters exceeding 56” the tolerances shall be taken
as -1.6mm and +1.6mm.
3. Diameter of Pipe Body:
The external diameter of the pipe body, as measured from the
circumference, shall not deviate from the nominal diameter by more than ±
3.0 mm.
4. Out of Roundness:
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Shall be in accordance with the requirements of API 5L.

For pipes with outer diameters exceeding 56”, the allowed out of roundness
at the pipe ends shall be 1% of the diameter, whereas the pipe body is
allowed to have an out of roundness of 1.5% of diameter.
5. Bulges, Dents and Flat Areas:
Deviations from the original contour of the pipe shall not exceed 6.0 mm,
nor shall they extend in any direction over a distance longer than 1/4 of the
pipe diameter. Dents containing creases, sharp edged imperfections or
gouges shall be considered as defects.
6. Wall Thickness
The negative tolerance shall be max. -0.5 mm. The positive tolerance shall
be max. + 1.5 mm.
7. Pipe Length
The pipes shall be supplied with a maximum length of 18 m. The minimum
length shall be 16.0 m.
8. Straightness
The distance from the pipe surface to a straight line parallel to a straight line
through the centre of the end planes shall not exceed the values given in
API 5L.
9. Pipe Ends
The pipe ends shall be at right angles to the pipe axis. The deviation from
the right angle shall not exceed 1.6 mm.
The reinforcement of the weld inside and outside shall be removed over a
distance of at least 150 mm from both ends of the pipe.
The ends of pipes to be joined by butt-welding shall be machine-bevelled to
an angle of 30° (+5°, -0°) with a root face of 1.6 +/- 0.8 mm.
Visual Inspection:
1. The parent metal shall be free of scabs, nicks, dents, gouges, arc burns and
other visible surface defects.
2. The centre lines of the inside and outside welds (misalignment) shall be
within the limits as specified in Table 14 of API 5L.
3. The offset of the prepared edges of the plates at the weld joint shall not
exceed 10 % of the specified wall thickness with a maximum of 1.6 mm.
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4. The welds shall be free of cracks, craters, pinholes, and lack of penetration
or fusion.
5. Undercut shall be allowed provided that the requirements as per
Section 9.10.2 of API 5L are fulfilled.
6. The pipe making process and the welding procedure shall be arranged to
produce a minimum of peaking. The local deviation from the circular shape
of the pipe at the edge of the weld seam shall not exceed 1.5 mm, relative to
the pipe body.
7. The height of the weld reinforcement shall be as small as possible and shall
not exceed 3.0 mm.

Non-Destructive Tests:
The pipe shall not be acceptable if, as a result of non-destructive testing, any of
the following defects are evident:
1. Laminations in strips or plates detected by continuous ultrasonic testing
within 25 mm of the edges or at the bevelled pipe ends.
The ultrasonic inspection may be carried out during / prior to manufacture of
the pipe.
2. Cracks
3. Lack of Penetration
4. Off-seam welding which shows lack of penetration between inside and
outside welds
5. Other imperfections exceeding the acceptance criteria of API 5L.
Mechanical Technological Tests:
1. Tensile Test
Each tensile specimen shall meet the requirements of this Specification and
API 5L.
2. Guided Bend Test
No defect is allowed with more than 3 mm extension in any direction.
In case of premature tearing starting from the edges without any apparent
reason two new tests have to be performed.
3. Charpy Impact Test
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The specimen shall fulfil the requirements given in the Section 5.3 of this
Specification.
4. Chemical Analysis
The chemical analysis shall fulfil the requirements given in the Section 4.1.3
of this Specification and the requirements of API 5L.
5. Defects Occurring at Periodic Intervals
If, when testing pipes during production, the same injurious defect as per
this Specification occurs continuously or periodically, the Engineer is
permitted to stop production. The Pipe Supplier shall be requested to modify
the production so that the defect in question no longer occurs.
It has to be proven by tests on five pipes from the same series that the
defect has been eliminated.

5.4 Repairing Defects

Defect repair procedures are to be performed as per API Standard 5L with the
additional requirements as mentioned below:
1. Defects in Base Material
Isolated minor surface defects can be removed by grinding, provided that
the remaining wall thickness meets the requirements as per Annex C.2.3 of
API 5L and that there is a smooth transition between the ground area and
the original contour. A repair of base material by welding is not permitted.
2. Welding Seam Defects
If repair of weld seam has been performed after hydrostatic testing, than the
pipe shall be hydrostatically re-tested after repair
The repaired locations shall be tested by UT and RT. The complete length
of all repair welds shall not exceed 4 % of the total welding seam length of a
pipe.
Repeated repairs at the same spot are not allowed.

5.5 Test and Production Records

An individual digital “Pipe Record” shall be issued for each pipe in which all
information relating to the individual pipe will be included. As a minimum the
record shall contain the following information:
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1. Pipe number
2. Identification of steel charge
3. Results of all production tests and inspections
4. Indication and report of repairs
Upon request the Pipe Supplier shall furnish a certificate of compliance
according to API Standard 5L Section 13.
The format of the “Pipe Record” and information of the Pipe Supplier’s pipe and
material tracking system have to be submitted for approval by the Engineer
before start of production.
The “Pipe Record” shall be held in evidence by the Pipe Supplier for 10 years.
After this time the "Pipe Record" is to be handed over by the Pipe Supplier to the
Engineer at his request.

6 PRESERVATION, MARKING AND SHIPPING

6.1 Preservation

In case the bare pipe will not be delivered directly to coating applicator, the pipe
shall be protected with a removable varnish as temporary corrosion protection
during storage.
In addition the ends of each pipe shall be protected by bevel protectors of a type
to be approved by the Engineer.

6.2 Marking

6.2.1 Plates and Strips

Plates and strips shall be marked with round steel stamps or other proper method
and shall show the following:
a. Number of steel charge
b. Plate number
c. Manufacturer's symbol
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6.2.2 Pipes
The following shall be applied to the internal surface of the pipe with a synthetic
resin paint using a stencil according to API 5L:
· Pipe number
· Pipe Supplier
· Specification
· Compatible standards
· Specified dimensions
· Grade and class
· Product specification level
· Manufacturing process
· Heat treatment
The marking shall have at least a distance of 150 mm to the pipe end.
Further marking details, like colour coding etc., shall be specified in the purchase
order.
The pipe number shall be stamped on the bevel at one end of the pipe.
For each item the series of pipe numbers shall be different i.e. any one-pipe
number shall not be used more than once for the complete order.

6.3 Shipping and Loading

Shipping and loading preparation shall be in accordance with API 5L and

Specification M18 “Handling Storage and Transportation of Line Pipe Material”.
The Pipe Supplier shall submit detailed loading, stacking and shipping
procedures for approval by Engineer.

7 DOCUMENTATION

Documentation to be provided by the Pipe Supplier shall be in accordance with

API 5L and the requirements for this Specification.