DOC. NO.

KOC-MP-018 Page 1 of 17
1 REV. 1
I

KUWAIT OIL COMPANY (K.S.C.)

KOCSTANDARD
FOR
SEAMLESS PIPE TO API 5L

DOC NO: KOC-MP-018

ISSUING AUTHORITY :

STANDARDS DIVISION
DOC. NO. KOC-MP-018 Page 2 of 1 7
1 REV. 1

KOC STANDARD FOR

SEAMLESS PIPE TO API 5 L

DOC NO : KOC-MP-018
DOC. NO. KOC-MP-018 Page 3 of 17
11 REV. 1

TABLE OF CONTENTS

PAGE NOS.

SCOPE . 4

GENERAL / APPLICATION 4

TERMINOLOGY . 4

REFERENCE CODES AND STANDARDS 5

ENVIRONMENTAL CONDITION 6

PROCESS OF MANUFACTURE & MATERIAL 6

CHEMICAL PROPERTIES 6

MECHANICAL PROPERTIES 7

HYDROSTATIC TESTS 8

DIMENSIONS, WEIGHTS, LENGTHS, ETC. 8

INSPECTION 9

QUALITY ASSURANCE 10

DOCUMENTATION 10

MANUFACTURING PROCEDURE QUA1 11

MARKING 12

STORAGE, HANDLING AND SHIPPING 12

DATA SHEET / ORDERING INFORMATION 13

APPENDIX A: 15
LINE PIPE FOR SOUR SERVICE
11 DOC. NO. KOC-MP-018 1) Page 4 of 17 111 REV. 1 1

1.0 SCOPE :

This Standard defines the minimum requirements for manufacture, testing,

marking and purchasing of carbon steel Seamless Line Pipe required for
KOC pipeline and related facilities. Seamless pipes shall be manufactured
in accordance with the requirements of the latest edition of API Spec. 5L,
as supplemented by this specification and the purchase order.

APPENDIX "A" details additional requirements for line pipe in "SOUR

SERVICE or SOUR ENVIRONMENT".

2.1 Carbon Steel Seamless Line Pipe is intended to be used for all oillgas,
submarine, on-shore, offshore pipeline applications, and other facilities
such as Gathering Centers, Booster Stations, Manifolds, Tank Farm areas,
etc. for process and utility services. Further, this Standard does not apply
to low-criticality pipelines e.g water, or effluent duties, general pipeworks,
or highly corrosive fluid services.

2.2 Seamless pipes shall be used in Sour Environment as defined in NACE MR-
0175, and in services with presence of CO,.

2.3 Pipes shall be procured from manufacturers who possess a valid license for
use of API Monogram and who are capable of meeting the requirements of
this Standard.

2.4 This Standard shall be used in totality when the quantity is large to make
a mill run of the pipe. The clauses of this Standard shall be selectively
used for purchasing small quantities of out-of-stock line pipes.

3.0 TEBMINOLOGY : A --

3.1 HIC: Hydrogen Induced Cracking

3.2 KOC : Kuwait Oil Company (K.S.C.)

3.3 NPS : Nomiqal Pipe Size (Diameter)

3.4 SSC : Sulfide Stress Cracking

1 3.5 Sour Environments :

Sour environments are defined as fluids containing water as a liquid and

hydrogen sulphide at concentrations and pressure exceeding the limits
defined in clauses 3.5.1. 3.5.2 and 3.5.3.
DOC. NO. KOC-MP-018 1 1
Page 5 of 17 1 REV. 1

3.5.1 Sour Gas :

Materials shall be selected t o be resistant to sulphide stress corrosion

(SSC) if the gas being handled is at a total pressure of 0.4 MPa (65 psia)
or greater and if the partial pressure of H,S i n the gas is greater than
0.0003 MPa (0.05 psia). For further clarification, refer NACE MR0175 and
Appendix "A" .

3.5.2 Sour Oil & Multiphase:

Materials shall be selected to be resistant t o SSC if:

(i) total system pressure exceeds 1.8 MPa (265 psia) and if partial
pressure of H2S is greater than 0.0003 MPa(0.05 psia), or
(ii) i f partial pressure of H2S exceeds 0.07 M P a ( l 0 psia) i n the gas
phase, or
(iii) if the H,S content is greater than 15% in gas phase.
(For further clarification refer NACE MR0175) and Appendix "A".

3.5.3 H,S Partial Pressure : = mole% of H2S x total system pressure

100

3.6 Submarine / Offshore :

Pipes which are submerged in sea water 1 brackish water and used in
offshore related construction.

4.0 REFERENCE CODES AND STANDARDS :

In the event of conflict between this specification and the codes referenced
herein, the most stringent requirement shall apply, unless otherwise
specified.

Any exceptions or deviations from this Standard, along with their merits
& justification, shall be brought t o the attention of KOC's Controlling
Department for their review, consideration and amendment b y Standards
Division (if required).

List of applicable codes and standards (Latest Revision shall be applicable):

API 5L Specification for Line Pipe

API RP 5LW , Recommended Practice for Transportation of

Line Pipe on Barges and Marine Vessels

ASME B 31.3 Chemical Plant and Petroleum Refinery Piping

 DOC. NO. KOC-MP-018 Page 6 of 17 1 REV. 1

ASME B 31.4 Liquid Transportation System for Hydrocarbons,

LPG, Anhydrous Ammonia and Alcohols

ASME B 31.8 GasTransmission and Distribution Piping System

ASTM A370 Test Methods and Definitions for Mechanical

Testing of Steel Products

NACE MR0175 Sulphide Stress Cracking Resistant Metallic

Materials For Oil Field Equipment

TM0284-87 -
Test Methods Evaluation of pipeline steels for
resistance to stepwise cracking (NACE
Standard)
5.0 ENVIRONMENTAL CONDITION :

5.1 The environment of Kuwait is severe, and Pipes will be subjected to sand
and fine particle dust storms, sand laden winds, chemical contaminants
+
and extreme temperatures (-3OC to 55OC in shade). The exposed black
body metal temperature due to solar radiation is 85OC.

6.0 PROCESS OF MANUFACTURE AND MATERIAL :

Pipe furnished to this Standard shall be made by the "Seamless" (SMLS)

process.

All steel shall be fully killed and made to fine grain practice for improved
toughness. Vacuum degassed steel shall be used for pipe wall thickness
above 20mm (314 in.).

Heat Treatment: Quenched and tempered pipe shall be supplied for grades
X56 and above. Pipe of lower grades shall be supplied either normalized
or quenched and tempered per API Spec 5L, unless otherwise specified in
the Data Sheet.

The pipes shall not be cold expanded.

7.0 CHEMICAL PROPERTIES :

7.1 The manufacturer shall furnish material test certificates and chemical
analysis report giving the heat analysis of each heat of steel used in the
manufacture of pipe. This report shall also list the pipe numbers of those
pipes made from the heat of steel, for final certification and shipment.

7.2 The manufacturer shall furnish the results of product analysis. The full
analysis shall be carried out on the first pipe rolled from each heat. Where
more than 50 pipes are rolled from one heat,'another full product analysis
shall be carried out every 50 pipes.
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 - -- - - - -

DOC. NO. KOC-MP-018 Page 7 of 17 - 11 REV. 1

7.3 The product chemical composition shall meet the following modified
requirements, in addition to API Spec. 5L.

Element % Maximum
Carbon 0.20
Manganese As per API Spec. 5L
Phosphorus 0.025
Sulfur 0.01 5
Silicon 0.35
Aluminum 0.05
Niobium +Vanadium +Titanium 0.12

7.4 The product Carbon Equivalent (CE) for all grades shall be calculated using
the following formula and it shall not exceed 0.42Oh (max).

Where: C = Carbon, Mn =Manganese, Cr = Chromium, Mo =Molybdenum, V = Vanadium,

Ni= Nickel, Cu = Copper

When the pipeline data sheet defines the service as sour, additional
limitations on the above equation shall be necessary. (See Appendix A)

8.0 MECHANICAL PROPERTIES :

Mechanical properties shall be as per API Spec. 5L and as specified here below.

The maximum tensile strength shall not exceed the API Spec. 5L Table 3
specified minimum tensile strength by more than 138 MPa (20,000 psi) for
grades X52 and higher. Maximum yield strength shall not exceed the API
Spec. 5L Table 3 specified minimum yield strength by more than 103 MPa
(15,000 psi) for grades X52 and higher.

Tensile Tests - Transverse tensile test and longitudinal tensile tests, when
specified on the Data Sheet shall be carried out on the first pipe from each
heat. Where more than 50 pipes are made from one heat, another set of
tests shall be carried out every 50 pipes. However, when the service is
submarine, both tests shall be mandatory and requirements of Appendix A
shall apply. Tensile testing procedure, specimens and acceptance criteria
as API Spec 5L.

Fracture ToughnessTests - Charpy V-notch impact testing shall be required

when so indicated on the Data Sheet. Test procedure, and test frequency
shall be based on API Spec. 5L (SR5B). Fracture Testing shall be normally
required for gas lines, sour and submarine service. Test shall be mandatory
for submarine service (See Appendix A).
 DOC. NO. KOC-MP-018 I Page 8 of 17 1 REV. 1 I
8.4 Hardness Testing shall be required when indicated on the Data Sheet and
is defined in Appendix "A". Normally, it shall be required for gas lines,
sour and submarine service. Maximum hardness shall not exceed Rockwell
C Hardness scale (HRC) 22 for sour service to satisfy NACE MR-0175
limits. (See Appendix A).

HYDROSTATIC TESTS :

9.1 Mill Inspection Hydrostatic Test:

For all sizes and grades, each length of pipe shall be subjected to mill
hydrostatic test at a pressure not less than that calculated by the formula
(in clause 9.4.3 of API 5L), with fiber stress as 90% specified minimum
yield strength (SMYS). Alternate hydrostatic test pressure, if required,
shall be specified in the Data Sheet.

For all sizes, hydrostatic test pressure shall be held for not less than 10
seconds

9.2 Verification of Tests:

Each test record shall be marked with the number of the pipe to which it
refers. Any pipe which leaks or bursts during tests shall be retained for
thorough investigation in presence of KOC's representative I Third Party
Inspector.

DIMENSIONS, WEIGHTS, LENGTHS, DEFECTS AND END FINISHES :

Dimensions, weights, lengths, straightness, defects, end finishes and

tolerances shall be as per API Spec. 5L unless otherwise specified in Data
I
Sheet.

All pipes shall be supplied in nominal lengths of 1 2 meters (do!~b.Wrxdom,.

length), unless otherwise indicated in Data Sheet.

Total length supplied per item on an order shall not deviate from that
+
specified in the order beyond the tolerance of 1 % and -0%.

Jointers shall not be supplied.

Weld Repair : Repair by welding of Seamless pipe is not permitted.

Dents and Cracks: Not permitted.

Lamination : Pipe bevels containing laminations shall be cut back until all
laminations detectable by wet magnetic particle inspection have been
removed.

-
11.0 INSPECTION :

Manufacturer shall furnish all applicable test certificates as per SR15, of

API Spec. 5L, and in relation to manufacturing procedure and tally sheets
(pipe number list).
Following will be the scope of third party 1 purchaser inspection, but not
necessary limited to:

Verify actual manufacturing procedure against approved procedure

and this standard.
Identify incoming Ingots, billets or bars against steel marker's
certification.
Verify steel 1 pipe 1 test traceability.
Verify reference Standards for Ultrasonic testing.
Witness calibration runs for NDE and verify their frequency.
Monitor NDE examinations and review records.
Surveillance of heat treatment operations.
Verify calibration of hydrostatic test recording equipment.
Monitor hydrostatic testing and review records.
Verify sampling of test specimens
Witness mechanical tests
Visual and dimensional checks of finished pipes
Check final markings as per API Spec. 5L.
Witness fitment of end caps on bevelled or square end pipes by the
manufacturer.
Sign and stamp all reports.

Non-Destructive Inspection of seamless line pipe shall be carried out per

API Spec. 5L, SR-4 if specified in Data Sheet. Ultrasonic examination shall
be preferred, and it shall be carried out after completion of manufacture
and hydrostatic test. If ultrasonic equipment is unable to detect transverse
defects, quenched and twsjxxed-pipe shall also be examined by an
electromagnetic technique.

Wet Magnetic Particle lnspection shall be employed per API Spec 5L, SR
4.2 t o inspect imperfections, such as Laminations in the weld bevel or
Longitudinal defects. Any imperfection detected in the weld bevel shall be
cause for re-bevelling. When depth of all imperfections is greater than
12%% of the specified wall thickness, the imperfection shall be considered
as defect.

The full circumference of the pipe ends shall be ultrasonically inspected.

using compression wave for lamination. and using shear wave for other
defects, for a distance of at least 25mm (1 inch). Lamination exceeding
12mm (% inch) in diameter or extending into the face of the bevel shall not
be acceptable, and cracks of any detectable size shall not be acceptable.
 DOC. NO. KOC-MP-018 I Page 10 of 17 REV. 1

QUALITY ASSURANCE :

The manufacturer shall. operate a quality system which ensures that the
requirements of this Standard are achieved. The quality system shall preferably
be based on I S 0 9000 series of standards and the manufacturer shall
demonstrate compliance by providing a copy of the accredited certificate or the
manufacturer's quality manual. Verification of the manufacturer's quality system
is normally part of the pre-qualification procedure, and is therefore not detailed
in the core text of this Standard.

13.1 MANUFACTURING PROCEDURE SPECIFICATION

The manufacturer shall submit with their quotation a procedure, which

shall include :

Steel maker, and plant at which steel is produced.

Steel making process.
Limits on heat and product analysis.
Casting technique, ingot or billet soaking, holding and billet finish,
working temperatures and control methods.
Ingot or billet piercing and forming pipe shape techniques.
Heat treatments details on finished pipes.
Pipe-end ultrasonic testing techniques with acceptance criteria.
Details of full body ultrasonic and electromagnetic testing
equipment, techniques and calibration frequency.
Methods of marking defects.
Acceptance criteria for pipe body laminations.
Method of measuring pipe wall thickness, including sensitivity and
calibration technique.
. -- -. Techniques for wet magnetic particle inspection. . .-_ -..
Techniques proposed for measuring sequences.
Expected ranges of all mechanical test results.
Pipe traceability and identification scheme.
Flow diagram showing the sequence of all operations for pipe
manufacturing, heat treatments, and testing.

13.2 A t least one c o p i of material certification, tally sheets, and release

documentation shall be dispatched with the pipes to facilitate goods
receiving inspection.

13.3 Final dossiers shall include the following:

a Manufacturing Procedure Specification

a Manufacturing Procedure Qualification Records
a Concessions
 Original stamped or embossed, all certificates and reports as per
clause 11.0 of this Standard.
Tally Sheets

13.4 All correspondences, drawings, instructions, data sheets, or any other

written information shall be in English language. All dimensions, units of
measurement,. physical constants, etc. shall be in SI units, unless
otherwise specified.

MANUFACTURING PROCEDURE QUALIFICATION :

Manufacturing procedure qualification shall be carried out based on the procedure

submitted by the manufacturer and that approved by KOC. All tests shall be
witnessed by KOC's representative / Third Party inspector.

First length of pipe produced represent each nominal wall thickness, material
grades and steel source shall be examined and tested as per requirements of this
Standard and API-Spec. 5L to include the following tests:

0 Chemical composition
0 Tensile properties
Fracture toughness
Hardness survey
0 Hydrostatic test
Visual inspection for surface defects and dimensional tolerances
Ultrasonic examinations per API Spec 5L, SR4.

All of these tests should be preferably done from both pipe ends except
hydrostatic test.
Reports shall be approved by KOC prior to commencement of regular production.

Procedure qualification shall be repeated upon any changes in the manufacturing

procedure as deemed necessary by KOC Representative / Third party Inspector.

Appendix "A" details requirements for line pipe in "Sour Service or Sour
Environment". In addition, manufacturing qualifications shall be in relation to:

i1 A full pipe weldability trial shall be completed. The purpose of this test is
to ensure the pipe can be welded under field conditions at typical heat
input levels.

ii) Qualification Test for Resistance to Hydrogen Induced Cracking (HIC) per
NACE Standard (TM0284-87).
MARKING :

In additional to the marking specified in API Spec. 51, each pipe length shall be
marked with API Monogram. Marking shall be by paint stencilled only.
Manufacturer shall also ensure marking of pipe numbers on both ends to verify
pipe traceability with the reports and the requirements of API Spec 5L.
The word "Sourw shall be included in the pipe marking for sour service
application and Colour Codes can be applied in the field, if required.

STORAGE, HANDLING AND SHIPPING :

All handling, and storage shall be done with care to avoid any mechanical damage
or corrosion to the pipe. Loading and shipping shall be as per API RP 5LW, unless
otherwise specified.
 DOC. NO. KOC-MP-018 I Page 13 of 17 1 REV. 1

17.0 DATA SHEET 1 ORDERING INFORMATION

Specification API 5L SEAMLESS Grade

NPS in Quantity Meters Feet

Nominal Wall Thickness in mm Schedule

Nominal Length 0 12m 0 Others (Specify) m

(Double random length)

End Finish 0 Plain Ends (Bevelled)

0 Others (Specify)
Certificates of Tests and lnspection Yes as per SR15 of API 5L

Non-Destructive Inspection (SR-4) 0 Yes 0 No

0 Others (Specify)
Alternate Heat Treatment (specify)

Alternate Mill hydrostatic test required 0 Yes 0 No

(If yes,specify)

Field hydrostatic test pressure KPa ~sig

Flow Medium Composition (Service)

Sour Environment 0 Yes 0 No

Maximum Design Pressure kPa ~sig

Maximum Design Temp. OC Min. Design Temp. O C

Installation 0 Above ground 0 Underground Submarine

Transverse Tensile Test & Longitudinal Tensile Test Yes 0 No

(For Submarine Application)

Third Party Inspection Yes No

Coating & Protection 0 As per API 5 1

Special Coating & Protection 0 Yes 0 No
(If yes, specify)

End Protection 0 Yes 0 No

(If . yes, specify)

Marking 0 As per API 5L

Special Marking 0 Yes 0 No
(If yes, specify)

Additional Documentation 0 Yes No

(If yes, specify)

Additional Requirements 0 Yes No

(if yes, specify)
 DATA SHEET (Cont.)

KOC SUPPLEMENTARY REQUIREMENTS

For Sour Service

Hydrogen Induce Cracking (HIC)

Sensitivity Tests 0 Yes 0 No

Sulfide Stress Cracking (SSC) Test Yes No

Longitudinal Tensile Tests Yes 0 No

Fracture Toughness (Charpy Impact) Tests 0 Yes 0 No

i) Test Temperature: ( OC) (OF)

ii) AVG. Impact Energy: Joule Ft-lbs.

Full Body Ultrasonic Inspection 0 Yes No

Hardness Testing Yes 0 No

Compression Wave Scanning Test Yes No

Magnetic Particle Test (Pipe Ends) 0 Yes No

Other Tests (specify) : 0 Yes No

Manufacturing Procedure Specification Yes 0 No

(Reference Clause 13.1)
 DOC. NO. KOC-MP-018 Page 1 5 of 17 Il REV. 1 I
APPENDIX "A"

LINE PIPE FOR SOUR SERVICE

SCOPE :

The following KOC supplementary requirements shall apply only when specified
on the purchase order Data Sheet. The supplementary requirements are, in
addition to the requirements stipulated in General specification, for extra testing
or inspection for SourISubmarine service.

MATERIAL AND CHEMICAL COMPOSITION :

A.2.1 Steel used for the manufacture of line pipe shall be of the fully killed type
made to fine grain low hydrogen practice. The steel shall have inclusion
morphology and microstructure which will be resistant to Hydrogen
Induced Cracking (HIC) with adequate toughness to assure self arrest of
an unstable crack.

A.2.2 The following limitations on chemical analysis shall be confirmed by the

manufacturer:

Element Oh Maximum

Carbon 0.18
Manganese Per API 5L
Phosphorus
Sulfur
Silicon
Nickel
Chromium
Molybdenum
Copper
Aluminium -
Calcium
Nitrogen
Niobium +Titanium +Vanadium

A.2.3 The product Carbon Equivalent (CE) shall be 0.38% maximum for all
grades using the formula in Clause 7.4.

MECHANICAL TESTS :

The tensile strength requirement shall be the same as per clause 8.1 of this
Standard.

-
A.4 KOC SUPPLEMENTARY REQUIREMENTS :
(Only when specified in Pipeline Data Sheet)

Hydrogen Induced. Cracking (HIC) Sensitivity Tests :

The sensitivity of the steel to Hydrogen Induced Cracking upon exposure

to Hydrogen Sulphide saturated brine shall be determined using the test
methods as per NACE Standard (TM0284-87).

Sulfide Stress Cracking (SSC) Test:

Brittle failure by cracking under the combined action of tensile stress and
corrosion in the presence of water and HS , shall be per NACE Standard
(TMO177-87).

Longitudinal Tensile Tests :

For pipe sizes NPS 8 and larger, longitudinal basemetal tensile tests shall
be required in addition to the transverse basemetal tensile tests required by
API Spec. 5L. The same properties shall be achieved at least in both
longitudinal and transverse directions.

Fracture Toughness (CHARPY IMPACT) Tests : (API Spec. 5L SF? 5B)

Fracture toughness tests shall be conducted, regardless of pipe size,

according to API Spec. 5L SR5B. The test temperature and the average
value for impact energy absorbed shall be as shown in Pipeline Data Sheet
per specific project. However, typical test temperature of 20°C (36OF)
and averages impact energy 27 joules (20FT-tbs) can be suitable values.

Three transverse specimens of weld metal, HAZ, and basemetal shall be

cut for each test on a lot basis per API Spec. 5L SR5B.2.

Full Body Ultrasonic Inspection (API Spec. 5L SR4)

Seamless pipe shall be inspected by ultrasonic in its full body in accordance

with API Spec. 5L supplementary requirements SR4.

Hardness Tests:

One ring cross section shall be cut from each pipe from which tensile test
samples are cut.

Rockwell hardness readings shall be made at the O.D, ID, and mid wall, as
four quadrants spaced 90° degrees apart around the circumference. A
reading shall be defined as the average of three impressions made at a
given location. All lengths where a reading exceeds Rockwell C22 shall be
rejected. (Hardness limit of Rockwell C22 is added to assure resistance to
sulfide stress cracking).
7. Compression wave scanning Test:

Compression wave scanning test shall be performed for laminations and

wall thickness check for some critical duties per API Spec 5L.

8. Magnetic Particle Test:

Magnetic particle examination (of pipe ends only) shall be performed for
pipes on critical duties per API Spec 5L.