DNV-OSS-313: Pipe Mill and Coating Yard - Qualification

OFFSHORE SERVICE SPECIFICATION

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DNV-OSS-313

Pipe Mill and Coating Yard - Qualification

APRIL 2009

This document has been amended since the main revision (April 2009), most recently in October 2011. See “Changes” on page 3.

DET NORSKE VERITAS AS

is service document is the subject of intellectual property rights reserved by Det Norske Veritas AS (DNV). The userprohibited by anyone else but DNV and/or its licensees to offer and/or perform classification, certification and/orces, including the issuance of certificates and/or declarations of conformity, wholly or partly, on the basis of and/orocument whether free of charge or chargeable, without DNV's prior written consent. DNV is not responsible for theing from any use of this document by others.

pdf version of this document found through http://www.dnv.com is the officially binding version

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 andconsultancy services relating to quality of ships, offshore units and installations, and onshore industries worldwide, andcarries out research in relation to these functions.

DNV service documents consist of amongst other the following types of documents:— Service Specifications. Procedual requirements.— Standards. Technical requirements.— Recommended Practices. Guidance.

The Standards and Recommended Practices are offered within the following areas:A) Qualification, Quality and Safety MethodologyB) Materials TechnologyC) StructuresD) SystemsE) Special FacilitiesF) Pipelines and RisersG) Asset OperationH) Marine OperationsJ) Cleaner EnergyO) Subsea Systems

© Det Norske Veritas AS April 2009

Any comments may be sent by e-mail to [email protected] subscription orders or information about subscription terms, please use [email protected] Typesetting (Adobe Frame Maker) by Det Norske Veritas

This service document has been prepared based on available knowledge, technology and/or information at the time of issuance of this document, and is believed to reflect the best ofcontemporary technology. The use of this document by others than DNV is at the user's sole risk. DNV does not accept any liability or responsibility for loss or damages resulting fromany use of this document.

Amended October 2011 Offshore Service Specification DNV-OSS-313, April 2009see note on front cover Changes –

CHANGES

Amendments October 2011

— A restricted use legal clause has been added on the front page.

Scope of documentThis Offshore Service Specification describes the: “Pipe mill qualification service” - as a new service offeredby DNV. This service is based on:

— the requirements to line-pipe manufacture in the widely used DNV-OS-F101 “Submarine PipelineSystems”.

— qualification of coating application can also be carried out according to the same principles, and then DNV-RP-F106 used as a reference.


Offshore Service Specification DNV-OSS-313, April 2009 Amended October 2011 – Contents see note on front cover

CONTENTS

Sec. 1 General ................................................................................................................................................ 6

A. Scope............................................................................................................................................................................... 6A 100 Objective ............................................................................................................................................................... 6A 200 DNV deliverable ................................................................................................................................................... 6A 300 Motivation............................................................................................................................................................. 6A 400 Limitations ............................................................................................................................................................ 6

B. Background.................................................................................................................................................................... 6B 100 Pipeline projects ................................................................................................................................................... 6B 200 Line pipe manufacture .......................................................................................................................................... 7B 300 DNV-OS-F101...................................................................................................................................................... 7B 400 Coating systems and DNV-RP-F106.................................................................................................................... 7

C. References, Definitions and Abbreviations................................................................................................................. 7C 100 References............................................................................................................................................................. 7C 200 Definitions, verbal forms ...................................................................................................................................... 8C 300 Definitions ............................................................................................................................................................ 8C 400 Abbreviations........................................................................................................................................................ 8

Sec. 2 Qualification Project .......................................................................................................................... 9

A. Responsibilities .............................................................................................................................................................. 9A 100 Local unit .............................................................................................................................................................. 9A 200 Custodian unit ....................................................................................................................................................... 9

B. Project Overview........................................................................................................................................................... 9B 100 General.................................................................................................................................................................. 9B 200 Project initiation.................................................................................................................................................... 9B 300 Kick-off meeting................................................................................................................................................. 10B 400 Document review................................................................................................................................................ 10B 500 Site visits – production monitoring..................................................................................................................... 10B 600 MPQT report....................................................................................................................................................... 10B 700 DNV verification report...................................................................................................................................... 10B 800 Statement of Compliance.................................................................................................................................... 10

Sec. 3 Activities ............................................................................................................................................ 11

A. Project Initiation ......................................................................................................................................................... 11A 100 General................................................................................................................................................................ 11A 200 Scope of qualification ......................................................................................................................................... 11A 300 Qualification parameters..................................................................................................................................... 11A 400 General contract conditions ................................................................................................................................ 11

B. Kick-off Meeting ......................................................................................................................................................... 12B 100 General................................................................................................................................................................ 12

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

D. Site Visits – Production Monitoring .......................................................................................................................... 12D 100 General................................................................................................................................................................ 12D 200 DNV site visit team............................................................................................................................................. 13D 300 DNV monitoring scope ....................................................................................................................................... 13D 400 Access to production........................................................................................................................................... 13D 500 Site visit report.................................................................................................................................................... 13D 600 Product quality control........................................................................................................................................ 13

Sec. 4 Documents......................................................................................................................................... 14

A. General ......................................................................................................................................................................... 14A 100 Documents from pipe mill and coating yard....................................................................................................... 14A 200 Documents from DNV ....................................................................................................................................... 14

B. Production and Control Procedures ......................................................................................................................... 14B 100 Requirements ...................................................................................................................................................... 14B 200 DNV verification ................................................................................................................................................ 14

C. MPQT Report.............................................................................................................................................................. 14C 100 Requirements ...................................................................................................................................................... 14C 200 DNV verification ................................................................................................................................................ 15


Amended October 2011 Offshore Service Specification DNV-OSS-313, April 2009see note on front cover Contents –

D. DNV Verification Report............................................................................................................................................ 15D 100 General................................................................................................................................................................ 15D 200 Range of qualification......................................................................................................................................... 15D 300 Other information ............................................................................................................................................... 16

E. Statement of Compliance ........................................................................................................................................... 16E 100 General................................................................................................................................................................ 16E 200 Validity ............................................................................................................................................................... 16E 300 References........................................................................................................................................................... 16E 400 Required information .......................................................................................................................................... 16

Sec. 5 Materials and Processes................................................................................................................... 17

A. Materials ...................................................................................................................................................................... 17A 100 General................................................................................................................................................................ 17A 200 C-Mn steel........................................................................................................................................................... 17A 300 Corrosion Resistant Alloy (CRA) ...................................................................................................................... 17A 400 Lined/Clad .......................................................................................................................................................... 17A 500 External Coating ................................................................................................................................................. 17

B. Production Processes .................................................................................................................................................. 17B 100 General................................................................................................................................................................ 17B 200 Seamless pipe...................................................................................................................................................... 18B 300 Welded pipe ........................................................................................................................................................ 18B 400 Lined/Clad .......................................................................................................................................................... 19B 500 Coating................................................................................................................................................................ 20

App. A Statement of Compliance – Pipe Mill ............................................................................................. 21

App. B Statement of Compliance – Coating Yard ..................................................................................... 22

App. C VerCom Template ............................................................................................................................ 23

App. D Site Visit Report .............................................................................................................................. 24


Offshore Service Specification DNV-OSS-313, April 2009 Amended October 2011 – Sec.1 see note on front cover

SECTION 1GENERAL

A. Scope

A 100 Objective101 This document describes the pipe mill qualification service of DNV. This service is based on therequirements to line pipe manufacture in DNV-OS-F101.102 Following the same principles, the qualification of coating application can be carried out according toDNV-RP-F106.

A 200 DNV deliverable201 The key DNV deliverable is a Statement of Compliance (SoC) upon successful completion of thequalification 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 thepipe mill/coating yard and the qualification project. This assessment is detailed in Site Visit Reports.

A 300 Motivation301 The market for offshore pipelines demands rigorous quality. The required quality for offshore line pipeis set by leading standards such as DNV-OS-F101. DNV provides solutions to assist pipe mills in documentingthat 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 Line pipe purchasers will benefit from this DNV service:

— an objective and independent assessment of pipe mill/coating yard capabilities will be available, limitingproject risk

— the procedures and production practices will be of high quality, due to the DNV review and monitoringactivities. 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 anopportunity to get DNV assistance to bring mill procedures and practices up to a high-quality level.

A 400 Limitations401 A SoC does not exempt the pipe mill/coating yard from carrying out a full project-specific qualificationaccording 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 thefinished pipe, and are not applicable to plates. However, the plate production shall be monitored as part of themanufacture of welded pipes.403 Components (valves, fittings etc) and activities taking place during other phases (installation,commissioning) are not covered by this document.404 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 concernsduring 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 andinformation 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 isprocurement 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 predefineddimensions; rather the line pipe specification is a direct consequence of the system design.


Amended October 2011 Offshore Service Specification DNV-OSS-313, April 2009see note on front cover Sec.1 –

B 200 Line pipe manufacture

201 The procedures at the pipe mill shall be project specific, so that they properly reflect all elements of theproject 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 thepersonnel, as well as the project requirements.

203 Line pipe manufactured according to DNV are made with the same manufacturing steps as any other linepipe - 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 wellmaintained

— quality control personnel, who work independently of the production personnel and understand theimportance 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 ofdocuments 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 designthrough fabrication and installation to decommissioning.

303 One significant advantage of using DNV-OS-F101 is that the design criteria are carefully calibratedagainst the quality of the line pipe and components. The fabrication requirements in DNV-OS-F101 are ingeneral stricter than other line pipe standards; however the increased quality of the line pipe is reflected byhigher 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 bedesigned and installed according to DNV-OS-F101. Secondly a number of supplementary requirements aredefined, which may be applied as found necessary. These are for Sour Service (S), Fracture Arrest (F), PlasticDeformation (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 beenprepared 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, thecoating system can be designed to provide mechanical protection during installation and operation, and/orthermal 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 dedicatedcoating yard. This coating is referred to as “line pipe coating” (sometimes “factory coating”). In order tofacilitate girth welding, areas at each end of the individual pipe length are left uncoated. These areas arenormally coated after welding, by applying a field joint coating (FJC) system (FJC systems are covered inDNV-RP-F102).

404 Submarine pipelines are almost invariably designed with a cathodic protection (CP) system. The CPdesign 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 ofsubmarine pipelines at the coating yard (line pipe coating), and includes the qualification and production ofcoating.

406 DNV-RP-F106 contains requirements and recommendations that are general and advice on howamendments can be made to include project specific requirements and requirements/guidelines by a regulatingauthority, or to reflect the pipeline operator’s 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”.

C. References, Definitions and Abbreviations

C 100 References

DNV-OS-F101 Submarine Pipeline SystemsDNV-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 whichno 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.

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 parametersaffecting the quality of a process. Work proceeds without the presence and any special information to theinspector, 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 ofrequirements. This is typically associated with an extended volume of testing, as compared to normalproduction.

305 Statement of Compliance: A statement or report signed by a qualified party affirming that, at the time ofassessment, the defined production met the defined requirements.

306 Trial Production: A small production run carried out in order to show that the procedures areimplemented and that the final product meets the defined requirements. The trial production shall meet therequirements 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 inaccordance 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 notproceed 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/herpresence is not required.

C 400 Abbreviations

AUT Automated Ultrasonic TestingCP Cathodic ProtectionCRA Corrosion Resistant AlloyDNV Det Norske VeritasID Internal DiameterITP Inspection and Test PlanM MonitoringMPQT Manufacturing Procedure Qualification TestMPS Manufacturing Procedure SpecificationNDT Non Destructive TestingOS Offshore StandardOSS Offshore Service SpecificationPQT Production Qualification TestR Document ReviewRP Recommended PracticeSoC Statement of ComplianceUT Ultrasonic TestingQ-plan Quality PlanVerCom Verification CommentW WitnessingWT Wall Thickness.



SECTION 2QUALIFICATION 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 servicedescribed 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 contractsigning.

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 unitis described in this document.

106 The cost of the custodian unit’s 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 qualityof the pipe mill/coating yard qualification service, and will ensure a uniform application of DNV-OSS-313 inDNV 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 thefollowing:

— Review of the contract before signing, in order to verify that the scope of work complies with this servicedescription.

— Verification of DNV VerCom before they are sent to the client. The local unit should perform the documentreview 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 shouldbe monitored by the local unit, by agreement.

— Signature on both the DNV Verification Report and the Statement of Compliance. These deliverablesshould first be prepared and verified by the local unit, before the custodian unit performs the finalverification.

204 The custodian unit will use properly qualified personnel, as determined by the Head of Section. Thesepersonnel 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 Høvik,Norway.

B. Project Overview

B 100 General

101 This section presents a general overview of the qualification process. The activities and documentsinvolved are briefly described.

102 The technical requirements to procedures, documentation and control are fully described in DNV-OS-F101 and DNV-RP-F106 (as applicable). A qualification project shall be considered a normal productionqualification, 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 custodianunit.

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 thesystem design phase. This is typically:

— Line pipe: Steel grade, pipe diameter, wall thickness, design temperature (minimum) and supplementaryrequirements

— Coating: Coating system, maximum design temperature (to be used for testing of certain properties) andthickness 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 previousexperience 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 within-depth 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 productcontrol (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 essentiallythe same as a MPQT as defined in DNV-OS-F101 and PQT in DNV-RP-F106. For welded pipe, the plate millshall 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 theequipment, the knowledge and experience of the personnel and the implementation of the procedures in theproduction.

503 The MPS and ITP, which have been accepted by DNV, form the basis for the monitoring. All activitiesnoted 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, ifincluded in the qualification.

505 A detailed site visit report shall be issued by DNV after each visit. The site visit report shall describe indetail 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 arepresented.

602 The report shall contain all relevant documentation from the trial production, and shall be submitted toDNV 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. Thiscan 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 requirementsof DNV-OS-F101 or DNV-RP-F106. However, DNV does not make any statement for the future quality of theproduction.

804 The SoC will refer only to DNV-OS-F101 or DNV-RP-F106 (as applicable). If the qualification projectwas based on a project specification, this specification can be referenced in the verification report.



SECTION 3ACTIVITIES

A. Project Initiation

A 100 General101 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 millsenior management.

A 200 Scope of qualification201 The following parameters shall as a minimum be agreed:

— extent of qualification (which and quantity of different steel grades, diameters, wall thicknesses, coatingsystems 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 chemicalcomposition 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. Coatingyard qualification is based on DNV-RP-F106 in addition to DNV-OS-F101.204 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 reviewprocess will be necessary.

A 300 Qualification parameters301 The pipe mill/coating yard shall define such parameters of the project as would normally come from thesystem 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 havebeen defined by the potential client.

— If the aim of the qualification is to obtain a SoC for general commercial purposes, the parameters shouldreflect 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 thequalification based on this specification. There are two conditions:

— The specification shall comply fully with DNV-OS-F101 or DNV-RP-F106 and gives only requirementsthat are additional to the standard.

— The SoC will refer only to DNV-OS-F101 or DNV-RP-F106. The project specification can be referencedin the DNV verification report.

If it is found that the project specification does not fully comply with DNV-OS-F101 or DNV-RP-F106, thequalification 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 ofthe qualification. If the qualification pipes do not meet the supplementary requirements, reference to them willnot 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 conditions401 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 thesupport of the mill top management it may be difficult to successfully complete the project.

B. Kick-off Meeting

B 100 General101 A kick-off meeting should be included in the scope of work, in particular if the pipe mill/coating yardhas 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 theminimum participants from DNV. This initial phase will typically be to:

— present the requirements in DNV-OS-F101 or DNV-RP-F106— 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 DNV’s 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.

C. Document Review

C 100 General101 The relevant documents and procedures will be reviewed and VerCom issued by DNV specialists within-depth 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 byDNV 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 thetrial production. DNV will then as soon as possible receive updated procedures, preferably during the trialproduction. No SoC can be issued until all VerComs have been satisfactorily closed.

C 200 Relevant documents201 Procedures related to overall production (MPS, Quality Plan, Inspection and Test Plan) and productcontrol (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 beissued for information, or as agreed in the scope of work.

C 300 Requirements301 The requirements to the documents are described in DNV-OS-F101 or DNV-RP-F106. Documents fora qualification project shall meet all requirements as a normal production.

D. Site Visits – Production Monitoring

D 100 General101 The pipe mill or coating yard shall be responsible for conducting the trial production. This is essentiallythe same as a MPQT as defined in DNV-OS-F101 and PQT as defined in DNV-RP-F106. For welded pipe, theplate 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 duringthe 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 trialproduction, preferably the same persons that performed the document review. They will assess the quality ofthe equipment, the knowledge and experience of the mill/plant personnel and the implementation of theprocedures, which have been accepted by DNV.

202 General inspectors/surveyors may assist during the trial production, and work under the supervision ofthe specialists.

203 The size of the monitoring team will depend on the complexity of the production, and the number ofactivities to be 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 activitiesnoted 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 thisservice description. Checklists shall not replace a written site visit report, with detailed description ofobservations 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 theproduction and the parameter control, and DNV shall have access to all mill facilities during the trialproduction. This also applies to the plate mill (e.g. finishing rolling stand and accelerated cooling), if includedin 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 asmonitoring of production and witnessing of testing.

502 The site visit report shall describe in detail what has been monitored, and an assessment of all relevantpipe mill/coating yard operations, including materials testing.

503 When deemed necessary, results from the production and testing shall be included. All results orobservations from production or testing that do not meet the requirements will be reported by DNV in the sitevisit reports.

D 600 Product quality control

601 If more than one pipe from each heat is produced, DNV will designate one pipe as the qualification pipeearly in the production process, and always before NDT. This is in order to fully include all variables in theproduction 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 shallbe for the pipe mill to have the smallest variation possible. For seamless pipes the qualification pipe is typicallychosen 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 allmaterial testing. This monitoring can be carried out by general inspectors/surveyors, but the laboratoryfacilities 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 seethat the respective measurements are carried out in a correct manner and further to witness that the correctvalues are reported.

604 Some testing, deemed less critical, can be monitored instead of witnessed. This shall be agreed with theDNV materials specialists in the project team prior to start of qualification.



SECTION 4DOCUMENTS

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.

A 200 Documents from DNV

201 The table below outlines the documents that will be prepared by DNV.

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 inorder 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 beanswered. This may also require updates of the procedures. For welded pipes, plate mill procedures shall bereviewed 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 agreedin the contract.

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 notlimited to:

— overview of pipe numbers and corresponding heat and plate numbers, as applicable— product and heat chemical analysis— pipe heat treatment records, when applicable

Responsible part Documents for review Documents for informationPipe mill — MPS

— ITP— NDT procedures— MPQT report

— welding procedures (if applicable)— heat treatment procedure (if applicable)— material handling, if not in MPS— welding consumables handling, if not in MPS— procedure for dimensional control

Coating yard — MPS— ITP— PQT report

Some of the information in the MPS is for information

Plate mill(if applicable)

— MPS— ITP— NDT procedures

Documents issued by DNVContract with detailed scope of workVerification comments to mill documents and procedures prior to qualification productionSite visit reports from all DNV monitoring activitiesVerification comments to the pipe mill/coating yard MPQT reportFinal verification report, which summarises all DNV activitiesStatement of Compliance, if all requirements are met



— 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 concernsor non-conformances.104 The pipe mill/coating yard shall state whether all the project requirements have been met.

C 200 DNV verification201 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 sitevisit reports.

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 canbe 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 signedby the custodian unit.

105 The verification report will contain all relevant documentation from DNV produced during thequalification 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.

D 200 Range of qualification

201 The SoC is issued with the specific parameters used for the qualification project. However, thequalification gives an indication of the mill capabilities, and it can be assumed that the pipe mill can make linepipe 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 therange 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 considersthat 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.

It is assumed that the pipe mill has the technical capabilities to meet the requirements of DNV-OS-F101 forline 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 purchasershould review this report (also referenced on the SoC), and make an independent evaluation of the pipe millcapabilities.”

203 The verification report for line pipe coating will normally contain a statement with guidance related tothe 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 considersthat 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-F106for coating application within the indicated ranges. The purchaser should in all cases duly consider that aproject-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 purchasershould review this report (also referenced on the SoC), and make an independent evaluation of the coating yardcapabilities.”

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 canbe included in the verification report.

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 withthe main qualification parameters, as agreed in the scope of work. The DNV verification report will bereferenced on the SoC.

103 The SoC will not be issued before updated procedures have been received and approved, the productiontrial 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 requirementsof DNV-OS-F101 or DNV-RP-F106. However, DNV does not make any statement for the future quality of theproduction.

203 The intention of the strict time limitation on SoC validity is to limit DNV’s liability. DNV reviews theprocedures and monitor the production, and the SoC confirms that the trial production was successful. Thismeans that the pipe mill was able to meet all the requirements during the trial production. This is not a basisfor guaranteeing anything about future performance. The pipe mill should be able to meet the DNV-OS-F101or 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-RP-F106. If the qualification project was based on aproject 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 unitrepresentative.

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 (forwelded 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.



SECTION 5MATERIALS AND PROCESSES

A. Materials

A 100 General101 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. Someissues are outlined below.

A 200 C-Mn steel201 DNV-OS-F101 for C-Mn pipes contains all the requirements in ISO 3183 for PSL 2 pipe for offshoreservice. Additional and modified requirements are given in DNV-OS-F101, resulting in stricter process andquality control. Note that DNV-OS-F101 remains self-contained, hence it is not necessary to include ISO 3183as 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 fullydeveloped for these materials, and it is more difficult to carry out a qualification according to this servicedescription.304 Line pipe of martensitic materials is only seamless. Line pipe of duplex materials can be both seamlessand made from plates.

A 400 Lined/Clad401 Lined and clad line pipe are made from a two types of material. The structural integrity is ensured by a backingmaterial, commonly C-Mn steel. The corrosion resistance, against the internal fluid, is ensured by a CRA on the insideof the backing material.402 There are production challenges for lined/clad line pipe that are not encountered when producing line pipefrom a single material.

403 Clad pipe has a metallurgical bond between backing material and CRA, while lined pipe has amechanical bond.404 Clad pipe are welded pipe, where the plate has been rolled so that a C-Mn steel layer and a CRA layerare 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 eitherseamless or welded.406 The production of lined/clad pipes shall basically meet the same requirements as CRA or C-Mn steel linepipe, but with the added requirements to the interface and bonding between the two materials.

A 500 External Coating501 Qualification of coating yards shall be based on DNV-OS-F101 and DNV-RP-F106.502 DNV does not have a document for internal coating (also called “flow coating”). Hence qualification ofinternal coating application will not be carried out.

B. Production Processes

B 100 General101 Below are outlined the qualification scope of work for the different line pipe production process coveredby DNV-OS-F101 and DNV-RP-F106.102 This is primarily intended as information for the pipe mills and for the project initiation phase (contractnegotiation).103 The below tables will not be used as checklists during document verification or monitoring, though theyprovide 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 acontinuous process.

202 Heat treatment is often applied to seamless pipes, in order to obtain the required material properties.

B 300 Welded pipe

301 Welded pipes are made in two main manufacturing steps. First the plate is rolled, and secondly the pipeis formed and welded (e.g. UOE or JCO). Both steps are essential for the line pipe quality, and shall bemonitored during the qualification project.

Table 5-1 Seamless Pipe - Production Monitoring

Item Description Inspection Level

1 Material identification and pipe tracking system. Handling of non-conforming pipes. M / R

2 Pipe production, all processes. Temperature control and determination of dimensions. Technology to minimize the risk of rejects. M

3 Pipe heat treatment M4 Pipe straightening and pipe sizing M

5 Hydrostatic TestCheck calibration of gauge M

Hydrostatic test M

6 AUT of pipeCalibration of equipment W

Production control M

7

Magnetic Particle Inspection (MT)

— pipe ends and bevel— after pipe body grinding

Equipment and sensitivity check W


8

Manual UT

— pipe ends (if applicable)— re-testing of indications

Calibration of equipment W

Production testing M

9 End facing and bevelling M10 Dimensional inspection M11 Visual inspection, including cleanliness of inside pipe body M12 Wall thickness measurement after repair by grinding M13 Removal and identification of test coupons M

14 Mechanical testing of test specimens W / M / R

15 Chemical analyses R16 Weighing of pipes M17 Bevel protectors (if applicable) M

18

Marking:

— tracking records— dye stamp weld bevel— paint mark internal— colour code external

MMMM

19 Documentation, release list and material certificates R20 Pipe storage and transportation M

Table 5-2 Plate Rolling - Production MonitoringItem Description Inspection Level

1 Material certificates R2 Slab re-heating, rolling and accelerated cooling processes M3 Plate heat treatment (if applicable) M

4 AUT on plateCalibration of equipment WProduction control M

5 Automatic ultrasonic re-test inspectionManual ultrasonic inspection

MM

6 Visual inspection M7 Identification of test coupons M8 Plate release M



B 400 Lined/Clad

401 Production of lined and clad line pipe will consist of a combination of seamless pipe and welded pipeproduction. 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 aremanufactured separately, and subsequently a re-rolled as a package/sandwich to bind them together. Themonitoring 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 moreextensive 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 asseamless 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.

Table 5-3 Welded Pipe - Production MonitoringItem Description Inspection Level

1Material identification and pipe tracking system. Handling of non-conforming pipes. M / R

2 Edge milling (bevelling) and pipe forming M3 All welding processes and welding consumable handling (if applicable) M / R4 Pipe heat treatment (if applicable) M5 Pipe Expansion M

6 Hydrostatic TestCheck calibration of gauge M

Hydrostatic test M

7 Radiographic inspection (RT) Equipment set-up / Calibration WProduction testing M

8 AUT of weldCalibration of equipment W


9

Magnetic Particle Inspection (MT)

— pipe ends and bevel— after pipe body grinding— longitudinal weld

Equipment and sensitivity check W


10

Manual UT

— pipe ends (if applicable)— re-testing of indications

Calibration of equipment W

Production testing M

11 Weld repairs (if included in the scope of work) M12 End facing and bevelling M13 Dimensional inspection M14 Visual inspection, including cleanliness of inside pipe body M15 Wall thickness measurement after repair by grinding M16 Removal and identification of test coupons M

17 Mechanical testing of test specimens W / M / R

18 Chemical analyses R19 Weighing of pipes M20 Bevel protectors (if applicable) M

21

Marking:

— tracking records— dye stamp weld bevel— paint mark internal— colour code external

MMMM

22 Documentation, release list and material certificates R23 Pipe storage and transportation M



B 500 Coating501 The qualification scope of work is dependent on the actual coating system to be applied; i.e. detailedmonitoring of the coating process in the coating plant and subsequent inspection and testing of the appliedcoating must be defined for each coating system. The following production monitoring items are independentof line pipe coating system:

Table 5-4 Line pipe coating – Production MonitoringItem Description Inspection Level

1 Coating material batch certificates R2 Inspection of bare pipe prior to surface preparation M3 Surface preparation M

4 Inspection after blast cleaning, i.e. surface imperfections, contaminations such as dust and chlorides, cleanliness, surface roughness M

5 Coating application, i.e. air temperature, steel temperature, humidity during painting application, surface pre-treatment (if applicable) M

6 Final coating inspection/testing in yard, i.e. coating thickness, holiday detection, peeling test M

7 Materials testing of materials and applied coating in laboratory

Coating material testing (density, particle size, moisture content, thermal analysis etc)

M/WFinal coating testing (impact resistance, cathodic disbondment, hot water soak test)

8 Marking M9 Handling and storage of coated pipes M

10 Coating repair M11 Stripping of rejected coating M12 Documentation R


Amended October 2011 Offshore Service Specification DNV-OSS-313, April 2009see note on front cover App.A –

APPENDIX A STATEMENT OF COMPLIANCE – PIPE MILL


Offshore Service Specification DNV-OSS-313, April 2009 Amended October 2011 – App.B see note on front cover

APPENDIX B STATEMENT OF COMPLIANCE – COATING YARD


Amended October 2011 Offshore Service Specification DNV-OSS-313, April 2009see note on front cover App.C –

APPENDIX C VERCOM TEMPLATE

VERIFICATION COMMENTS: Summary:

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

Document revision VerCom revision Prepared by Verified bySign Date Sign Date

Total number of verification commentsNumber of verification comments category ANumber of verification comments category TQ / with status openNumber of verification comments category NC / with status openNumber of verification comments closed with note (CN)

VerCom no.: Description: Category *) Status**)

NC = Non-Conformance O = OpenTQ = Technical Query C = ClosedA = Advice (no reply necessary) CN = Closed with Note


Offshore Service Specification DNV-OSS-313, April 2009 Amended October 2011 – App.D see note on front cover

APPENDIX D SITE VISIT REPORT


DNV-OSS-313: Pipe Mill and Coating Yard - Qualification

Documents

Transcript of DNV-OSS-313: Pipe Mill and Coating Yard - Qualification