OFFSHORE SERVICE SPECIFICATION DNV-OSS-313

PIPE MILL AND COATING YARD - QUALIFICATION

APRIL 2009

DET NORSKE VERITAS

FOREWORD
DET NORSKE VERITAS (DNV) is an autonomous and independent foundation with the objectives of safeguarding life, property 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: Offshore Service Specifications. Provide principles and procedures of DNV classification, certification, verification and consultancy services. Offshore 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 H) Marine Operations J) Wind Turbines O) Subsea Systems

Amendments and Corrections

This document is valid until superseded by a new revision. Minor amendments and corrections will be published in a separate document normally updated twice per year (April and October). For a complete listing of the changes, see the Amendments and Corrections document located at: http://webshop.dnv.com/global/, under category Offshore Codes. The electronic web-versions of the DNV Offshore Codes will be regularly updated to include these amendments and corrections.

Comments may be sent by e-mail to rules@dnv.com For subscription orders or information about subscription terms, please use distribution@dnv.com Comprehensive information about DNV services, research and publications can be found at http://www.dnv.com, or can be obtained from DNV,
Veritasveien 1, NO-1322 Hvik, Norway; Tel +47 67 57 99 00, Fax +47 67 57 99 11.

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. Computer Typesetting (Adobe FrameMaker) by Det Norske Veritas. Printed in Norway.

If any person suffers loss or damage which is proved to have been caused by any negligent act or omission of Det Norske Veritas, then Det Norske Veritas shall pay compensation to such person for his proved direct loss or damage. However, the compensation shall not exceed an amount equal to ten times the fee charged for the service in question, provided that the maximum compensation shall never exceed USD 2 million. In this provision "Det Norske Veritas" shall mean the Foundation Det Norske Veritas as well as all its subsidiaries, directors, officers, employees, agents and any other acting on behalf of Det Norske Veritas.

Offshore Service Specification DNV-OSS-313, April 2009 Page 3

Scope of document This Offshore Service Specification describes the: "Pipe mill qualification service" - as a new service offered by DNV.

This service is based on: the requirements to line-pipe manufacture in the widely used DNV-OS-F101 "Submarine Pipeline Systems". qualification of coating application can also be carried out according to the same principles, and then DNV-RP-F106 used as a reference.

DET NORSKE VERITAS

Offshore Service Specification DNV-OSS-313, April 2009 Page 4

DET NORSKE VERITAS

Offshore Service Specification DNV-OSS-313, April 2009 Contents Page 5

CONTENTS
Sec. 1
A A A A B B B B C C C C 100 200 300 400

General................................................................... 7
Objective........................................................................... 7 DNV deliverable ............................................................... 7 Motivation......................................................................... 7 Limitations ........................................................................ 7 Pipeline projects ............................................................... 7 Line pipe manufacture ...................................................... 7 DNV-OS-F101.................................................................. 7 Coating systems and DNV-RP-F106................................ 8

A. Scope ...................................................................................... 7

D 400 D 500 D 600

Access to production....................................................... 12 Site visit report................................................................ 12 Product quality control ................................................... 12

Sec. 4
A 100 A 200 B 100 B 200 C 100 C 200 D 100 D 200 D 300 E E E E

Documents........................................................... 13
Documents from pipe mill and coating yard .................. 13 Documents from DNV ................................................... 13 Requirements .................................................................. 13 DNV verification ............................................................ 13 Requirements .................................................................. 13 DNV verification ............................................................ 13

A. General..................................................................................13

B. Background............................................................................. 7
100 200 300 400 100 200 300 400

B. Production and Control Procedures ......................................13

C. References, Definitions and Abbreviations ............................ 8

References......................................................................... 8 Definitions, verbal forms .................................................. 8 Definitions ........................................................................ 8 Abbreviations.................................................................... 8

C. MPQT Report .......................................................................13

D. DNV Verification Report .....................................................13

General............................................................................ 13 Range of qualification..................................................... 14 Other information ........................................................... 14

Sec. 2
A 100 A 200 B B B B B B B B

Qualification Project ............................................ 9

Local unit .......................................................................... 9 Custodian unit ................................................................... 9 General.............................................................................. 9 Project initiation................................................................ 9 Kick-off meeting............................................................... 9 Document review.............................................................. 9 Site visits production monitoring................................... 9 MPQT report................................................................... 10 DNV verification report.................................................. 10 Statement of Compliance................................................ 10

A. Responsibilities....................................................................... 9

E. Statement of Compliance .....................................................14

100 200 300 400 General............................................................................ 14 Validity ........................................................................... 14 References....................................................................... 14 Required information...................................................... 14

B. Project Overview .................................................................... 9

100 200 300 400 500 600 700 800

Sec. 5
A A A A A B B B B B 100 200 300 400 500 100 200 300 400 500

Materials and processes ..................................... 15

General............................................................................ 15 C-Mn steel ...................................................................... 15 Corrosion Resistant Alloy (CRA) .................................. 15 Lined/Clad ...................................................................... 15 External Coating ............................................................. 15

A. Materials ...............................................................................15

Sec. 3
A A A A 100 200 300 400

Activities .............................................................. 11
General............................................................................ 11 Scope of qualification ..................................................... 11 Qualification parameters................................................. 11 General contract conditions ............................................ 11 General............................................................................ 11

A. Project Initiation ................................................................... 11

B. Production Processes ............................................................15

B. Kick-off Meeting .................................................................. 11

B 100

General............................................................................ 15 Seamless pipe.................................................................. 15 Welded pipe .................................................................... 16 Lined/Clad ...................................................................... 17 Coating............................................................................ 17

C. Document Review ................................................................ 12

C 100 C 200 C 300 General............................................................................ 12 Relevant documents........................................................ 12 Requirements .................................................................. 12

App. A STATEMENT OF COMPLIANCE Pipe Mill............................................................... 18 App. B STATEMENT OF COMPLIANCE Coating Yard ....................................................... 19 App. C VerCom TEMPLATE........................................ 20 App. D SITE VISIT REPORT ...................................... 21

D. Site Visits Production Monitoring..................................... 12

D 100 D 200 D 300

General............................................................................ 12 DNV site visit team......................................................... 12 DNV monitoring scope................................................... 12

DET NORSKE VERITAS

Offshore Service Specification DNV-OSS-313, April 2009 Page 6 Contents

DET NORSKE VERITAS

Offshore Service Specification DNV-OSS-313, April 2009 Sec.1 Page 7

SECTION 1 GENERAL
A. Scope
A 100 Objective 101 This document describes the pipe mill qualification service of DNV. This service is based on the requirements to line pipe manufacture in DNV-OS-F101. 102 Following the same principles, the qualification of coating application can be carried out according to DNV-RP-F106. A 200 DNV deliverable 201 The key DNV deliverable is a Statement of Compliance (SoC) upon successful completion of the qualification program. The SoC is valid on the date of issuance, and lists the parameters (ID, WT, steel grade, coating system, design temperature etc) that define the scope of the qualification. 202 DNV shall also issue a Verification Report, where all DNV activities are summarised. The conclusion qualification successful or not shall be presented. In addition, DNV shall give a general assessment of the pipe mill/coating yard and the qualification project. This assessment is detailed in Site Visit Reports. A 300 Motivation 301 The market for offshore pipelines demands rigorous quality. The required quality for offshore line pipe is set by leading standards such as DNV-OS-F101. DNV provides solutions to assist pipe mills in documenting that their product meets the requirements of DNV-OS-F101. 302 There are several reasons for a pipe mill to carry out a DNV qualification: pre-qualification for a pipeline project the client requires a SoC before the pipe mill can enter the tender phase a SoC may substitute for project references a SoC may be used in commercial negotiations and for marketing purposes. 303 ice: Line pipe purchasers will benefit from this DNV serv404 DNV will only monitor a qualification production as a part of this service, not a full scale production. There are questions and concerns particularly related to large scale productions, different from the concerns during a small qualification production, that will not be covered by DNV as part of the qualification project. This can be related to production capacity, storage capacity, stability of production over long time and information handling in the quality control department and administration.

B. Background
B 100 Pipeline projects 101 Pipeline projects are expensive and submarine pipelines even more so. One of the major costs is procurement of line pipe, and material cost is a large factor. This makes it worthwhile to tailor the diameter, wall thickness and steel grade specifically to the project. DNV-OS-F101 does not prescribe a list of predefined dimensions; rather the line pipe specification is a direct consequence of the system design. B 200 Line pipe manufacture 201 The procedures at the pipe mill shall be project specific, so that they properly reflect all elements of the project specification and the standard and implement all applicable requirements. 202 The pipe mill procedures are dictated by the equipment available, the knowledge and experience of the personnel, as well as the project requirements. 203 Line pipe manufactured according to DNV are made with the same manufacturing steps as any other line pipe - the main difference is in the requirements to process control and quality control. 204 The quality of the line pipe is ensured by several complementary factors: competent and motivated production workers, who use equipment that is suitable to the task and well maintained quality control personnel, who work independently of the production personnel and understand the importance of adhering to established procedures procedures that are thoroughly qualified. B 300 DNV-OS-F101 301 DNV-OS-F101 is one of the DNV Offshore Standards for pipelines. The Offshore Standards are a set of documents for the offshore energy industry and contain technical advice about design, manufacturing, installation and operation of offshore structures and installations. 302 DNV-OS-F101 is a standard that covers all phases in the lifetime of a pipeline system, from design through fabrication and installation to decommissioning. 303 One significant advantage of using DNV-OS-F101 is that the design criteria are carefully calibrated against the quality of the line pipe and components. The fabrication requirements in DNV-OS-F101 are in general stricter than other line pipe standards; however the increased quality of the line pipe is reflected by higher utilisation of the materials in the design. 304 DNV-OS-F101 has two levels of requirements. The basic level must be met by all projects that shall be designed and installed according to DNV-OS-F101. Secondly a number of supplementary requirements are defined, which may be

an objective and independent assessment of pipe mill/coating yard capabilities will be available, limiting project risk the procedures and production practices will be of high quality, due to the DNV review and monitoring activities. This will minimise the time required to start the production after contract signing. 304 DNV provide proactive feedback and guidance as far as possible. The qualification process is an opportunity to get DNV assistance to bring mill procedures and practices up to a high-quality level. A 400 Limitations 401 A SoC does not exempt the pipe mill/coating yard from carrying out a full project-specific qualification according to DNV-OS-F101 or DNV-RP-F106 at the start of a pipeline project. 402 This qualification service does not apply to plate mills. All requirements in DNV-OS-F101 are to the finished pipe, and are not applicable to plates. However, the plate production shall be monitored as part of the manufacture of welded pipes. 403 Components (valves, fittings etc) and activities taking place during other phases (installation, commissioning) are not covered by this document.

DET NORSKE VERITAS

Offshore Service Specification DNV-OSS-313, April 2009 Page 8 Sec.1

applied as found necessary. These are for Sour Service (S), Fracture Arrest (F), Plastic Deformation (P), Dimensions (D) and Utilisation (U). B 400 Coating systems and DNV-RP-F106 401 DNV-RP-F106 is one of the DNV Recommended Practices for pipelines. DNV-RP-F106 has been prepared to facilitate the specification and quality control of coating work. 402 The primary objective of external coating on submarine pipelines is corrosion control. In addition, the coating system can be designed to provide mechanical protection during installation and operation, and/or thermal insulation. Concrete coating for the primary purpose of anti-buoyancy is not covered by this document. 403 Coating for external corrosion control of pipelines is applied to individual pipe lengths at a dedicated coating yard. This coating is referred to as line pipe coating (sometimes factory coating). In order to facilitate girth welding, areas at each end of the individual pipe length are left uncoated. These areas are normally coated after welding, by applying a field joint coating (FJC) system (FJC systems are covered in DNVRP-F102). 404 Submarine pipelines are almost invariably designed with a cathodic protection (CP) system. The CP design for submarine pipelines is closely related to the design and quality control of pipeline coatings. 405 DNV-RP-F106 covers the process of applying external coating systems for corrosion control of submarine pipelines at the coating yard (line pipe coating), and includes the qualification and production of coating. 406 DNV-RP-F106 contains requirements and recommendations that are general and advice on how amendments can be made to include project specific requirements and requirements/guidelines by a regulating authority, or to reflect the pipeline operators general philosophy on pipeline corrosion control. In addition, DNV-RP-F106 contains detailed requirements to specific systems used for submarine pipelines as specific Coating Data Sheets.

204 "Will": Indicates a mandatory action or activity to be undertaken by DNV. (Ref. "shall" for other parties.) C 300 Definitions 301 Certification: Not covered by this OSS. 302 Document review: Verification of documents. 303 Monitoring: A continuous, albeit not necessarily constant and complete, observation of parameters affecting the quality of a process. Work proceeds without the presence and any special information to the inspector, but the inspector may attend this activity at any time. 304 Qualification: An activity carried out to confirm that a procedure, material or technology meets a set of requirements. This is typically associated with an extended volume of testing, as compared to normal production. 305 Statement of Compliance: A statement or report signed by a qualified party affirming that, at the time of assessment, the defined production met the defined requirements. 306 Trial Production: A small production run carried out in order to show that the procedures are implemented and that the final product meets the defined requirements. The trial production shall meet the requirements to MPQT in DNV-OS-F101 or PQT in DNV-RP-F106. 307 Verification: An examination to confirm that an activity, a product, a service or a document is in accordance with specified requirements. 308 Verification comments: DNV comments given to a reviewed document. 309 Witnessing: The presence at and observation of a defined and specified event or test. Work shall not proceed until the inspector is available to witness the test. This is equivalent to a Hold point in the production. The inspector may, however, in advance inform in writing or through a formal minute of meeting that his/her presence is not required. C 400 AUT CP CRA DNV ID ITP M MPQT MPS NDT OS OSS PQT R RP SoC UT Q-plan VerCom W WT Abbreviations Automated Ultrasonic Testing Cathodic Protection Corrosion Resistant Alloy Det Norske Veritas Internal Diameter Inspection and Test Plan Monitoring Manufacturing Procedure Qualification Test Manufacturing Procedure Specification Non Destructive Testing Offshore Standard Offshore Service Specification Production Qualification Test Document Review Recommended Practice Statement of Compliance Ultrasonic Testing Quality Plan Verification Comment Witnessing Wall Thickness.

C. References, Definitions and Abbreviations

C 100 References DNV-OS-F101 Submarine Pipeline Systems DNV-RP-F106 Factory Applied External Pipeline Coatings for Corrosion Control. C 200 Definitions, verbal forms 201 Shall: Indicates requirements strictly to be followed in order to conform to this OSS and from which no deviation is permitted. 202 Should: Indicates that among several possibilities, one is recommended as particularly suitable, without mentioning or excluding others, or that a certain course of action is preferred but necessarily required. Other options may be applied subject to agreement. 203 May: Verbal form used to indicate a course of action permissible within the limits of this OSS.

DET NORSKE VERITAS

Offshore Service Specification DNV-OSS-313, April 2009 Sec.2 Page 9

SECTION 2 QUALIFICATION PROJECT

A. Responsibilities
A 100 Local unit 101 The local unit is any DNV unit that has been in contact with a client concerning the qualification service described in DNV-OSS-313. 102 The local unit will be responsible for the contract with the client. 103 The local unit will consult with the custodian unit during the contract negotiation phase, before contract signing. 104 The local unit will carry out the qualification project according to this service description. 105 The local unit will involve the custodian DNV unit. The minimum scope of work for the custodian unit is described in this document. 106 The cost of the custodian units work will be covered by the local unit. A 200 Custodian unit 201 The custodian unit is a designated DNV unit, which is responsible for the technical integrity and quality of the pipe mill/coating yard qualification service, and will ensure a uniform application of DNV-OSS-313 in DNV worldwide. 202 The custodian unit is responsible for maintaining and updating DNV-OSS-313. 203 The minimum involvement of the custodian unit in all pipe mill/coating yard qualification projects is the following: Review of the contract before signing, in order to verify that the scope of work complies with this service description. Verification of DNV VerCom before they are sent to the client. The local unit should perform the document review and write VerCom. Participation during site visits when production takes place. As applicable, the following shall participate: Line pipe/plate manufacture specialist, NDT specialist, coating specialist. Material testing activities should be monitored by the local unit, by agreement. Signature on both the DNV Verification Report and the Statement of Compliance. These deliverables should first be prepared and verified by the local unit, before the custodian unit performs the final verification. 204 The custodian unit will use properly qualified personnel, as determined by the Head of Section. These personnel do not necessarily belong to the unit itself. 205 DNV Energy Technical Director is responsible for designating the custodian unit. 206 The custodian unit is the DNV Energy Materials Technology (materials laboratory) section at Hvik, Norway. DNV-RP-F106 (as applicable). A qualification project shall be considered a normal production qualification, merely without the following large-scale production. 103 More details of the qualification process are given in later sections of this document. B 200 Project initiation 201 The scope of work is determined in cooperation between the client, DNV local unit and DNV custodian unit. 202 An important success factor is involvement and commitment to the qualification process by pipe mill/coating yard senior management. 203 The pipe mill/coating yard shall define such parameters of the project as would normally come from the system design phase. This is typically: Line pipe: Steel grade, pipe diameter, wall thickness, design temperature (minimum) and supplementary requirements Coating: Coating system, maximum design temperature (to be used for testing of certain properties) and thickness of individual coating layers (maximum and minimum) 204 The qualification of the coating yard can be carried out independently of any pipe mill qualification. B 300 Kick-off meeting 301 A kick-off meeting should be included in the scope of work, in particular if the pipe mill has no previous experience with DNV-OS-F101 or DNV-RP-F106. B 400 Document review 401 The relevant documents and procedures will be reviewed and VerCom issued by DNV specialists with indepth technical knowledge. 402 The documents and procedures shall be accepted by DNV before the trial production can commence. Documents for a qualification project shall meet all requirements as a normal production. 403 Procedures related to overall production (MPS, Quality Plan, Inspection and Test Plan) and product control (NDT, dimensional control, material testing) are the most important with regard to the qualification. B 500 Site visits production monitoring 501 The pipe mill or coating yard shall be responsible for conducting the trial production. This is essentially the same as a MPQT as defined in DNV-OS-F101 and PQT in DNV-RPF106. For welded pipe, the plate mill shall also carry out a trial production. 502 DNV specialists in pipe/coating manufacture and NDT shall be present during the trial production, preferably the same persons that performed the document review. They shall assess the quality of the equipment, the knowledge and experience of the personnel and the implementation of the procedures in the production. 503 The MPS and ITP, which have been accepted by DNV, form the basis for the monitoring. All activities noted in the MPS shall be witnessed for at least one pipe, and reported in a site visit report. 504 There shall be no restrictions on the access to production facilities. This also applies to the plate mill, if included in the qualification.

B. Project Overview
B 100 General 101 This section presents a general overview of the qualification process. The activities and documents involved are briefly described. 102 The technical requirements to procedures, documentation and control are fully described in DNV-OS-F101 and

DET NORSKE VERITAS

Offshore Service Specification DNV-OSS-313, April 2009 Page 10 Sec.2

505 A detailed site visit report shall be issued by DNV after each visit. The site visit report shall describe in detail what has been witnessed, and an assessment of all relevant operations including materials testing. B 600 MPQT report 601 The pipe mill/coating yard shall issue a MPQT report, where the qualification production and results are presented. 602 The report shall contain all relevant documentation from the trial production, and shall be submitted to DNV for review and acceptance. B 700 DNV verification report 701 DNV will issue a Verification Report, where all DNV activities are summarised. 702 The conclusion, qualification successful or not, will be presented and substantiated.

703 DNV will also give a general assessment of the pipe mill/coating yard and the qualification project. This can be based on observations in the site visit reports (any significant concerns should be highlighted). B 800 Statement of Compliance 801 A SoC will be issued upon successful completion of all the stages in the qualification process. 802 The SoC is valid only on the date of issue. 803 DNV, with the SoC, confirms that the pipe mill/coating yard has fully met all the relevant requirements of DNV-OSF101 or DNV-RP-F106. However, DNV does not make any statement for the future quality of the production. 804 The SoC will refer only to DNV-OS-F101 or DNV-RPF106 (as applicable). If the qualification project was based on a project specification, this specification can be referenced in the verification report.

DET NORSKE VERITAS

Offshore Service Specification DNV-OSS-313, April 2009 Sec.3 Page 11

SECTION 3 ACTIVITIES
A. Project Initiation
A 100 General 101 The scope of work is determined in cooperation with the client, DNV local unit and DNV custodian unit. 102 An important success factor is involvement and commitment to the qualification process by pipe mill senior management. A 200 Scope of qualification 201 The following parameters shall as a minimum be agreed: extent of qualification (which and quantity of different steel grades, diameters, wall thicknesses, coating systems etc.) plate mill included or not (for welded pipe) extent of document review (which documents, number of review cycles) extent of monitoring activities. 202 For welded pipes it is important to include the activities at the plate mill. The requirements in DNV-OS-F101 are only to the finished pipe, but some controls are performed on the plate before entering the pipe mill (e.g. pipe body AUT). In addition, the microstructure and steel grade is determined by the chemical composition and the rolling practice, and this is an essential variable for the pipe manufacture. 203 The qualification of the coating yard can be carried out independently of pipe mill qualification. Coating yard qualification is based on DNV-RP-F106 in addition to DNV-OSF101. 204 If the plate mill is well known to DNV, witness of a trial plate production at the plate mill can be waived. This will be determined by the custodian unit. 205 For pipe mills unfamiliar with DNV-OS-F101, it should be expected that an extensive document review process will be necessary. A 300 Qualification parameters 301 The pipe mill/coating yard shall define such parameters of the project as would normally come from the system design phase. This is typically steel grade, pipe diameter, wall thickness, design temperatures (maximum and minimum), coating system and supplementary requirements. 302 The choice of parameters should be guided by the following: If the pipe mill/coating yard aims for a specific project, it is recommended to use such parameters as have been defined by the potential client. If the aim of the qualification is to obtain a SoC for general commercial purposes, the parameters should reflect the pipe mill/coating yard capabilities and intended market. 303 The pipe mill/coating yard may have a client specification. Subject to agreement, DNV can carry out the qualification based on this specification. There are two conditions: The specification shall comply fully with DNV-OS-F101 or DNV-RP-F106 and gives only requirements that are additional to the standard. The SoC will refer only to DNV-OS-F101 or DNV-RPF106. The project specification can be referenced in the DNV verification report. If it is found that the project specification does not fully comply with DNV-OS-F101 or DNV-RP-F106, the qualification shall disregard the specification and be based solely on the DNV standard. 304 The supplementary requirements (S, F, P, U and D) should, if applicable, be included from the start of the qualification. If the qualification pipes do not meet the supplementary requirements, reference to them will not be made on the SoC and in the DNV verification report. Still, if all the normal requirements in DNV-OS-F101 are met, a SoC will be issued. A 400 General contract conditions 401 There are a number of assumptions, based on local conditions, which need to be included in the contract. 402 Some typical items are listed below. This list is only included for guidance: All documents shall be in English. All documents issued by DNV will be in English. DNV will not supply any translation or interpretation services. The contract price covers two document review cycles. This means the agreed documents will be reviewed, VerCom issued and subsequently the updated documents will be checked against the VerComs. The number of site visits, their duration and personnel required shall be clearly defined. Decide whether repair welding procedures shall also be qualified (normally not included) Variation Orders should be described and how they should be handled. 403 The pipe mill/coating yard should designate a single point of contact for DNV. In addition, without the support of the mill top management it may be difficult to successfully complete the project.

B. Kick-off Meeting
B 100 General 101 A kick-off meeting should be included in the scope of work, in particular if the pipe mill/coating yard has no previous experience with DNV-OS-F101 or DNV-RP-F106. 102 DNV project manager and DNV specialist responsible for pipe manufacture/coating application is the minimum participants from DNV. This initial phase will typically be to: present the requirements in DNV-OS-F101 or DNV-RPF106 present the Scope of Work as agreed in the contract DNV familiarisation with the pipe mill/coating yard (production facilities, testing laboratories) agree upon documents to be submitted, more in detail. agree upon project schedule, as far as possible present DNVs expectations to the mill in order to increase the probability for success clearly inform the client that they should run an internal trial production prior to inviting DNV for attendance as far as possible, answer any questions the pipe mill has to the standards requirements and the qualification process.

DET NORSKE VERITAS

Offshore Service Specification DNV-OSS-313, April 2009 Page 12 Sec.3

C. Document Review
C 100 General 101 The relevant documents and procedures will be reviewed and VerCom issued by DNV specialists with indepth knowledge of pipe manufacture, line pipe coating, NDT and testing. 102 The documents and procedures shall be revised by the pipe mill/coating yard and finally accepted by DNV before the trial production can commence. This means that all VerCom shall be closed. 103 As an option, some comments can be discussed and closed during a pre-production meeting before the trial production. DNV will then as soon as possible receive updated procedures, preferably during the trial production. No SoC can be issued until all VerComs have been satisfactorily closed. C 200 Relevant documents 201 Procedures related to overall production (MPS, Quality Plan, Inspection and Test Plan) and product control (NDT, dimensional control, material testing) are the most important with regard to the qualification. 202 The following documents are the minimum scope of the document review: MPS (plate, pipe and/or coating) Q-plan/ITP (plate, pipe and/or coating) All NDT procedures for final control (plate and pipe). 203 Detailed procedures related to welding, heat treatment, expansion, dimensional control etc should be issued for information, or as agreed in the scope of work. C 300 Requirements 301 The requirements to the documents are described in DNV-OS-F101 or DNV-RP-F106. Documents for a qualification project shall meet all requirements as a normal production.

monitored, as well as the duration of the site visit. D 300 DNV monitoring scope

301 The MPS and ITP, which have been accepted by DNV, form the basis for the monitoring. All activities noted in the MPS will be witnessed for at least one pipe, and reported in a site visit report. 302 Production activities not stated in the MPS are not permitted. 303 Every operation will be witnessed for at least one pipe or plate. 304 The calibration (static and dynamic) and set-up of all NDT equipment shall be witnessed. 305 Checklists may be developed for individual projects, but such lists are not developed as a part of this service description. Checklists shall not replace a written site visit report, with detailed description of observations and assessments. D 400 Access to production

401 There shall be no restrictions on the access to production facilities. DNV will assess the stability of the production and the parameter control, and DNV shall have access to all mill facilities during the trial production. This also applies to the plate mill (e.g. finishing rolling stand and accelerated cooling), if included in the qualification. D 500 Site visit report

501 A detailed site visit report will be issued by DNV after each visit. This includes all visits; such as monitoring of production and witnessing of testing. 502 The site visit report shall describe in detail what has been monitored, and an assessment of all relevant pipe mill/coating yard operations, including materials testing. 503 When deemed necessary, results from the production and testing shall be included. All results or observations from production or testing that do not meet the requirements will be reported by DNV in the site visit reports. D 600 Product quality control

D. Site Visits Production Monitoring

D 100 General 101 The pipe mill or coating yard shall be responsible for conducting the trial production. This is essentially the same as a MPQT as defined in DNV-OS-F101 and PQT as defined in DNV-RP-F106. For welded pipe, the plate mill shall also carry out a trial production. 102 It is strongly recommended that the pipe mill/coating yard carries out in-house production tests before inviting DNV to monitor a trial production, in particular if the mill has no previous experience with DNV-OS-F101 or DNV-RP-F106 production. This message should be stated in the proposal as well as discussed during the kick-off meeting. D 200 DNV site visit team 201 DNV specialists in pipe manufacture, line pipe coating and NDT shall be present during the trial production, preferably the same persons that performed the document review. They will assess the quality of the equipment, the knowledge and experience of the mill/plant personnel and the implementation of the procedures, which have been accepted by DNV. 202 General inspectors/surveyors may assist during the trial production, and work under the supervision of the specialists. 203 The size of the monitoring team will depend on the complexity of the production, and the number of activities to be

601 If more than one pipe from each heat is produced, DNV will designate one pipe as the qualification pipe early in the production process, and always before NDT. This is in order to fully include all variables in the production process; there will be a chance that the pipe can be rejected due to unacceptable NDT indications. In a large scale production there will always be a certain distribution of the pipe quality, and the incentive shall be for the pipe mill to have the smallest variation possible. For seamless pipes the qualification pipe is typically chosen after right heat treatment, while for welded pipe after forming. 602 The final stage of the trial production is material testing of the pipes or coating. DNV will witness all material testing. This monitoring can be carried out by general inspectors/surveyors, but the laboratory facilities shall be assessed by a DNV specialist before testing is started. 603 All the dimensional measurements of at least two trial production pipes shall be witnessed. This is to see that the respective measurements are carried out in a correct manner and further to witness that the correct values are reported. 604 Some testing, deemed less critical, can be monitored instead of witnessed. This shall be agreed with the DNV materials specialists in the project team prior to start of qualification.

DET NORSKE VERITAS

Offshore Service Specification DNV-OSS-313, April 2009 Sec.4 Page 13

SECTION 4 DOCUMENTS
A. General
A 100 Documents from pipe mill and coating yard 101 The table below outlines the documents that shall be prepared by the pipe mill and plate mill if included. Responsible part Pipe mill Documents for review

C. MPQT Report
C 100 Requirements 101 The pipe mill/coating yard shall issue a MPQT report according to DNV-OS-F101 and/or DNV-RP-F106, where the qualification production and the results are presented. 102 The report shall contain all relevant documentation from the trial production. This includes, but is not limited to: overview of pipe numbers and corresponding heat and plate numbers, as applicable product and heat chemical analysis pipe heat treatment records, when applicable records from NDT; production and calibration records dimensional control records. Please note that during qualification the value of all measured parameters shall be recorded, not just accepted/not accepted. material certificates of plates, when applicable material certificates for welding consumables, when applicable pressure testing records. 103 The pipe mill/coating yard shall present an analysis of the data. This analysis shall highlight any concerns or non-conformances. 104 The pipe mill/coating yard shall state whether all the project requirements have been met. C 200 DNV verification 201 The MPQT report shall be submitted to DNV for review and acceptance. 202 DNV will verify that all results reported by the pipe mill/ coating yard are consistent with the DNV site visit reports.

Documents for information

Coating yard

MPS welding procedures ITP (if applicable) NDT procedures heat treatment proceMPQT report dure (if applicable) material handling, if not in MPS welding consumables handling, if not in MPS procedure for dimensional control MPS Some of the informa ITP tion in the MPS is for PQT report information NDT procedures

MPS Plate mill (if applicable) ITP

A 200

Documents from DNV

201 The table below outlines the documents that will be prepared by DNV.
Documents issued by DNV Contract with detailed scope of work Verification comments to mill documents and procedures prior to qualification production Site visit reports from all DNV monitoring activities Verification comments to the pipe mill/coating yard MPQT report Final verification report, which summarises all DNV activities Statement of Compliance, if all requirements are met

D. DNV Verification Report

D 100 General 101 DNV will issue a Verification Report, where all DNV activities are summarised. 102 The conclusion, qualification successful or not, will be presented and substantiated. 103 DNV will give a general assessment of the pipe mill/ coating yard and the qualification project. This can be based on observations in the site visit reports (any significant concerns should be highlighted). 104 The local unit should prepare the verification report. The verification report shall be accepted and signed by the custodian unit. 105 The verification report will contain all relevant documentation from DNV produced during the qualification project. This includes, but is not limited to: scope of work all VerCom, which shall be closed at this stage all site visit reports reference to all relevant pipe mill/coating yard documents, including MPQT report.

B. Production and Control Procedures

B 100 Requirements 101 The mill procedures shall describe the practices in the mill, and shall present the activities carried out in order to meet the requirements of DNV-OS-F101 and DNV-RP-F106. 102 Detailed requirements to the procedures are found in DNV-OS-F101 and DNV-RP-F106. B 200 DNV verification 201 Pipe mill/coating yard procedures will be reviewed by DNV. DNV will issue VerCom, which shall be answered. This may also require updates of the procedures. For welded pipes, plate mill procedures shall be reviewed and accepted by DNV. 202 The pipe mill/coating yard procedures shall be accepted by DNV before the trial production can start. 203 Not all mill procedures shall be reviewed by DNV. The scope of the procedure verification shall be agreed in the contract.

DET NORSKE VERITAS

Offshore Service Specification DNV-OSS-313, April 2009 Page 14 Sec.4

D 200 Range of qualification 201 The SoC is issued with the specific parameters used for the qualification project. However, the qualification gives an indication of the mill capabilities, and it can be assumed that the pipe mill can make line pipe according to DNV-OS-F101 in a certain range around the qualification parameters. 202 The verification report for pipe production will normally contain a statement with guidance related to the range of qualification. The following text can be used: The qualification has been carried out for the parameters stated on the SoC. Based on this, DNV considers that the pipe mill has demonstrated production capabilities for the following variations: material (C-Mn, CRA or lined/clad): no variation steel grade: any lower strength production process: no variation nominal ID: 15% nominal WT: 10% design temperature: any increase.

E. Statement of Compliance
E 100 General 101 A SoC will be issued upon successful completion of all the activities in the qualification process. 102 The SoC is a one-page diploma stating the name and location of the pipe mill/coating yard, together with the main qualification parameters, as agreed in the scope of work. The DNV verification report will be referenced on the SoC. 103 The SoC will not be issued before updated procedures have been received and approved, the production trial has been completed successfully and the MPQT report has been reviewed and approved. E 200 Validity 201 The SoC is valid only on the date of issue. This will be stated on the SoC. 202 DNV, with the SoC, confirms that the pipe mill/coating yard has fully met all the relevant requirements of DNV-OSF101 or DNV-RP-F106. However, DNV does not make any statement for the future quality of the production. 203 The intention of the strict time limitation on SoC validity is to limit DNVs liability. DNV reviews the procedures and monitor the production, and the SoC confirms that the trial production was successful. This means that the pipe mill was able to meet all the requirements during the trial production. This is not a basis for guaranteeing anything about future performance. The pipe mill should be able to meet the DNV-OS-F101 or DNV-RP-F106 requirements, but it is not certain that it will do it. E 300 References 301 The SoC will refer only to DNV-OS-F101 or DNV-RPF106. If the qualification project was based on a project specification, this specification can be referenced in the verification report. 302 The SoC will, as a minimum, be signed by the DNV project manager and the custodian unit representative. E 400 Required information 401 The following information will be stated on the SoC: Project information: Project number, client, location of pipe mill/coating yard, location of plate mill (for welded pipe). Qualification scope: line pipe designation, coating system, line pipe dimensions, design temperature. Reference to the DNV verification report, DNV-OS-F101 or DNV-RP-F106, as well as DNV-OSS-313. The following phrase: This statement is valid on the date of issue. Signature of project manager (local unit) and verifier (custodian unit) Confirmation that the pipe mill has demonstrated to meet the requirements of DNV-OS-F101 or DNV-RP-F106 (as applicable). A template for a SoC is included in Appendix A for line pipe and Appendix B for coating.

It is assumed that the pipe mill has the technical capabilities to meet the requirements of DNV-OS-F101 for line pipe production within the indicated ranges. The purchaser should in all cases duly consider that a project-specific qualification shall be carried out as required by DNV-OS-F101. This is not a replacement for the technical competence and assessment of a line pipe purchaser. The purchaser should review this report (also referenced on the SoC), and make an independent evaluation of the pipe mill capabilities. 203 The verification report for line pipe coating will normally contain a statement with guidance related to the range of qualification. The following text can be used: The qualification has been carried out for the parameters stated on the SoC. Based on this, DNV considers that the coating yard has demonstrated production capabilities for the following variations: steel pipe material: no variation coating system: no variation production process: no variation pipe nominal ID: 15% pipe nominal WT: 10% thickness of individual coating layers: 10% design temperature: any decrease.

It is assumed that the coating yard has the technical capabilities to meet the requirements of DNV-RP-F106 for coating application within the indicated ranges. The purchaser should in all cases duly consider that a project-specific qualification shall be carried out as required by DNV-RP-F106. This is not a replacement for the technical competence and assessment of a line pipe purchaser. The purchaser should review this report (also referenced on the SoC), and make an independent evaluation of the coating yard capabilities. D 300 Other information 301 The verification report will state whether qualification of repair welding was carried out. 302 If a project specification was used as the basis for the qualification, a reference to this specification can be included in the verification report.

DET NORSKE VERITAS

Offshore Service Specification DNV-OSS-313, April 2009 Sec.5 Page 15

SECTION 5 MATERIALS AND PROCESSES

A. Materials
A 100 General 101 DNV-OS-F101 recognises three general types of material that can be used for the production of line pipe. The qualification process can be carried out for any of these materials. 102 Technical requirements for the production and control of all these materials are in DNV-OS-F101. Some issues are outlined below. A 200 C-Mn steel 201 DNV-OS-F101 for C-Mn pipes contains all the requirements in ISO 3183 for PSL 2 pipe for offshore service. Additional and modified requirements are given in DNV-OS-F101, resulting in stricter process and quality control. Note that DNV-OS-F101 remains self-contained, hence it is not necessary to include ISO 3183 as a reference. A 300 Corrosion Resistant Alloy (CRA) 301 CRA is a large group of materials that to greater or lesser extent have resistance to corrosion. In addition, depending on the chemical composition and microstructure, other properties will differ from that of C-Mn steel. 302 The main materials used for submarine pipelines are duplex (ferritic-austenitic) and martensitic steels. For these materials DNV-OS-F101 is a self-contained standard. 303 Other CRA that can be encountered are austenitic and nickel-based materials. DNV-OS-F101 is not fully developed for these materials, and it is more difficult to carry out a qualification according to this service description. 304 Line pipe of martensitic materials is only seamless. Line pipe of duplex materials can be both seamless and made from plates. A 400 Lined/Clad 401 Lined and clad line pipe are made from a two types of material. The structural integrity is ensured by a backing material, commonly C-Mn steel. The corrosion resistance, against the internal fluid, is ensured by a CRA on the inside of the backing material. 402 There are production challenges for lined/clad line pipe that are not encountered when producing line pipe from a single material.
Table 5-1 Seamless Pipe - Production Monitoring Item 1 2 3 4 5 6 Description Material identification and pipe tracking system. Handling of non-conforming pipes. Pipe production, all processes. Temperature control and determination of dimensions. Technology to minimize the risk of rejects. Pipe heat treatment Pipe straightening and pipe sizing Check calibration of gauge Hydrostatic Test Hydrostatic test AUT of pipe Magnetic Particle Inspection (MT) 7 pipe ends and bevel after pipe body grinding Calibration of equipment Production control Equipment and sensitivity check Production control Inspection Level M/R M M M M M W M W M

403 Clad pipe has a metallurgical bond between backing material and CRA, while lined pipe has a mechanical bond. 404 Clad pipe are welded pipe, where the plate has been rolled so that a C-Mn steel layer and a CRA layer are metallurgically bonded together. 405 Lined pipe are a CRA pipe inserted into a C-Mn steel pipe. Both CRA pipe and C-Mn pipe can be either seamless or welded. 406 The production of lined/clad pipes shall basically meet the same requirements as CRA or C-Mn steel line pipe, but with the added requirements to the interface and bonding between the two materials. A 500 External Coating 501 Qualification of coating yards shall be based on DNVOS-F101 and DNV-RP-F106. 502 DNV does not have a document for internal coating (also called flow coating). Hence qualification of internal coating application will not be carried out.

B. Production Processes
B 100 General 101 Below are outlined the qualification scope of work for the different line pipe production process covered by DNVOS-F101 and DNV-RP-F106. 102 This is primarily intended as information for the pipe mills and for the project initiation phase (contract negotiation). 103 The below tables will not be used as checklists during document verification or monitoring, though they provide some guidance for the work DNV will carry out. B 200 Seamless pipe 201 Seamless pipe are made from a bloom, which is pierced and rolled to specified dimensions in a continuous process. 202 Heat treatment is often applied to seamless pipes, in order to obtain the required material properties.

DET NORSKE VERITAS

Offshore Service Specification DNV-OSS-313, April 2009 Page 16 Sec.5

Table 5-1 Seamless Pipe - Production Monitoring (Continued) Item Manual UT 8 9 10 11 12 13 14 15 16 17 Description Calibration of equipment Inspection Level W M M M M M M W/M/R R M M M M M M R M

pipe ends (if applicable) Production testing re-testing of indications End facing and bevelling Dimensional inspection Visual inspection, including cleanliness of inside pipe body Wall thickness measurement after repair by grinding Removal and identification of test coupons Mechanical testing of test specimens Chemical analyses Weighing of pipes Bevel protectors (if applicable) Marking: tracking records dye stamp weld bevel paint mark internal colour code external Documentation, release list and material certificates Pipe storage and transportation

18

19 20

B 300 Welded pipe 301 Welded pipes are made in two main manufacturing
Table 5-2 Plate Rolling - Production Monitoring

steps. First the plate is rolled, and secondly the pipe is formed and welded (e.g. UOE or JCO). Both steps are essential for the line pipe quality, and shall be monitored during the qualification project. Inspection Level R M M W M M M M M M
Inspection Level M/R M M/R M M M M W M W M W M

Item 1 2 3 4 5 6 7 8

Description Material certificates Slab re-heating, rolling and accelerated cooling processes Plate heat treatment (if applicable) Calibration of equipment AUT on plate Production control Automatic ultrasonic re-test inspection Manual ultrasonic inspection Visual inspection Identification of test coupons Plate release

Table 5-3 Welded Pipe - Production Monitoring Item Description Material identification and pipe tracking system. Handling of non-conforming pipes. 1 2 3 4 5 6 7 8 Edge milling (bevelling) and pipe forming All welding processes and welding consumable handling (if applicable) Pipe heat treatment (if applicable) Pipe Expansion Check calibration of gauge Hydrostatic Test Hydrostatic test Radiographic inspection (RT) AUT of weld Magnetic Particle Inspection (MT) 9 pipe ends and bevel after pipe body grinding longitudinal weld Equipment set-up / Calibration Production testing Calibration of equipment Production control Equipment and sensitivity check Production control

DET NORSKE VERITAS

Offshore Service Specification DNV-OSS-313, April 2009 Sec.5 Page 17

Table 5-3 Welded Pipe - Production Monitoring (Continued) Item Description Manual UT Calibration of equipment 10 pipe ends (if applicable) Production testing re-testing of indications 11 Weld repairs (if included in the scope of work) 12 End facing and bevelling 13 Dimensional inspection 14 Visual inspection, including cleanliness of inside pipe body 15 Wall thickness measurement after repair by grinding 16 Removal and identification of test coupons Mechanical testing of test specimens 17 18 19 20 Chemical analyses Weighing of pipes Bevel protectors (if applicable) Marking: tracking records dye stamp weld bevel paint mark internal colour code external Documentation, release list and material certificates Pipe storage and transportation

Inspection Level W M M M M M M M W/M/R R M M M M M M R M

21

22 23

B 400

Lined/Clad

401 Production of lined and clad line pipe will consist of a combination of seamless pipe and welded pipe production. In addition, there will be specific activities related to lined and clad line pipe. 402 The production of clad plate is carried out in three main stages. The C-Mn and CRA plates are manufactured separately, and subsequently a re-rolled as a package/sandwich to bind them together. The monitoring is generally the same as for welded pipe plate rolling. 403 The production of clad line pipe is similar to the production of welded pipe see above. There are more extensive welding procedures and control procedures due to the additional layer. 404 For lined pipe, both the C-Mn backing pipe and the CRA liner pipe is manufactured separately, either as seamless pipe or as welded pipe see above.

405 The following items shall be monitored for the insertion of CRA liner in C-Mn pipe: cleaning, drying and inspection of the mating surfaces on the two pipes monitor humidity during assembly (and witness test) expansion of the assembly, to ensure mechanical gripping force locking of liner by seal weld or pipe end cladding. B 500 Coating

501 The qualification scope of work is dependent on the actual coating system to be applied; i.e. detailed monitoring of the coating process in the coating plant and subsequent inspection and testing of the applied coating must be defined for each coating system. The following production monitoring items are independent of line pipe coating system:
Inspection Level R M M M M M

Table 5-4 Line pipe coating Production Monitoring Item Description 1 Coating material batch certificates 2 Inspection of bare pipe prior to surface preparation 3 Surface preparation Inspection after blast cleaning, i.e. surface imperfections, contaminations such as dust and 4 chlorides, cleanliness, surface roughness Coating application, i.e. air temperature, steel temperature, humidity during painting appli5 cation, surface pre-treatment (if applicable) Final coating inspection/testing in yard, i.e. coating thickness, holiday detection, peeling 6 test Coating material testing (density, particle size, moisture content, thermal analysis etc) Materials testing of materials and applied 7 coating in laboratory Final coating testing (impact resistance, cathodic disbondment, hot water soak test) 8 9 10 11 12 Marking Handling and storage of coated pipes Coating repair Stripping of rejected coating Documentation

M/W

M M M M R

DET NORSKE VERITAS

Offshore Service Specification DNV-OSS-313, April 2009 Page 18 App.A

APPENDIX A STATEMENT OF COMPLIANCE PIPE MILL

DET NORSKE VERITAS

Offshore Service Specification DNV-OSS-313, April 2009 App.B Page 19

APPENDIX B STATEMENT OF COMPLIANCE COATING YARD

DET NORSKE VERITAS

Offshore Service Specification DNV-OSS-313, April 2009 Page 20 App.C

APPENDIX C VERCOM TEMPLATE

DNV Project Title: Document Title: DNV Project No.: Document Number:

Document revision

VerCom revision Sign

Prepared by Date Summary: Sign

Verified by Date

VERIFICATION COMMENTS:

Total number of verification comments Number of verification comments category A Number of verification comments category TQ / with status open Number of verification comments category NC / with status open Number of verification comments closed with note (CN) VerCom no.: Description: Category *) Status **)

NC = Non-Conformance TQ = Technical Query A = Advice (no reply necessary)

O = Open C = Closed CN = Closed with Note

DET NORSKE VERITAS

Offshore Service Specification DNV-OSS-313, April 2009 App.D Page 21

APPENDIX D SITE VISIT REPORT

Figure 1

DET NORSKE VERITAS

Offshore Service Specification DNV-OSS-313, April 2009 Page 22 App.D

DET NORSKE VERITAS