Israel Gas Transmission Project

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PLE601enpro/06.04.dot

Company Contractor

Israel Gas Transmission Project

4 06/06/2011 Completely Revised. PM HT

Rev. Date Description Prepared Checked Approved Date Approved

No. Contractor Company

Document Title

Electric Resistance Welded (HFW) Pipes Nominal Pipe Size DN 100 -

500 mm

Company Representative : Menashe Sarid Area Code: GEN

Reference : ./.

PO. No. : ./. ./.

Contractor Representative : Friedrich v.d. Schulenburg

Project Identification

60.0710.0000-04-x

Document-No.

EEN-EPI-SPC-002

Rev.

4

Document Originator : Wilhelm Piepenbrock EEN Job-No.

YC PP Contractor

Code

Dis.-

Code

Doc.-

Type

Ser.

No.

x

Table of Contents

Contractor

Company

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Project Title: Israel Gas Transmission Project Proj. Identification : 60.0710.0000-04-x

Document Title: Electric Resistance Welded (HFW) Pipes Nominal Pipe Size DN 100 - 500 mm

Document No.: EEN-EPI-SPC-002

Revision: 4 Date: 06-06-2011


1 Scope 5

2 Quality Assurance 7

2.1 Quality Plan 7 2.2 Inspection Notice 7

3 Manufacturing Process 8

3.1 Manufacturing Procedure Specification (MPS) 8 3.2 Manufacturing Procedure Qualification 8 3.3 Steel Making Process 8 3.4 Chemical Composition 8 3.5 Pipe Tracking 8 3.5 Coil Manufacture 9 3.6 Coil Material Testing Requirements 9 3.8 Manufacturing Process of the Pipe 10

4 Inspection 12

5 Chemical Requirements 14

5.1 Cast (Ladle) Analysis 14 5.2 Frequency of Cast (Ladle) Analysis 15 5.3 Product Analysis 15 5.4 Frequency of Product Analysis 15 5.5 Test Failures 16

6 Manufacturing Procedure Qualification Tests 17

6.1 General 17 6.2 Non-destructive Testing Requirements 17 6.3 Mechanical Testing Requirements 18 6.4 Testing Details 18 6.5 Strain Ageing Test (if required in the Scope of Work) 18 6.6 Surface Quality 19 6.7 Weldability Testing 19 6.8 Test Results 19

7 FIRST DAY AND PRODUCTION TESTS 20

7.1 First Days Production Tests 20 7.1.1 Pipe Selection 20 7.1.2 Non-destructive Testing Requirements 20 7.1.3 Mechanical Testing Requirements 21 7.1.4 Testing Details 21 7.1.5 Test Results 21

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7.2 Production Tests 21 7.2.1 Non Destructive Tests 21 7.2.2 Destructive Tests 22 7.2.3 Frequency and extent of Pipe Production Tests 22 7.2.4 Testing Details 23 7.2.5 Test Results 23

8 NON-DESTRUCTIVE TESTING 24

8.1 General 24 8.2 Ultrasonic Testing 24 8.3 Visual Inspection 25 8.4 Magnetic Particle Inspection of Pipe Ends 26 8.5 Acceptance Criteria 26 8.6 Checks for Residual Magnetism 26

9 MECHANICAL PROPERTIES AND TESTS 27

9.1 General 27 9.2 Longitudinal Tensile Properties 27 9.3 Transverse Tensile Properties 28 9.4 Hot Tensile Tests 28 9.5 Flattening Test 29 9.6 Impact Strength (CharpyTesting) 29 9.7 Macrostructure and Hardness Tests 31 9.8 Defective Specimens 32 9.9 Re-Heat Treatment 32

10 HydrostaticTesting 33

11 DIMENSIONS, WEIGHTS AND LENGTHS 34

11.1 Diameter - Pipe Body 34 11.2 Diameter - Pipe Ends 34 11.3 Out of Roundness - Pipe Body 34 11.4 Wall Thickness 35 11.5 Nominal Weight 35 11.6 Length 35 11.7 Straightness 35 11.8 Squareness 35 11.9 Pipe Ends 36 11.10 Bulges and Flat Areas 36

12 REPAIRS AND SURFACE FINISH 37

12.1 Dents 37 12.2 Defects 37 12.3 Hard Spots 37 12.4 Weld Flash 37

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12.5 Repair of Defects 37 12.6 Rejections 38 12.7 Surface Finish 38

13 Pipe Marking 39

13.1 Identification and Marking 39 13.2 Die Stamping 39 13.3 Colour Coding 40

14 Coating and Corrosion Protection 41

14.1 External Coating 41 14.2 Internal Coating 41 14.3 Corrosion Protection 41

15 Documentation 42

15.1 General 42 15.2 Manufacturing Procedure Specification 42 15.3 Manufacturing Procedure Qualification Test Reports 43 15.4 Periodic Reporting 43 15.4.1 Daily Production Report 43 15.4.2 Weekly Production Report 44 15.5 Final Documentation 44 15.5.1 Manufacturing Data Book (including first day production tests) 44 15.5.2 Mill test certificates 45 15.5.3 Pipe Tally Lists 46 15.5.4 Letter of guarantee/conformity 46 15.6 Delivery Documentation 46

16 Storage, Loading and Shipment 47

Appendix 1 Pipe End Drawing 48

Appendix 2 . Location of Charpy-V Notch Specimens 49

Appendix 3 . Vicker Hardness Survey in HFI-ERW Area for Production Test 50

17 Revision Record 51

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1 Scope

1.1 This specification defines the minimum technical requirements for the manufacture and

supply of carbon steel linepipe, said linepipe being manufactured by the high-frequency induction welding (HFIW) method

1.2 In principal, this specification is valid for line pipe within the range of nominal outside diameter from 114.3 to 508.0mm inclusive (Nominal Pipe Size DN 100 to 500) which will be used for Natural Gas Pipeline Service with design pressures up to 80 bar g andin the temperature range from –10°C to 50°C.

The pipe shall be manufactured in one or more of the grades specified in accordance with ANSI/API 5L/ISO 3183.

API 5LGrade X52 X60 X65 X70

ISO 3183 Grade L360 L415 L450 L485

Further specific details shall be issued in the Scope of Work. 1.3 All material shall comply with the requirements of this Specification and with ANSI/API

Specification 5L 44th Edition which is now harmonised with ISO 3183. This is in compli-ance with NEN 3650-2 Annex B.

1.4 All requirements of NEN 3650 shall apply.

1.5 The edition of each code and standard current at the date of enquiry shall apply (unless a specific version is clearly stated in this Specification or in the Scope of Work),

1.6 Where conflict occurs between the requirements of this Specification and referenced codes and standards, the Specification requirements shall apply. Where any of the documents are revised and the revision affects the scope of supply, Contractor shall no-tify INGL in writing immediately. Written clarification must be given by INGL before Con-tractor and/or Manufacture commences work.

1.7 Pipe furnished to this Specification shall be readily weldable using automatic or manual welding equipment in common usage for pipelines without the need for post weld heat treatment.

1.8 The Specification of steel used, Manufacturer and the Laboratories in which the testing is

performed shall be approved by INGL.

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1.9 The Manufacturer shall:

• Prior to manufacturing procedure qualification tests and within 3 weeks of con-tract award submit to Company for approval a Manufacturing Procedure Specification containing the information stipulated in this specification.

• After receiving the approval, carry out manufacturing procedure qualification and first day production tests to the satisfaction of Company and the Certifying Authority and in accordance with the requirements of this specification.

• Perform production tests regularly as required during the pipe manufacture and in accordance with this specification.

• Manufacture and test the full amount of pipe ordered by Company in strict ac-cordance with this specification.

• Faithfully identify and record the details of each pipe to ensure its traceability throughout the production process and subsequent load out.

• Document and submit to Company all required information concerning the manufacturing and testing of base material and pipe within the time stipulated in this specification.

• Fit Company approved end protectors to each pipe; load-out the pipe onto the designated transport.

1.10 INGL shall be notified by Contractor of any production, of base material or pipe, being

performed outside the approved plant and shall furnish a production schedule for it. In no case shall pipe production, that forms part of the INGL order, take place outside ap-proved manufacturing plant(s).

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2 Quality Assurance

2.1 Quality Plan

The Contractor and Manufacturer shall have in operation a Quality System based on the requirements of ISO 9002 or API Q1. see Doc. Nº. EEN-EPI-SPC-004 "General Quality Assurance Requirements".

Contractor shall submit a Quality Plan (Test and Inspection Plan), based on the manu-facturing Quality Manual, covering (as a minimum) all production, pipe tracking system, inspection and testing operations, for review and approval by INGL not less than 21 days prior to the commencement of any work. Contractor's subsequent Quality Control of the work shall strictly adhere to the agreed Quality Plan. The Quality Plan shall show hold, witness, re-view and monitor points for INGL and Cer-tifying Authority

2.2 Inspection Notice

The Contractor shall give the Company's inspector at least five working days notice of the time and location of fabrication, inspection and testing work. All line-pipe production shall be subject to running mill inspection by INGL and/or the Certifying Authority. Intermediate inspections and/or examinations carried out or stage approvals given by INGL or the Certifying Authority do not absolve the CONTRACTOR from his responsibil-ity that the material(s) have to comply fully with all rules, regulations and specifications.

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3 Manufacturing Process

3.1 Manufacturing Procedure Specification (MPS)

3.1.1 A complete and detailed MPS shall be prepared by Contractor and submitted to Com-

pany for approval prior to the award of a contract for the manufacture of the pipe and prior to the pre-production meeting. The MPS shall include an outline of the manufactur-ing procedures performed to ensure that the pipe meets all of the requirements of this specification (see section 11.2).

3.2 Manufacturing Procedure Qualification

3.2.1 For each diameter and wall thickness of pipe, one completely finished pipe shall be

subjected to full non-destructive and mechanical testing prior to the start of production or immediately after any changes in the approved manufacturing procedure. Production of pipe should not commence until the results of the testing have been accepted, and approval has been given to proceed, by Company and the Certifying Authority.

3.2.2 Failure of any of the qualification tests shall be cause for rejection of the manufacturing

procedure and all pipes produced to it. Company reserves the right to require re-qualification in the case of any changes to the manufacturing procedure specification.

3.3 Steel Making Process

3.3.1 The steel shall be made by either a basic oxygen or an electric arc furnace process. The

steel shall be fully killed, fine grain treated and processed to control hydrogen content. 3.3.2 Other processes used in the steel making shall be included in the manufacturing proce-

dure specification provided for review. 3.4 Chemical Composition

3.4.1 Contractor shall include a chemical composition range in the manufacturing procedure

specification. This range shall be within the limits specified in Section 5.1 of this Specifi-cation. All pipes shall meet the chemical composition limits in the agreed Manufacturing Procedure Specification.

3.5 Pipe Tracking

3.5.1 Contractor shall operate a pipe tracking system, which ensures full traceability of each

individual pipe to its particular heat and coil number and to inspection records of all stages of the manufacturing process.

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3.5.2 Contractor shall provide full details of the pipe tracking system for review by Company.

3.5 Coil Manufacture

3.6.1 The coil used to produce the pipe shall be manufactured from fully killed, fine-grained

steel. Each coil shall have a proper traceable identification marked on its surface stating at least the heat number of the steel, the coil number and the steel grade. The marking shall bear clear reference to the relevant EN 10204 3.1 material certificate that must be issued to cover each heat of steel from which the coils are produced.

3.6.2 Manufacturer shall be responsible for the quality of the coil once it has been accepted for

pipe manufacture irrespective of the coil source. 3.6.3 Strip shall be rolled from continuously cast slab. All parent metal shall be from a single

source and come from an identical manufacturing/processing route. 3.6.4 A well established and documented rolling/forming practice shall be used and the mill

shall be adequately instrumented to ensure proper control of start and finish rolling tem-perature, rolling reduction and post rolling cooling rate, and hence consistency in the me-chanical properties of the product.

3.6.5 Strip thickness shall be controlled by continuous gamma or x-ray devices. After rolling but

prior to ultrasonic testing, at least 2 mm shall be removed from each edge of the strip. Strip edges shall be milled to the required width prior to forming.

3.6.6 Details of strip heat treatment shall be submitted to Company for approval as a part of

the manufacturing procedure specification (see 3.1). 3.6 Coil Material Testing Requirements

3.7.1 Two (2) coils out of each of the first five (5) heats of steel (10 coils) shall be subjected to

mechanical testing. If from these tests it is evident that uniform results have been reached, subsequent

testing may be reduced to one coil out of each heat of steel or as otherwise agreed with Company.

3.7.2 The following tests shall be carried out on each of the selected test coils in accordance

with this specification:

• Two test specimens, one taken perpendicular to the final direction of rolling and one taken in the direction of rolling (transverse and longitudinal), shall be removed from the coil and used to determine the yield strength, ultimate tensile strength and elongation.

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• Chemical analysis of the coil material.

• Charpy Testing.

3.7.3 The results of the above stated testing shall be recorded on 3.1 certificates according to EN 10204.

On receipt of coils in the pipe mill the following confirmation tests shall be carried out: One sample shall be removed from each of 3 coils form different heats, as selected by

Company, and tested in accordance with 3.7.2. This testing will be a Hold point for Company.

3.7.4 Coil material shall be ultrasonically inspected along its edges and across its surface area

in a pattern agreed to and approved by Company and the Certifying Authority. 3.7.5 Manufacturer shall demonstrate to Company the proposed methods of ultrasonic

inspection and prove that it can meet the required standards of detection outlined in this Specification.

3.7.6 Isolated laminations in the remaining part of the body of the coil shall not exceed 100

mm measured in any direction and shall not number more than one occurrence of lamination per two square meters of surface area.

3.7.7 If during subsequent cutting of the coils, laminations or other defects are discovered

which are greater in size than the dimensions outlined above, the coil in question shall be replaced by Manufacturer without cost to Company.

3.7.8 All strip for HFIW pipe shall be ultrasonically examined according to EN 10246-15 for

laminations over a width of at least 25mm from all final edges where welding is to be carried out. Inspection, other than edge inspection, may be carried out on the pipe instead of the strip subject to agreement by Company.

3.8 Manufacturing Process of the Pipe

3.8.1 The pipe shall contain one straight seam weld made by welding the longitudinal edges

of coil as it is preformed using the high frequency induction welding process. The joint efficiency factor for the weld shall be 1.0.

Welding procedures shall be submitted for approval by Company as part of the M.P.S.

and be in compliance with ANSI/API 5L./ISO 3183. The Contractor shall provide records to the satisfaction of the Company to prove that all welding operators have adequate training and experience.

3.8.2 All pipe shall be subjected to heat treatment. The final heat treatment procedure shall be in

accordance with the Company approved MPS.

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3.8.3 The heat treatment shall consist of a simulated normalizing treatment including, as a minimum, either weld seam or full body tempering.

3.8.4 All pipe forming which result in pipe with a permanent strain greater then 0.05 shall be full body heat treated. Strain shall be calculated by dividing the nominal Wall Thickness by the Outside Diameter.

3.8.5 If only the weld seam area is tempered then the width of the tempered zone shall be a

minimum of 10mm on each side of the weld line at the inner pipe surface as established by a visual macro-etch. Full details of heat treatment temperatures and times, heated band widths (internal and external) and cooling rates shall be submitted to the Company for approval as part of the MPS. The Contractor shall provide evidence that the heat treatment will ensure a consistent fully refined microstructure in the weld area.

3.8.6 Each pipe produced shall be uniquely marked to ensure its traceability throughout the

manufacturing process.

3.8.7 The inside and outside weld bead shall be removed prior to the pipe passing through non-destructive testing

3.8.8 Individual pipe joints shall not contain any circumferential weld from joining different

coils.

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4 Inspection

4.1 An inspection and test plan shall be included as part of the Manufacturing Procedure Specification that Manufacturer is required to submit to Company for approval.

This plan shall include, but not be limited to, the following information:

• A list of inspection and testing actions.

• The order and related time period in which each action shall take place.

• Whether the action should be monitored or witnessed by Company and/or the Certifying Authority.

Manufacturer shall endeavour to adhere as closely as possible to the submitted

planning. Should significant changes in the planning be unavoidable a revised and updated copy shall be given to Company without delay. In order that Company and/or the Certifying Authority may, at their discretion, witness any inspection or testing Manufacturer shall give Company at least ten (10) days written notice stating date, time and location of such actions.

4.2 Company, at its discretion, reserves the right to inspect the pipe or base material at all or

any of the manufacturing stages; accordingly, free access to the pertinent sections of Manufacturer's, or its Sub-Contractor’s, premises for this purpose shall be available at all times during the production of Company's order.

Manufacturer shall provide suitable office space and inspection facilities as required by

Company and the Certifying Authority in the plant where the pipe or base material is being produced.

4.3 Company reserves the right to conduct or require Manufacturer to perform additional

testing should it be deemed necessary. The testing methods and procedures shall be confined to those outlined in this Specification.

4.4 In the event that particular defects are continuously found in the finished product,

Company and Manufacturer shall mutually agree on, and Manufacturer shall implement, any additional procedures and inspection methods which may be necessary to correct the faults and to ensure that the particular type of defect does not re-occur during subsequent production. In such a case, the cost of implementing any additional procedures and inspection shall be borne by Manufacturer. Under no circumstances shall any action or omission of Company relieve Manufacturer of his responsibility for the quality of the finished pipe. In all cases where Company or the Certifying Authority has rejected pipes, the burden of proof that the rejected pipes do meet the requirements lies solely with Manufacturer.

4.5 Ample lighting, both overhead and at pipe ends (for internal inspection) shall be provided

for Company's inspector at the final inspection bench. The possibility of rolling each pipe for inspection purposes shall be provided.

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Manufacturer shall have personnel and ultrasonic or other suitable equipment available for use on Company inspector’s instructions to examine remaining wall thicknesses after defects are ground out.

4.6 If 10% or more pipes from any one shift's production are rejected for any re-occurring

type of defect, this shall be sufficient reason for Company's inspector to refuse any more pipes for final examination until the cause of the defect has been established and eliminated.

4.7 It shall be Manufacturer's responsibility to remove pipes not meeting the requirements of

this Specification. 4.8 Company shall have the final decision as to the acceptability of the finished pipes

meeting the requirements of this Specification. 4.9 Company's Representative shall, after final inspection and acceptance, release the pipes

for shipment. Copies of the written release notes shall be distributed as follows:

� Original to Company. � One copy to Manufacturer. � One copy to the Certifying Authority. � One copy to Company's Representative.

4.10 3.2 certificates to EN 10204 shall be required to cover all pipes that pass final inspection.

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5 Chemical Requirements

5.1 Cast (Ladle) Analysis

5.1.1 The chemical composition of the steel grade specified shall be in accordance with the

following table. Elements not mentioned in this table shall not be added intentionally without Company approval except for elements which may be added for deoxidation and

finishing the heat (see note a) in table).

Maximum content by % mass Grade C d Si Mn d P S V Nb Ti Ca Others

L360 X52

0.16 0.45 1.60 0.025 0.020 0.05 0.05 0.04 0.006 a

L415 X60

0.16 0.45 1.60 0.025 0.020 0.08 0.05 0.06 0.006 a,b,c

L450 X65

0.16 0.45 1.60 0.025 0.020 0.10 0.05 0.06 0.006 a,b,c

L485 X70

0.16 0.45 1.60 0.025 0.020 0.10 0.05 0.06 0.006 a,b,c

a) 0.015 ≤ Altot <0.060: N ≤ 0.012: Al ≥ 2 ; Cu ≤ 0.25; Ni ≤ 0.30; Cr ≤ 0.30; Mo ≤ 0.10. N 1 b) The sum of V, Nb, Ti shall not exceed 0.15% (see 5.1.2) c) For these steel grades, a molybdenum content up to 0.35% may be agreed. d) For each reduction of 0.01% below the max. carbon content an increase of 0.05% man-

ganese above the specified maximum value is permitted with a max. increase of 0.2%.

In addition the carbon equivalent value (CEv ) as determined by the following formula shall be as low as possible to obtain the required mechanical properties but in any case it shall not exceed 0.41 for the product analysis.

CEv = C + Mn + (Cr+Mo+V) + (Cu+Ni) %

6 5 15 5.1.2 Should manufacturer propose that vanadium, niobium and titanium be added to the steel

to obtain the required mechanical properties, the proposed quantities of each element shall be stated at the time of submitting the tender documents. In any case the total per-centages of these elements shall not exceed 0.15% without prior written approval from Company, which will only be given after agreement has been obtained from the Certifying Authority.

5.1.3 The chemical check analysis shall show the actual percentages of all elements referred to in this Specification.

5.1.4 The results of the cast (ladle) analysis for each heat of steel used for Company’s order

shall be recorded by means of 3.1 certificates according to EN 10204.

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5.2 Frequency of Cast (Ladle) Analysis

Contractor shall provide the cast (ladle) analysis for each heat of steel. The cast analysis

shall not exceed the chemical composition requirements as specified in section 5.1. 5.3 Product Analysis

5.3.1 A product analysis shall be performed and taken from the mechanical test samples. All

specified elements and CEv shall be reported and meet the specified limits. 5.3.2 The acceptable deviation of the product analysis from the heat (ladle) analysis shall

comply with the following table;

Element

Limiting value for the cast analy-sis according to 5.1

% by mass

Permissible deviation of the product analysis

% by mass C ≤ 0.16 + 0.02

Si ≤ 0.45 + 0.05

Mn ≤ 1.60 + 0.10

P ≤ 0.025 + 0.005

S ≤ 0.020 + 0.005

V ≤ 0.10 + 0.01

Nb ≤ 0.05 + 0.01

Ti ≤ 0.06 + 0.01

V + Nb + Ti ≤ 0.15 + 0.02

Cr ≤ 0.30 +0.05

Ni ≤ 0.30 + 0.05

Mo ≤ 0.10 + 0.03

Cu ≤ 0.25 + 0.05

Al ≤ 0.015 < 0.060 ± 0.005

N ≤ 0.012 + 0.002

5.3.3 Product analysis methods shall be submitted for Company review. 5.4 Frequency of Product Analysis

5.4.1 A product analysis shall be performed on one of the first pipes from each heat, and each

batch of 50 pipes if there are more than 50 pipes in a heat. The elements listed in 5.1.1 and 5.3.2, and any other intentionally added elements, shall be reported by Contractor.

5.4.2 A product analysis shall be performed on at least 2 samples per heat, taken from the

mechanical test samples. All specified elements and CE shall be reported and meet the specified limits.

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5.5 Test Failures

a) Only those coils that meet the agreed limits will be accepted for rolling to pipe. b) If any product analysis falls outside the agreed limits two further determinations

shall be made from the same test coupon. If either of these falls out of the agreed limits, then the analysis shall be undertaken on each pipe from the heat and only those which meet the agreed limits will be deemed acceptable.

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6 Manufacturing Procedure Qualification Tests

6.1 General

One completely finished pipe shall be subjected to full non-destructive and mechanical

testing as noted below prior to the start of production or immediately after any changes in the approved manufacturing procedure. Production of pipe should not commence until the results of the testing have been accepted, and approval has been given to proceed, by Company and the Certifying Authority.

However, Manufacturer may, entirely at his own risk, elect to qualify the manufacturing

procedure whilst first day production is in progress. This means that if the manufacturing procedure qualification tests are rejected by Company or the Certifying Authority for any reason all pipes produced up until that time shall also be rejected. Qualification of the manufacturing procedure in parallel with the first day's production does not eliminate Company's requirement for first day production tests (see 7.1.1). Testing shall be performed at a certified testing facility or an approved alternative.

6.2 Non-destructive Testing Requirements

Visual: complete internal and external pipe surface including seam weld area. full dimensional control

Sections 8.0 and 12.0

After acceptance of visual examination the following inspections and checks shall be performed on the test pipe:

Ultrasonic: 100% of longitudinal seam weld 100 mm wide full circumferential band at each end of the pipe.

Section 8.2

MPI: complete weld bevel at each end of the pipe.

Section 8.4

Residual magnetism: around the circumference of each pipe end.

Section 8.6

Hydrostatic: Full pressure test Section 10

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6.3 Mechanical Testing Requirements

The test pipe shall be subjected to the following tests:

Longitudinal Tensile test

3x As per,9.2 1x Strain Aged as per 9.2.4

Transverse Base Material Tensile test 3x As per 9.3

Transverse Weld Tensile test 3x As per 9.3

Hot Tensile Test 1 as per 9.4

Flattening test 2 x 2 end of coil samples. 2 x weld stop samples

Charpy V-Notch Test Transition Curve samples (see 9.6.2) 1 x set transverse base material 1 x set longitudinal base material 2 sets of 3 transverse weld specimens (1 set each: centre of weld, +2 mm from fusion line). As per 9.6 Strain Aged Samples as per 6.5

Macro 12 x transverse weld As per 9.7

Hardness / on 2 of the macro specimens

Chemical Analysis As per 5.0

6.4 Testing Details

Full details of the tests stated above, including acceptance criteria, are given in the

referenced Sections of this Specification.

6.5 Strain Ageing Test (if required in the Scope of Work)

A sample taken from the pipe shall be strained 2.0% in a direction transverse to the

longitudinal axis of the pipe and then heated for 1 hour at 250ºC. Three Charpy specimens shall be machined from the sample in the transverse direction and tested to the requirements of this Specification. Charpy values shall meet the requirements given in Section 9.4 of this Specification and all specimens shall display at least 80% shear area.

Additionally strain aged charpy testing shall be carried out on a set of samples taken from each of the following locations, pipe body, weld fusion line and weld fusion line +2mm. These specimens shall be removed from a pipe which have been subjected to a 2% longitudinal tensile strain and an aging treatment of 250°C for 1 hour and then tested in accordance with and meet the requirements detailed above.

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6.6 Surface Quality

The surface quality shall be checked on an ongoing basis to confirm lack of surface

defects and its suitability for coating. 6.7 Weldability Testing

6.7.1 The pipe shall be suitable for field welding with SMAW, GMAW, SAW or GTAW proesses without the need for pre-heating or post weld heat treatment.

6.7.2 Contractor shall submit to Company, for approval, historical weldability results showing acceptable weldability without the need for preheating or post weld heat treatment. The historical data shall show acceptable weldability on a similar grade and pipe size as to be used.

6.7.3 In the case of historical weldability results not being approved by Company a Weldability

test shall be carried out as per ISO 3183:2007. Company will provide to Contractor the welding procedure specifications, which the selected installation Contractor is proposing to use for the joining of the pipe. Contractor shall review these procedures for suitability and select one for the weldability tests.

6.7.4 Two weldability tests shall be performed. One shall be carried out using a Company ap-proved automatic pipe welding machine. The other shall be performed using Company approved manual shielded metal arc welding electrodes. No post weld treatment shall be used in making the welds. Pup pieces used for the tests shall be a minimum of 1.5 times nominal pipe diameter in length. The test pieces shall be welded in the 5G fixed position under the joint direction of the Manufacturer and Company. All welding parameters shall be measured and recorded. The weld shall meet all the tests required by Company and the Certifying Authority for welding procedure qualification. In addition, a hardness sur-vey using 10 kg Vickers on a macro section taken at the 3 o'clock position shall not re-veal any hardness greater than 240 HV10. Company shall select the locations on the macro section for the hardness determination. Hardness traverses shall be selected 1 mm from each pipe surface and at other locations. Hardness surveys shall also be car-ried out at the seam weld/girth weld intersection, as required by Company, with maxi-mum individual hardness limited to 240 HV10.

6.7.5 Subject to Manufacturer submitting acceptable historical data on weldability to Company for review, weldability testing may be waived.

6.8 Test Results

The test results shall be verified by means of original test reports and 3.2 certificates

according to EN 10204.

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7 FIRST DAY AND PRODUCTION TESTS

7.1 First Days Production Tests

7.1.1 Pipe Selection

Two pipes from the first day's production, if possible from different heats, shall be

selected at random by Company and/or the Certifying Authority for testing. The first day production tests shall be repeated after any change in the manufacturing

procedure or prolonged break (more than 7 days) in production. Should it be the intention of the manufacturer to carry out Manufacturing Procedure

Qualification Tests during actual production then the “First Day” Production Tests shall be carried out at the 50th Pipe stage of production. In this case only one pipe needs to be tested as “First Day Production” in addition to the MPQ pipe. The selected pipe(s) shall be tested as follows:

7.1.2 Non-destructive Testing Requirements

Visual: complete internal and external pipe surface including seam weld area. full dimensional control

Sections 8.0 and 12.0

After acceptance of visual examination the following inspections and checks shall be performed on the test pipe:

Ultrasonic: 100% of longitudinal seam weld 100 mm wide full circumferential band at each end of the pipe..

Section 8.2

MPI: complete weld bevel at each end of the pipe.

Section 8.6

Residual magnetism around the circumference of each pipe end.

Section 8.8

Hydrostatic : Full pressure test Section 10

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7.1.3 Mechanical Testing Requirements

Longitudinal Tensile test

3x As per,9.2 1 x Strain aged as per 9.2.4



Hot Tensile Test 1 as per 9.4

Flattening test one set As per 9.5

Charpy V-Notch Test

1 x set transverse base material 1 x set longitudinal base material 2 x sets transverse weld As per 9.6

Hardness / Macro 2 x transverse weld As per 9.7

Chemical Analysis Section 5

Reeling Simulation Test As per 9.10

7.1.4 Testing Details


referenced Sections of this Specification. 7.1.5 Test Results

The test results shall be recorded by means of 3.2 certificates according to EN 10204.

7.2 Production Tests

7.2.1 Non Destructive Tests

During production all pipes shall be subjected to the following inspections, checks and

tests:

Ultrasonic testing 100% of longitudinal seam weld 100 mm wide full circumferential band at each end of each pipe.

Section 8.2

Magnetic particle inspection complete weld bevel at each end of each pipe

Section 8.6

Visual inspection complete internal and external pipe surface including seam weld.

Sections 8 and 12

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full dimensional control.

Residual magnetism around the circumference of each pipe end.

Section 8.8

Hydrostatic testing: Full pressure test Section 10

7.2.2 Destructive Tests

In addition to the above tests Company and/or the Certifying Authority shall select one

pipe from each heat of steel, with a minimum of one pipe out of every 50 pipes, which shall be subjected to the following mechanical testing:

Longitudinal Tensile test 2x As per 9.2 *



Hot Tensile test 1 as per 9.4

Flattening test 4 test per coil plus 2 tests in the case of a weld stop. As per 9.5

Charpy V-Notch test 1 x set transverse base material 1 x set longitudinal base material (one every 100 pipes) 2 x sets transverse weld. As per 9.6

Hardness / Macro 2 x transverse weld As per 9.7

Chemical Analysis Section 5

7.2.3 Frequency and extent of Pipe Production Tests

Chemical composi-tion

Mechanical Testing

NDT and Hydrostatic

test

Dimensional inspec-

tion

One in every 50 pipes, minimum once per heat

one set of tests from each end of the first coil from each heat and a mid-coil from the same heat, with a minimum of one in every 50 pipes (unless otherwise stated). For flattening tests the requirement is 4 tests per coil; plus 2 tests in the case of a weld stop.

Each pipe (acc. to sections 08 and 10.)

Every pipe or every 50th pipe (acc. to Sec-tion 11.) unless other-wise requested by Company.

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7.2.4 Testing Details


referenced Sections of this Specification.

7.2.5 Test Results

The test results shall be recorded by means of 3.2 certificates according to EN 10204.

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8 NON-DESTRUCTIVE TESTING

8.1 General

8.1.1 Non-destructive testing, as outlined in this section, shall be performed on all pipes that

comprise part of Company’s order without exception. These inspections shall conform to ANSI/API 5L / ISO 3183.

8.1.2 Complete and detailed procedures for all non-destructive testing shall be submitted to

Company for review prior to commencement of testing. 8.1.3 All operators of NDT equipment shall have a thorough knowledge of the operation of the

equipment to be used and may be required to demonstrate their ability to carry out NDT to the satisfaction of Company before the start of manufacture. Operator qualification shall be to a minimum of EN 473 Level 2. An examiner qualified to EN 473 Level 3 in all NDT techniques used, shall be available.

8.2 Ultrasonic Testing

8.2.1 Prior to beginning ultrasonic testing, on production pipes, Manufacturer shall, in the pres-

ence of Company and/or the Certifying Authority, perform ultrasonic testing for the pur-pose of establishing the production testing procedure.

8.2.2 Manufacturer shall prepare representative test pieces containing welds having known

defects, or alternatively provide standard test pieces with machined notches (N5) and holes in accordance with the specified standard on which the ultrasonic procedure testing will be carried out. These test pieces shall be sections of pipe having the same diameter, wall thickness and a similar weld as the production pipe that is to be inspected and shall be of sufficient length to allow the testing to be performed at normal testing speed.

8.2.3 The ultrasonic equipment shall be capable of detecting longitudinal as well as transverse

defects. 8.2.4 Prior to ultrasonic inspection it shall be ensured that the pipe surface is free of any loose

scale, dirt, grease or other foreign substance that may affect the test results. Manufac-turer shall use a suitable couplant between probe and pipe to provide optimum conductiv-ity of signals

8.2.5 The equipment shall be regularly calibrated using reference specimens prepared from

production pipe, or standard reference blocks. 8.2.6 The ultrasonic equipment shall be re-calibrated as a minimum:

• at the start of each shift

• at the middle of each shift

• at the end of each shift

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• whenever a malfunction is suspected

• after any break in production of more than two hours. 8.2.7 Calibration of ultrasonic equipment shall be performed at production speed using a

test/master pipe with known defects in accordance with ANSI/API 5L / ISO 3183. If the equipment is found to be faulty or to require re-calibration all pipes tested since the pre-vious calibration shall be re-inspected. The results of all calibrations shall be recorded and made available to Company.

8.2.8 Ultrasonic testing shall be carried out after all heat treatment, expansion operations and hydrostatic pressure testing have taken place.

8.2.9 The entire longitudinal seam weld of the pipe shall be checked with automatic ultrasonic

equipment which shall give an audible signal and shall visually mark, by paint or dye, any area where ultrasonic indications outside the acceptance levels are given.

8.2.10 The full length of each welded seam shall be subject to automatic ultrasonic examination,

according to ANSI/API 5L / ISO 3183, for longitudinal defects. The ultrasonic equipment shall include shear wave probes and be calibrated against a reference block containing a 2.4mm diameter drilled hole in addition to longitudinal internal and external N5 notches.

8.2.11 The full circumference of each pipe end over a width of 100 mm shall be ultrasonically

tested, either manually or automatically, using a Company approved ultrasonic proce-dure, for defects outside the acceptance levels. The ends of all pipes shall be examined for imperfections by an ultrasonic method using probes for laminar defects and by an an-gle probe method for cracks. Procedure and defect acceptance levels shall be as speci-fied in ANSI/API 5L / ISO 3183. If the pipe is subsequently cropped, the new end shall be examined.

8.2.12 In case of continuous occurrence of signals outside the acceptance limits in areas where,

upon subsequent investigation, no defects are detected, further investigations using other methods shall be executed to establish the cause of the signals.

8.2.13 All inspection and testing equipment shall be calibrated and certificates of calibration

made available for Company review.

8.2.14 Locations where defects are indicated shall be re-examined by hand held Ultrasonics and Magnetic Particle or radiography.

8.3 Visual Inspection

8.3.1 Visual inspection of both external and, as far as possible, internal surfaces of the pipes

shall be carried out to ensure that they are free of laminations, gouges, dents, nicks or any other surface defects. Minor surface irregularities caused by the manufacturing proc-ess are permissible provided that the wall thickness falls within the allowable tolerances

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stipulated elsewhere in this Specification. Defects found outside the stipulated tolerances shall cause the pipe to be rejected

8.3.2 The Contractor shall submit details of procedures used for visual inspection of the fin-

ished pipe and also the reference standards for acceptance/rejection. 8.4 Magnetic Particle Inspection of Pipe Ends

8.4.1 The surface of pipe ends shall be smooth and free from tool marks. The ends and faces

of all pipes shall be completely inspected for laminations by a Company reviewed mag-netic particle inspection (wet) procedure, which is at least in accordance with ASME V, Article 7, on the inside and outside surfaces.

8.4.2 Acceptance levels shall be in accordance with ASME VIII, Division 1, Appendix 6.4 8.4.3 The inspection shall consider both circumferential laminar indications on the face and

longitudinal indications within 200 mm of the pipe ends. 8.4.4 Any longitudinal indications in the pipe body shall be further evaluated using ultrasonic

equipment. Circumferential indications on the face may be accepted in accordance with ISO 3183:2007.

8.5 Acceptance Criteria

8.5.1 Longitudinal Seam Welds : Offset of the prepared edges of the coil at the weld joint shall

not exceed the limitations specified in ANSI/API 5L / ISO 3183. Should any of the following defects be found during non-destructive testing the weld

shall be rejected: 1) Inclusions which exceed 1.5 mm in width or depth or 5 mm in length. 2) Lack of penetration or lack of fusion. 3) Cracks. (Repair of a weld containing a crack is not allowed). 4) Defects in the adjacent parent metal.

8.5.2 Pipe Ends: Laminations or other injurious defects found in the inspected areas shall cause the pipe

to be rejected. 8.6 Checks for Residual Magnetism

The total circumference of each pipe end shall be checked for residual magnetism at the

final inspection bench. Pipes found with magnetism above 20 Gauss shall be demagnet-ised and rechecked prior to load out.

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9 MECHANICAL PROPERTIES AND TESTS

9.1 General

9.1.1 Contractor shall be responsible for the performance, evaluation, reporting and recording

of all required tests. The acceptance criteria shall be as given in this Section. 9.1.2 Production testing of finished pipes shall be performed as indicated in Section 7.2 of this

Specification. 9.1.3 In order to determine the mechanical properties of the pipe, various specimens shall be

cut from the selected test pipes and shall be subjected to mechanical testing, and meet the acceptance criteria, stated below. No mechanical testing shall take place on any pipe until the pipe has successfully passed the stipulated non-destructive and Hydrostatic Pressure Tests.

Company shall have the right to select pipes for production testing. 9.1.4 Test coupons shall be removed from alternating pipe ends. A set of test specimens shall be taken from the selected test pipes in accordance with the

requirements of ISO 3183:2007 and as detailed below. The samples shall be tested at room temperature.

9.2 Longitudinal Tensile Properties

9.2.1 Two Longitudinal tensile specimens per 100 lengths of pipe, or as a minimum once per

heat, shall be machined from the pipe body as indicated in ISO 3183:2007 and tested at room temperature (20ºC). The acceptance criteria shall be as stated below:

Item X52 L360

X60 L415

X65 L450

X70 L485

Minimum Yield Strength (N/mm2) Rt 0.5 Maximum Yield Strength (N/mm2) Rt 0.5 Minimum Tensile Strength (N/mm2) Minimum Elongation (%) Maximum Yield to Tensile Ratio : For Transverse samples For Longitudinal samples

360 460

460

notes 1 & 2

0.85 0.86

415 515

520

notes 1 & 2

0.86 0.87

450 550

535

notes 1 & 2

0.87 0.88

485 585

570

notes 1 & 2

0.88 0.90

Note 1: As per ISO 3183, Table 7 note f.

Note 2: The elongation shall be measured with a calibrated mechanical extensometer or multiplying dividers.

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9.2.2 The actual yield strength of the base material shall be as close as possible to the speci-fied minimum yield strength but shall, in no case, be more than that stated in 9.2.1.

9.2.3 Additionally, and if required in the Scope of Work, strain aged longitudinal tensile testing

shall be carried out as follows. The sample shall have been subjected to a 2% longitudi-nal tensile strain and an aging treatment of 250°C for 1 hour and then tested in accor-dance with the requirements of this specification. The yield to UTS ration shall not, in this case, exceed 0.90.

9.3 Transverse Tensile Properties

9.3.1 At least one transverse tensile test per 50 lengths of pipe, or as a minimum once per

heat, shall be required from the pipe body at 90° to the weld. The use of the ring expan-sion method for determination of transverse yield strength shall not be acceptable.

9.3.2 Transverse tensile properties shall conform to section 9.2.1. and 9.2.2. Reduction of Area

shall be reported. Round bar tensile test specimen may be used for transverse tensile tests.

9.3.3 One transverse Cross Weld Test shall be taken with the weld at the centre of the strip

and shall represent the full wall thickness of the pipe from which the specimen was cut. Weld tensile tests need not include determination of yield strength and elongation. The UTS shall be in accordance with 9.2.1 and the fracture position reported.

9.4 Hot Tensile Tests

9.4.1 If not included in the Scope of Work Contractor shall confirm with INGL whether Hot Ten-

sile Testing is required. In principal this is only a requirement when the design tempera-ture for the line pipe is greater than 50°C.

9.4.2 If required, at least one longitudinal hot tensile test per 50 lengths of pipe, or as a mini-

mum once per heat, shall be required from the pipe body. The test shall be carried out at 150 °C and the minimum acceptable yield strength shall be as follows:

API 5LGrade X52 X60 X65 X70

ISO 3183 Grade L360 L415 L450 L485

Minimum

Yield strength in N/mm2

(at 150 °C)

284 343 373 392

Maximum Yield Strength

See 9.2.1 above.

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9.5 Flattening Test

9.5.1 Flattening Test Samples: The size and preparation of the test samples and subsequent testing of it shall be in

accordance with the requirements of ISO 3183:2007. Flattening shall take place to 1/3, 2/3 and opposite sides touching of the original pipe

diameter. 9.5.2 Acceptance Criteria:

After flattening the test samples shall meet the following criteria:

• No weld opening at 2/3 flattening of original diameter.

• No crack or break other than in weld at 1/3 flattening of original diameter.

• No laminar or burnt metal apparent during flattening.

9.6 Impact Strength (CharpyTesting)

9.6.1 Specimens for Charpy V-notch testing shall be removed from the same selected test

pipe as the tensile test specimens. The size, preparation and testing of these specimens shall conform to the requirements of ISO 3183:2007.

9.6.2 For the manufacturing procedure qualification tests only, a total of 18 transverse Charpy

V-notch impact test specimens (six sets of three pieces) shall be removed from each test pipe. The five sets shall be tested in sequence at temperatures of -80° (for information only), -60°, -40o, -20o, 0o, and +20o Celsius to establish the transition curve. The values achieved at -20o C. shall be used to evaluate the test.

9.6.3 All other required impact test specimens taken from any of the designated test pipes

shall be tested at -20o C.

Transverse weld specimens shall be prepared so that the V-notch is located in the centre of the weld and fusion line +2 mm.

Transverse base material specimens shall be taken from each test pipe perpendicular to

the longitudinal axis of the pipe. Longitudinal base material specimens shall be taken in the direction of the longitudinal

axis of the pipe. The V-notch shall be machined in each specimen so that it runs perpendicular to the

pipe surface.

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Tongs for handling the test specimens and centring devices shall be at the same

temperature as the test specimen prior to each test. 9.6.4 Charpy impact tests (one set of 3 specimens for each location).shall be carried out on

specimens taken transverse to the pipe axis and machined with the notch in the following positions (Note: COMPANY may request etching to prove notch location):

a) Parent material b) Weld (fusion line) c) Fusion line +2mm

Minimum Impact Energy in Joules (at –20 °C)

Parent Material Weld and FL+2mm

Specimen size

In mm

Min. Av. Set of 3

Min. Single Min. Av. Set of 3

Min. Single

10 x 10*

100J

80J

45J

35J

* Specimen size means 10 x 10 mm with a 2mm notch machined in the centre with a depth of 2mm.

Only one value, of the three specimens tested, is allowed to be below the minimum av-erage with a minimum no less than the single value.

Energy Reduction Factors (ERF) for Sub-size Specimens

Specimen Section (in mm) ERF

10 x 10 1.00

10 x 7.5 0.83

10 x 5 0.67

10 x 2.5 0.5

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9.7 Macrostructure and Hardness Tests

9.7.1 Test Specimens Specimens for the examination of the macrostructure and for the determination of

hardness values shall be taken perpendicular to the longitudinal axis of the pipe with the seam weld located in the centre of the specimen.

The width of the specimens shall be at least three times the pipe wall thickness. The

specimens shall be suitably machined and etched to reveal the macrostructure, which shall be examined and photographed at up to 10 times magnification.

The hardness checks taken in accordance with ISO 3183:2007 employing a Vickers

hardness value of 10 kg. shall cover the weld, the heat affected zone and the base material. They shall consist of at least twelve readings taken in lines following the outside contours of the cross section and at a distance of approximately 2 mm below the top and above the bottom of the specimen.

On each line one reading shall be taken in the weld material, while at each side of the

weld two readings shall be taken in the heat-affected zone and two in the base material. In addition at least four readings shall be obtained approximately equally spaced in the centre line of the weld, perpendicular to the plate surface.

For the manufacturing procedure qualification tests a total of 12 specimens shall be

taken and prepared for macrostructure examination, two of these specimens shall further be used for hardness measurements. For the first day production and standard production tests, each test specimen shall be used for both macrostructure examination and hardness measurements.

9.7.2 Acceptance Criteria Macrostructure examination shall determine if the structure of the metal is sound and

free from cracks, stringers, inclusions, grain flow, etc. The type and amount of any inclusions found during macro examination shall be evaluated and the results recorded.

If irregularities or defects are found, further investigations shall be carried out on the same pipe initially tested. If the irregularities or defects initially detected are not an isolated case, additional macrostructure examination and/or NDT shall be carried out on the remaining pipes of the lot.

The maximum acceptable hardness value is 240 HV10. 9.7.3 Macro photographs shall clearly show the indentations caused during hardness readings.

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9.8 Defective Specimens

9.8.1 If any test specimen (MPQ/FDT or Production) fails to meet any of the specified require-

ments the reason shall be determined and re-testing may be permitted, after Company approval, as follows:

9.8.2.1 Tensile, hot tensile and flattening / bend tests:

• Two specimens, for each failed specimen, shall be removed from the area adja-cent to that from which the initial specimens were removed and shall be tested as per the requirements of this specification.

• If one or both specimens fail to meet the specified requirements the pipe in ques-tion shall be rejected and one specimen shall be taken from each of two other pipes selected by Company from the same heat as the original test pipe.

• Should any one of these specimens fail, the entire heat of steel or production run may be rejected. In all cases Company reserves the right to the final decision.

9.8.3.2 Impact tests:

• If the 3 specimens do not achieve the specified average requirement no re-testing shall be allowed and the heat of steel shall be rejected.

• If a single specimen fails to meet the specified single value requirement, two sets of 3 specimens shall be removed from the area adjacent to that from which the initial specimens were removed and shall be tested as per the requirements of this specification.

• If any one of the retest specimens fails to meet the specified requirements the pipe in question shall be rejected and one set of specimens shall be taken from each of two other pipes selected by Company from the same heat as the original test pipe.

• Should any one of these specimens fail, the entire heat of steel or production run may be rejected. In all cases Company reserves the right to the final decision.

9.9 Re-Heat Treatment

Re-heat treatment is not allowed, unless agreed in writing with INGL and after submittal

of justifiable reasons such a course of action. In this case the cost of any further (extra) testing required by INGL shall be met by CONTRACTOR.

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10 HydrostaticTesting

10.1 Each finished pipe shall be satisfactorily tested at the mill in accordance with API 5L/ISO 3183 Section 10.2.6.

The required minimum test pressure shall be calculated using the formula in API 5L/ISO

3183, section 10.2.6.5, at a hoop stress of 90% of SMYS. The upper limit of the test pressure shall not exceed 160 bar g. 10.2 The full test pressure shall be maintained for a minimum of 15 seconds on each pipe. 10.3 All recording equipment and gauges shall have a current certificate of calibration. Cali-

bration reports to be submitted to Company and to be included in the MRB (see 12.2 and 12.3)

10.4 The pressure test chart recorder shall be calibrated against the master gauge at least

twice per working shift. All hydrostatic pressure tests shall be chart recorded and log sheets. The frequency of master gauge calibration shall be increased if shown to be un-stable.

10.5 Test information shall be recorded on suitable log sheets/pressure charts, which shall

identify each pipe against its record, and these shall be made available to Company or its representative on request. The log sheets/pressure charts shall be retained as a re-cord.

10.6 Any pipe which leaks (or bursts) during test shall be rejected, quarantined and returned

for a joint investigation by Manufacturer and COMPANY. All other pipes from the same heat shall be quarantined pending the results of the investigation.

10.7 For every batch of pipes tested, an overall Hydrostatic Test Report shall be compiled

showing all essential PO information, i.e. the pipes tested (pipe numbers), the pressure used, holding time, the test results, etc. This report to be stamped/signed by the Com-pany and/or Certifying Authority and included in the MRB (See 12.3.1).

10.8 In cases where a pressure test is discontinued because of a temporary failure of the test

equipment, the pipe number of the pipe under test at the time of failure shall be recorded on the log sheets/pressure charts and it shall be shown clearly that the pipe has later re-ceived its proper test. Both records shall be retained as evidence.

10.9 Hydrostatic testing shall be performed prior to NDT.

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11 DIMENSIONS, WEIGHTS AND LENGTHS

11.1 Diameter - Pipe Body

11.1.1 The outside diameter of every 50th pipe shall be measured, using a diameter tape in ac-

cordance with a procedure approved by Company, at a minimum of two locations equally spaced along the length of the pipe. The O.D. of the pipe body shall not deviate from the specified nominal value by more than +1.5mm and –2mm.

11.2 Diameter - Pipe Ends

11.2.1 The inside diameters of both ends of every pipe shall be checked using a "Go - No Go"

gauge. The size of the “Go” plate shall be the nominal inside diameter minus 1.6 mm and the size of the “No-Go” plate shall be the nominal inside diameter plus 1.6 mm.

11.2.2 The “Go-No Go” gauge shall be of a design approved by Company. At the start of every

shift the dimensions of the “Go-No Go” gauge shall be checked. Alternatively and for the purpose of this requirement only the nominal diameter may be replaced by a fixed refer-ence internal diameter deviating from the specified nominal internal diameter. This fixed reference internal diameter shall not deviate more than +/- 1.5mm from the specified nominal internal diameter and shall be constant for the whole Contract. Company shall approve the value of this fixed reference diameter before the manufacturing of the gauges.

11.2.3 The inside diameter of every 50th pipe shall be measured at both ends. The minimum

and maximum value shall be determined using a rod gauge or similar measuring device capable of measuring with an accuracy of minimum 0.1mm. The measurements shall be taken at least 10mm from the pipe end inside the pipe and shall reflect the actual mini-mum and maximum value by multiple measurements within the same plane. The meas-ured minimum and maximum values shall be recorded and included in the MRB.

11.3 Out of Roundness - Pipe Body

11.3.1 The outside diameter of every 50th pipe shall be measured, using a diameter tape in ac-

cordance with a procedure approved by Company, at a minimum of 3 locations on the body of the pipe.

11.3.2 The difference between the maximum and minimum outside diameters on any one-pipe

length shall be less than 0.7%. 11.3.3 If a pipe fails to meet the requirements of 11.3.1 or 11.3.2, the previous 49 pipes shall be

measured and every following pipe shall be measured until such time that 20 consecu-tive pipes have been accepted, at which stage the inspection may revert back to every 50th pipe.

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11.4 Wall Thickness

The allowable tolerance on wall thickness over the complete pipe length shall be maxi-

mum + 10% of the nominal wall thickness with a reduction of 5% of the nominal wall thickness in local areas.

11.5 Nominal Weight

The weight of each pipe shall be recorded. Contractor shall provide the accuracy of weight measurements for review by Company. The weight shall not vary by more than -3.5 / +10% of the nominal pipe weight.

11.6 Length

11.6.1 The length of each pipe shall be measured and recorded. 11.6.2 A linepipe joint length range (Min/Max) of 12.2m +/- 0.3m with an average length of

12.2m is required. Manufacturer may propose different lengths which will be subject to approval by INGL. 11.6.3 Pipes outside of this range MAY be considered for use as Weld Procedure Qualification

pipes provided that they meet the relevant requirements. 11.6.4 Jointers shall not be permitted. 11.7 Straightness

The maximum deviation from a straight line shall not exceed 12mm over the whole

length. A minimum of 2 pipes per 50 shall be measured for straightness with the fre-quency increasing for out-of-straightness above 12mm. All pipes shall be rolled over a flat inspection bench to visually demonstrate straightness. Any pipe visually exhibiting out-of-straightness shall be measured.

11.8 Squareness

The squareness of the ends of finished pipes shall be checked in accordance with the

requirements of EN 10208-2 section 8.6.4 on pipes selected by Company. Full details of the method used shall be provided to Company for review.

The results of the squareness test shall be recorded and shall include pipe numbers and

all dimensions.

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11.9 Pipe Ends

11.9.1 All pipes shall be supplied with bevelled ends as shown in Appendix 1 unless otherwise

specified in the Scope of Work, and be free from harmful burrs. 11.9.2 The weld flash on the external and internal surfaces pipe shall meet the requirements of

section 12.4.

11.10 Bulges and Flat Areas

Deviations from the original contour of the pipe shall not exceed 3 mm in height or depth

or extend in any direction for a distance greater than 25% of the pipe diameter. Devia-tions are not allowed within 100 mm of the ends of the pipe.

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12 REPAIRS AND SURFACE FINISH

12.1 Dents

Dents are not allowed. 12.2 Defects

Any imperfections outside those allowed by ISO 3183:2007, shall be considered a defect.

Contractor shall provide details of the procedure to be used for visual inspection of inter-nal and external surfaces of the finished pipe.

12.3 Hard Spots

12.3.1 Hard spots shall be as defined by ISO 3183:2007 except that the hardness limit of this

Specification shall apply. 12.3.2 Contractor shall state in the manufacturing procedure specification the steps taken in

production to prevent the presence of hard spots.

12.4 Weld Flash

12.4.1 The outside flash of the weld shall be trimmed to a flush condition.

12.4.2 The inside flash of the welded pipe shall be trimmed with the height of the residual flash

no greater than 0.5mm.

12.4.3 The Contractor shall also demonstrate to the satisfaction of Company that any remnant of weld bead will not interfere with ultrasonic interpretation.

12.5 Repair of Defects

12.5.1 Repair of injurious defects in the base metal by welding shall not be permitted. However,

the defects may be removed by cutting off, as a cylinder, the section of pipe containing the defect. The remaining defect-free section of pipe shall be acceptable provided all di-mensions are within the specified tolerances prescribed in this Specification.

12.5.2 Any joint of pipe containing cracks in the seam weld, other than those occurring within

200 mm of the pipe end and which can be removed by cropping (as per Section 12.5.1), shall be permanently rejected

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12.5.3 The repair of dents shall not be permitted. 12.5.4 Minor defects in the base metal may be removed by grinding, provided the remaining

wall thickness falls within the wall thickness tolerances laid down in this Specification. The transition between the ground area and the original surface shall be smooth.

12.5.5 No repair(s) or surface grinding shall be performed after hydrostatic testing. If re-

pairs/grinding have been carried out after hydrostatic testing, the said pipe shall be re-tested

12.6 Rejections

If, at any stage in production, the pipe failure rate exceeds 5%, the quality control pro-

gramme shall be increased. If the total of test failures exceeds 10% of those tested or if, on any one day, more than 10% of the production is rejected, Contractor shall identify and eliminate production problems immediately.

12.7 Surface Finish

12.7.1 Acceptance criteria for surface finish shall be agreed between Contractor and Company

prior to commencement of production. 12.7.2 The pipe shall be free of all extraneous material such as oil, grease, metal turnings, etc.

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13 13 Pipe Marking

13.1 Identification and Marking

13.1.1 It is Contractor’s responsibility that all materials supplied to this Specification are cor-

rectly marked for identification against the certificate. When material is stored, the iden-tification marking shall be easily accessible.

13.1.2 Materials, which cannot be identified, shall be rejected. 13.1.3 Marking shall, in general, comply with the requirements of ISO 3183:2007, but die

stamping shall be used as specified in 13.2. The following data shall be stencilled on the inside of the pipe close to the pipe end, at

both ends of the pipe, in clearly legible letters and figures.

1. INGL (and Project name) 2. Purchase Order Number 3. Type of material. 4. Pipe number. 5. Heat number. 6. Pipe length, wall thickness and weight. 7. Month and year of manufacture. 8. Manufacturer's mark. 9. Third-party inspector's mark.

A painted rectangular frame shall enclose and clearly indicate the location of this data.

The digits shall be at least 22 mm high and shall be stencilled in white paint. 13.1.4 A stencil line in heat resistant paint shall be made in the pipe bore at the weld line posi-

tion.

Contractor shall submit details of stencil format for INGL approval prior to use.

All pipe markings shall be inspected prior to dispatch and any pipe lengths not correctly marked shall be rejected until identity is verified and the pipe correctly marked.

13.2 Die Stamping

13.2.1 In addition to the stencilled data mentioned in 13.1 Manufacturer shall low stress die-

stamp, on both pipe ends, the pipe number and heat number.

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13.2.2 Alternatively the heat number can be represented by code letters, or like, which will allow easy identification when reference is made to supporting documentation.

13.2.3 These numbers shall then be coated with clear lacquer to maintain visibility.

13.3 Colour Coding To distinguish between pipes of different wall thickness in the same diameter for use in different location classes, pipes shall be colour coded. The coding shall be a circumfer-ential paint strip at each end of each pipe. The following colours shall be used in order of increasing wall thickness: a) No colour -- class location 1 b) Yellow --- class location 2 c) Red ------- class location 3 d) Blue ------- class location 4 If any such colour coding is not visible after coating, said colour code shall be applied again after the coating operation.

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14 Coating and Corrosion Protection

14.1 External Coating The coating shall be carried out in accordance with specification Nº. EEN-EPI-SPC-011 ”Polyethylene Coating for Steel Pipes". Each pipe end shall be free of coating for 150 mm with a tolerance of ± 10 mm. The ends of the coating shall have a flat beveled surface. Non-coated pipes shall be free of all rolling scale, dirt, paint, oil and grease.

14.2 Internal Coating Each pipe with DN ≥ 450 shall be delivered with internal epoxy coating in accordance with specification Doc. Nº. EEN-EPI-SPC-013 "Internal Coating of Steel Pipes DN ≥ 450 mm", except small supplies, when agreed.

14.3 Corrosion Protection Bare pipes supplied in accordance with this specification shall be cleaned on outer sur-face by blasting and painted with one coat of primer. Said primer shall be fit for field coating by bituminous or polyethylene coating material and shall protect the pipe surface against corrosion during shipment. 50 mm of each welding end shall not be coated by primer. All bevel ends from the pipe shall be protected temporarily against corrosion by a protec-tive layer, which can be easily removed on site, e.g. by a wire brush.

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15 Documentation

15.1 General

Manufacturer shall provide INGL with comprehensive documentation as outlined below,

covering all the phases of work concerned with fulfilling the order. All documentation shall be written in the English language and shall bear clear reference to INGL's purchase order number(s) and project name.

15.2 Manufacturing Procedure Specification

Prior to Manufacturing Procedure Qualification Tests, Manufacturer shall submit to INGL

for approval a Procedure Specification stating, but not limited to, details of the following for both coil and/or pipe as applicable: a. Name of steel mill b. Steel making method c. De-oxidation practice d. De-sulphurisation practice e. Anticipated pipe steel specification and intended chemical composition range f. Special additions g. Ladle treatments h. Method of hydrogen content control i. Name of plate rolling mill j. Rolling details (including finish rolling) k. Rolling equipment used l. Rolling temperatures (for all stages of rolling), cooling rates and percentage reduc-

tion below 950 °C m. Defect repair procedures n. Detailed welding procedures and repair procedures o. Intended percentage of cold expansion (if proposed). p. Pipe manufacturing procedure and subsequent heat treatment. q. Hydrostatic testing procedure and pressure r. Mechanical Properties and testing Procedures s. Chemical Properties and testing Procedures t. Pipe Tracking System u. Inspection Plan v. Non-destructive inspection procedures (including visual inspection) w. Dimensional check methods x. Handling, transport and storage procedures y. Marking and Coding z. Strip feed pipe aa. Detailed welding parameters:

Voltage, current, welding speed, upset, apex angle, shroud arrangement, shielding gas composition and flow rate (if applicable)

bb. Full details of heat treatment temperatures and times, heated band widths (internal and external) and cooling rates

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cc. Closure contact pressure dd. Upset size and removal procedure ee. Strip rolling equipment and procedures ff. Handling, storage and transportation. gg. Reporting hh. Certifying Authority

15.3 Manufacturing Procedure Qualification Test Reports

On successful completion of the Manufacturing Procedure Qualification Tests, carried

out in accordance with this Specification, Manufacturer shall, within three weeks of the date of testing, prepare and submit to INGL the original plus two copies on CD-Rom of a test report which shall include, but not be limited to, details of the following: 1) WINZ Project name and Purchase Order Number 2) Pipe identification. 3) Results of tensile, yield and elongation tests and yield/tensile ratio 4) Results of impact tests. 5) Results of flattening tests. 6) Results of strain ageing tests. 7) Results of surface quality inspections. 8) Results of all non-destructive testing. 9) Results of weldability tests. 10) Chemical analyses (ladle and product check). 11) Results of dimensional and visual checks. 12) Results of hardness testing and photographs of macrostructure examination specimens. 13) Results of residual magnetism checks. 14) Results of hydrostatic testing. 15) Any further pertinent information.

15.4 Periodic Reporting

During the production of INGL ordered pipes, Manufacturer shall submit to INGL by telefax

regular information as follows: 15.4.1 Daily Production Report

Each day during the production run of INGL's order, Contractor shall submit to INGL's

designated project office in the Netherlands by telefax a Daily Production Report, to arrive no later than 0900 hrs, covering the previous 24 hours production (zero hours to 2400 hours). The report shall contain at least the following information: 1) Number of pipes produced. 2) Number of pipes passed non-destructive testing. 3) Number of pipes passed hydrostatic testing. 4) Number of pipes (and overall length) accepted at end bench (by Manufacturer).

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5) Number of pipes rejected. 6) Total number of pipes (and overall length) accepted at end bench to date (by

Manufacturer). 7) Details of any production tests performed. 8) Number of pipes ready for dispatch. 9) Number of pipes dispatched.

15.4.2 Weekly Production Report

Contractor shall, during the production run of INGL's order, submit to INGL's designated

project office by e-mail a Weekly Production Report that shall reach INGL no later than 1200 hrs on the Monday immediately following the production week in question. The report shall contain at least the following information: 1) Total number of pipes and overall length produced to date. 2) Total number of pipes and overall length accepted by Manufacturer to date. 3) Total number of pipes and overall length accepted by INGL to date. 4) Updated bar chart production planning showing progress achieved to date against scheduled progress. 5) Total number of pipes ready for dispatch. 6) Total number of pipes dispatched to date. 7) Predicted end date.

15.5 Final Documentation

15.5.1 Manufacturing Data Book (including first day production tests)

As soon as possible, but not later than three weeks after completion of production,

Manufacturer shall prepare and submit to INGL TWO original plus two copies on CD-Rom of a Production Report which shall contain, as a minimum, details of the following: 1) Purchase Order (PO) and variations to PO. 2) Approved Quality / Inspection and Test Plan 3) all approved queries and concessions 4) Contractor's daily/weekly/monthly reports issued to INGL 5) manufacturing procedures. 6) quality control/inspection procedures. 7) non-destructive testing procedures. 8) welding procedure(s) and qualification test results 9) copies, in sequential order, of all INGL issued approvals. 10) list of qualified welders 11) all ORIGINAL inspection and mechanical test reports and certification recording the

results of inspection and testing and where relevant the INGL and Certifying Author-ity stamps for witnessing and approval.

12) heat treatment records 13) Mill 3.2 Test Certificates (see 15.5.2) 14) Pipe lists (see Section 15.4 following).

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15) Ladle analyses for each heat of steel. 16) Deoxidisation process(es). 17) Results of residual magnetism checks. 18) Lengths and pipe identities of all rejected pipes. 19) Number of repairs with relevant pipe identities. 20) Other special reports reasonably requested by the INGL's inspector. 21) Details of mill tallies and cutting lengths, etc. 22) Contractor's Letter of Guarantee/conformity (see 15.5.4).

Contractor shall store 1 copy of the MRB for a period of 7 years. 15.5.2 Mill test certificates

Mill test certificates to EN 10204 3.2, shall include, but not be limited to, the following in-formation: 1) PROJECT Nr 2) Contractor's Identification 3) Company’s name, purchase order number and item 4) Heat Number and test number 5) Identification of Steel Type and Grade 6) Steel-making process 7) Heat treatment condition 8) Ladle analysis 9) Product analysis 10) Carbon Equivalent, Pcm and CE 11) pipe dimensions and tolerances 12) full tensile testing results, including;

- Yield Strength - Tensile Strength - Yield to Tensile Ratio - Elongation - Reduction of area

13) Flattening Test Results 14) Charpy Impact Results 15) Hardness Tests results 16) Photographs of macrostructure examination specimens. 17) Ultrasonic test reports references. 18) Hydrostatic test reports references. 19) Surface Inspection Results 20) Repairs (welds and dressing) 21) Field Weldability Procedures and Test Results 22) Any further items specifically indicated on the purchase order 23) INGL approval 24) Certifying Authority approval confirming witnessing of testing

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15.5.3 Pipe Tally Lists

Manufacturer shall provide INGL with detailed pipe lists for the complete production of

the order stating: 1) Pipe identification numbers (referenced to heat numbers). 2) Heat numbers. 3) Dimensions of pipes. 4) Weights of lots or of individual pipes. 5) Purchase order number(s). 6) Types of certificates issued.

The Pipe mill tally sheet shall be supplied on a CD-Rom, in a spread-sheet format (i.e.

Excel) as well as on a paper hard copy 15.5.4 Letter of guarantee/conformity

Contractor shall at delivery of the material issue to INGL a Letter of guaran-tee/conformity to cover: 1) that the materials and workmanship are fully in accordance with the PO, codes

and specifications 2) that the supplied materials are free from faults in materials and workmanship; 3) the materials integrity for a 12 month period after acceptance by INGL 4) that Contractor shall correct and/or replace any faulty/defective materials, to the

satisfaction of INGL, found in this 12-month period without any cost to INGL

15.6 Delivery Documentation

15.6.1 Extra copies of the Material's Mill Test Certificates shall be furnished by CONTRACTOR

simultaneously with delivery of the order or part quantities thereof to INGL. 15.6.2 During the construction phase, extra copies of the in 15.5.1 listed documentation shall be

furnished by Contractor, upon the request of INGL and/or the CERTIFYING AUTHOR-ITY, e.g. NDT and inspection reports.

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16 Storage, Loading and Shipment

. 16.1 Manufacturer shall submit to INGL for approval, information detailing the proposed

methods for handling, storage and protection of the pipes for transportation. Such activities shall be subject to verification by INGL or its appointed inspector.

16.2 Pipe shall be supplied with INGL approved pipe end caps. 16.3 No welding of temporary attachments for handling, stacking or securing shall be

permitted 16.4 All handling, loading and unloading shall be done in such a manner as to prevent

mechanical damage and corrosion. 16.5 All handling shall be done with slings, or padded hooks approved by INGL. 16.6 Rail cars, trucks, lighters, ships or other conveyances shall be cleaned of debris, or any

substance that might damage the pipes, prior to loading. 16.7 Suitable timber or other dunnage shall be used to protect the pipes against damage in

transit. 16.8 Loading onto or into rail cars, track, lighters, ships or other conveyances shall be per-

formed in accordance with API RP 5L, API RP 5L5 or API RP 5L6 as appropriate. In all cases loading shall be in accordance with a procedure reviewed by INGL. 16.9 No on-deck overseas shipment is allowed without prior written approval by INGL. 16.10 Finished pipes to be stored for a significant period of time at Manufacturer's works or

marshalling yard, shall be stored in such a manner as to prevent corrosion or any other damage occurring.

16.11 Pipe shall not rest on projections, which could result in point stresses or be allowed to

rub on an adjacent object. Pipe loading shall be limited to prevent stresses, which result in out-of-roundness.

16.12 Manufacturer shall be held responsible for all damage that occurs, subsequent to final

mill acceptance, resulting from loading, storage or shipping. 16.13 .Shipment shall be in compliance with:

Doc. Nº.: EEN-EPI-SPC-006 Shipping

Doc. Nº.: EEN-EPI-SPC-005 Packing

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Appendix 1 Pipe End Drawing

1.6-+

-0°+5°

90°

30°

D

d0.8

t

SHARP- EDGED.WITHOUT BURRS

i

0.8

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Appendix 2 Location of Charpy-V Notch Specimens

NOTCH POSITION

HAZ WELDLINE

FUSION LINE

HAZ*

1,5 mm

SEAM ANNEALED ZONE **

* = HAZ from welding process

** = Distance depending on wall thickness

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Appendix 3 Vicker Hardness Survey in HFI-ERW Area for Production Test

Wallthickness ≥ 10 mm

FUSION LINE

1,5 mm

HAZ*

2

2


Wallthickness < 10 mm

FUSION LINE

HAZ*

1,5 mm


2

2

* = HAZ from welding process

** = Distance depending on wall thickness, the corresponding location will be witnessed

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17 Revision Record

Rev. Date Description Prepared Checked Approved Date Approved

No. EEN Company

1 2004-06-16 Discipline Internal Check WPB LAM PIL

2 2004-06-18 Issued for IDC WPB LAM PIL

3 2004-08-19 Issued for Approval KAS LAM PIL

4 06/06/2011 Completely Revised. PM HT

Israel Gas Transmission Project

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