DEP 31.40.20.33-Gen. Specification Feb 2011

DEP SPECIFICATION

LINE PIPE INDUCTION BENDS (AMENDMENTS/SUPPLEMENTS TO ISO 15590-1)

DEP 31.40.20.33-Gen.

February 2011

(DEP Circular 102/11 has been incorporated)

(DEP Circular 56/12 has been incorporated)

ECCN EAR99

DESIGN AND ENGINEERING PRACTICE

DEM1

© 2011 Shell Group of companies All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, published or transmitted, in any form or by any means, without the prior

written permission of the copyright owner or Shell Global Solutions International BV.

This document contains information that is classified as EAR99 and, as a consequence, can neither be exported nor re-exported to any country which is under an embargo of the U.S. government pursuant to Part 746 of the Export Administration Regulations (15 C.F.R. Parts 746) nor can be made available to any national of such country. In addition, the information in this document cannot be exported nor re-exported to an end-user or for an end-use that is prohibited by Part 744 of the Export

Administration Regulations (15 C.F.R. Parts 744).

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This document has been supplied under license by Shell to:Shell [email protected] 21/03/2013 07:14:47

ECCN EAR99 DEP 31.40.20.33-Gen. February 2011

PREFACE

DEP (Design and Engineering Practice) publications reflect the views, at the time of publication, of Shell Global Solutions International B.V. (Shell GSI) and, in some cases, of other Shell Companies.

These views are based on the experience acquired during involvement with the design, construction, operation and maintenance of processing units and facilities. Where deemed appropriate DEPs are based on, or reference international, regional, national and industry standards.

The objective is to set the recommended standard for good design and engineering practice to be applied by Shell companies in oil and gas production, oil refining, gas handling, gasification, chemical processing, or any other such facility, and thereby to help achieve maximum technical and economic benefit from standardization.

The information set forth in these publications is provided to Shell companies for their consideration and decision to implement. This is of particular importance where DEPs may not cover every requirement or diversity of condition at each locality. The system of DEPs is expected to be sufficiently flexible to allow individual Operating Units to adapt the information set forth in DEPs to their own environment and requirements.

When Contractors or Manufacturers/Suppliers use DEPs, they shall be solely responsible for such use, including the quality of their work and the attainment of the required design and engineering standards. In particular, for those requirements not specifically covered, the Principal will typically expect them to follow those design and engineering practices that will achieve at least the same level of integrity as reflected in the DEPs. If in doubt, the Contractor or Manufacturer/Supplier shall, without detracting from his own responsibility, consult the Principal.

The right to obtain and to use DEPs is restricted, and is granted by Shell GSI (and in some cases by other Shell Companies) under a Service Agreement or a License Agreement. This right is granted primarily to Shell companies and other companies receiving technical advice and services from Shell GSI or another Shell Company. Consequently, three categories of users of DEPs can be distinguished:

1) Operating Units having a Service Agreement with Shell GSI or another Shell Company. The use of DEPs by these Operating Units is subject in all respects to the terms and conditions of the relevant Service Agreement.

2) Other parties who are authorised to use DEPs subject to appropriate contractual arrangements (whether as part of a Service Agreement or otherwise).

3) Contractors/subcontractors and Manufacturers/Suppliers under a contract with users referred to under 1) or 2) which requires that tenders for projects, materials supplied or - generally - work performed on behalf of the said users comply with the relevant standards.

Subject to any particular terms and conditions as may be set forth in specific agreements with users, Shell GSI disclaims any liability of whatsoever nature for any damage (including injury or death) suffered by any company or person whomsoever as a result of or in connection with the use, application or implementation of any DEP, combination of DEPs or any part thereof, even if it is wholly or partly caused by negligence on the part of Shell GSI or other Shell Company. The benefit of this disclaimer shall inure in all respects to Shell GSI and/or any Shell Company, or companies affiliated to these companies, that may issue DEPs or advise or require the use of DEPs.

Without prejudice to any specific terms in respect of confidentiality under relevant contractual arrangements, DEPs shall not, without the prior written consent of Shell GSI, be disclosed by users to any company or person whomsoever and the DEPs shall be used exclusively for the purpose for which they have been provided to the user. They shall be returned after use, including any copies which shall only be made by users with the express prior written consent of Shell GSI. The copyright of DEPs vests in Shell Group of companies. Users shall arrange for DEPs to be held in safe custody and Shell GSI may at any time require information satisfactory to them in order to ascertain how users implement this requirement.

All administrative queries should be directed to the DEP Administrator in Shell GSI.



TABLE OF CONTENTS

PART I INTRODUCTION AND GENERAL.............................................................................4 1 INTRODUCTION ........................................................................................................4 1.1 SCOPE........................................................................................................................4 1.2 DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS .........4 1.3 DEFINITIONS .............................................................................................................4 1.4 CROSS-REFERENCES .............................................................................................5 1.5 SUMMARY OF MAIN CHANGES...............................................................................5 1.6 PRINCIPAL'S ACCESS AND ACTIVITIES.................................................................5 1.7 DUAL UNITS...............................................................................................................5 1.8 COMMENTS ON THIS DEP.......................................................................................5 2. GENERAL...................................................................................................................6 PART II AMENDMENTS/SUPPLEMENTS TO ISO 15590-1 ..................................................7 1 Scope..........................................................................................................................7 2 Conformance ..............................................................................................................7 2.3 Compliance To Standard ............................................................................................7 3 Normative References ................................................................................................7 4 Terms and Definitions .................................................................................................7 4.16 Manufacturer...............................................................................................................7 5.2 Abbreviated Terms......................................................................................................7 6 Designation .................................................................................................................7 8 Information That Shall Be Supplied By The Purchaser ..............................................7 9 Manufacturing .............................................................................................................8 9.1 Mother Pipe.................................................................................................................8 9.2 Qualification Test Bend...............................................................................................8 9.4 Post-Bending Heat Treatment ....................................................................................8 9.5 Forming And Sizing After Bending..............................................................................8 9.7 Jointers And Girth Welds ............................................................................................8 9.8 End Preparation ..........................................................................................................8 10 Testing And Inspection ...............................................................................................9 10.1 General requirements .................................................................................................9 10.3 Chemical composition.................................................................................................9 10.4 Physical Testing..........................................................................................................9 10.5 Non-Destructive Testing ...........................................................................................11 10.6 Dimensions ...............................................................................................................11 10.7 Gauging.....................................................................................................................12 11 Inspection Document ................................................................................................12 Annex A Manufacturing Procedure Specification ....................................................................13 A.1 Introduction ...............................................................................................................13 A.2 Manufacturing Procedure Specification ....................................................................13 Annex B PSL2 Bends Ordered For Sour Service....................................................................14 B.2 Additional Information To Be Supplied By The Purchaser .......................................14 B.7 Non-destructive Inspection...............................................................................15 Annex C Heat Treatment Requirements..................................................................................16 C.1 Furnaces ...................................................................................................................16 C.2 Quenching Facilities..................................................................................................16 Annex D Additional Requirements For CRA Clad Overlay Bends ..........................................17 Annex E Additional Requirements For Duplex and 6Mo Bends..............................................18 E.1 Introduction ...............................................................................................................18 E.2 Manufacturing Procedure Qualification.....................................................................18 E.3 Production Testing ....................................................................................................18 PART III REFERENCES .........................................................................................................19



PART I INTRODUCTION AND GENERAL

1 INTRODUCTION

1.1 SCOPE

This DEP specifies requirements and gives recommendations for induction bends manufactured from seamless or welded pipe of unalloyed or low alloy steels for pipeline applications in oil and gas operations under both sour and non-sour service applications.

Part II of this DEP is written as amendments/supplements to ISO 15590-1:2009. For clarity, the section and paragraph numbering of ISO 15590-1 is used in Part II of this DEP. Clauses of ISO 15590-1 that are not amended by this DEP remain applicable as written.

This DEP contains mandatory requirements to mitigate process safety risks in accordance with Design Engineering Manual DEM 1 – Application of Technical Standards

This is a revision of the DEP of the same number dated September 2002 see (1.5) regarding the changes.

1.2 DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS

Unless otherwise authorised by Shell GSI, the distribution of this DEP is confined to Shell companies and, where necessary, to Contractors and Manufacturers/Suppliers nominated by them. Any authorised access to DEPs does not for that reason constitute an authorization to any documents, data or information to which the DEPs may refer.

This DEP is intended for use in pipeline facilities related to oil and gas production, gas handling, oil refining, chemical processing, gasification, and supply/distribution. This DEP may also be applied in other similar facilities.

When DEPs are applied, a Management of Change (MOC) process should be implemented; this is of particular importance when existing facilities are to be modified.

If national and/or local regulations exist in which some of the requirements could be more stringent than in this DEP, the Contractor shall determine by careful scrutiny which of the requirements are the more stringent and which combination of requirements will be acceptable with regards to the safety, environmental, economic and legal aspects. In all cases the Contractor shall inform the Principal of any deviation from the requirements of this DEP which is considered to be necessary in order to comply with national and/or local regulations. The Principal may then negotiate with the Authorities concerned, the objective being to obtain agreement to follow this DEP as closely as possible.

1.3 DEFINITIONS

1.3.1 General definitions

The Contractor is the party that carries out all or part of the design, engineering, procurement, construction, commissioning or management of a project or operation of a facility. The Principal may undertake all or part of the duties of the Contractor.

The Manufacturer/Supplier is the party that manufactures or supplies equipment and services to perform the duties specified by the Contractor.

The Principal is the party that initiates the project and ultimately pays for it. The Principal may also include an agent or consultant authorised to act for, and on behalf of, the Principal.

The lower-case word shall indicates a requirement.

The capitalised term SHALL [PS] indicates a process safety requirement.

The word should indicates a recommendation.



1.3.2 Specific definitions

Manufacturer Term used in ISO 15590, which shall be taken to mean the Manufacturer/Supplier.

Purchaser Term used in ISO 15590, which shall be taken to mean the Principal.

1.4 CROSS-REFERENCES

Where cross-references to other parts of this DEP are made, the referenced section number is shown in brackets. Other documents referenced by this DEP are listed in (Part III).

1.5 SUMMARY OF MAIN CHANGES

This DEP is a revision of the DEP of the same number dated September 2002, which was based on ISO 15590-1:2001. This DEP is now based on ISO 15590-1:2009.

Due to the fundamental change in overall scope and clause numbering in ISO 15590-1:2009, it is impractical to summarise the changes here.

1.6 PRINCIPAL'S ACCESS AND ACTIVITIES

The Principal’s representatives shall be permitted to witness all chemical testing, mechanical testing, and equipment calibration, and to inspect all bends. Sufficient notice (at least 14 days) shall be given of the time at which the production run is to begin.

The Principal’s representatives shall have free entry at all times to all parts of the Manufacturer’s works that will concern the manufacture, testing, inspection, quality control and shipping of the bends ordered. This includes the steel mill and the pipe mill if the original material for bending is supplied by the Manufacturer and any sub-contract locations such as heat treatment facilities. The Manufacturer shall make available to the Principal’s representatives, without charge, all reasonable facilities to inspect, measure, and test the pipe in all stages of production.

The Principal’s representative shall have the option to examine all materials rejected for any reason. The Principal’s representative shall be informed of any bend failures due to dimensions not meeting requirements and of any test specimen that fails to meet the requirements for any reason. All failed materials shall be retained until examined by the Principal’s representative.

The Manufacturer shall allow the Principal’s representative to inspect each pipe bend after manufacture and testing is completed but prior to loading for shipment.

1.7 DUAL UNITS Amended per Circular 56/12 Dual units have been incorporated throughout this DEP.

This DEP contains both the International System (SI) units, as well as the corresponding US Customary (USC) units, which are given following the SI units in brackets. When agreed by the Principal, the indicated USC values/units may be used.

1.8 COMMENTS ON THIS DEP

Comments on this DEP may be sent to the Administrator at [email protected], using the DEP Feedback Form. The DEP Feedback Form can be found on the main page of “DEPs on the Web”, available through the Global Technical Standards web portal http://sww.shell.com/standards and on the main page of the DEPs DVD-ROM.


mailto:[email protected]

http://sww.shell.com/standards


2. GENERAL

Part II of this DEP is written as amendments/supplements to ISO 15590-1:2009.

Wherever reference is made to ISO 15590-1, it shall be understood to mean ISO Standard 15590-1:2009 as amended/supplemented by this DEP.

For ease of reference, the section and clause numbering of ISO 15590-1 is used in Part II of this DEP.

Clauses of ISO 15590-1 that are not amended by this DEP shall remain applicable as written.



PART II AMENDMENTS/SUPPLEMENTS TO ISO 15590-1

1 Scope

Replace reference to ISO 3183:2007 with DEP 31.40.20.37-Gen.

Amend the second paragraph as follows:

This part of ISO 15590 is applicable to induction bends made form seamless and welded pipe of unalloyed or low-alloy steels. With the additional requirements as shown in Annex D, it may also be used for overlay clad bends where the overlay is not part of the structural integrity of the bend.

Amend the fourth paragraph as follows:

This part of ISO 15590 specifies the requirements and recommendations for the manufacture of product specification level PSL 2, as defined in DEP 31.40.20.37-Gen.

Delete second sentence of paragraph five.

2 Conformance

2.3 Compliance To Standard

Delete first sentence and replace with the following:

The Manufacturer/Supplier SHALL [PS] maintain and operate a quality assurance system that shall be in accordance with ISO 9001. The Principal for agreement may consider a quality assurance system based on an alternative standard. The quality system shall be available for review by the Principal.

Any conflicts between requirements of this DEP, related specifications, standards, purchase order, or drawing shall be referred to the purchaser for clarification before proceeding with the work.

3 Normative References

Add the following:

DEP 31.40.20.37-Gen., Line pipe for critical service (amendments/supplements to ISO 3183)

4 Terms and Definitions


4.16 Manufacturer

Add the following:

Where pipe manufacturing and/or heat treatment are subcontracted, the pipe mill and/or the processor shall also be considered to be the Manufacturer/Supplier.

5.2 Abbreviated Terms

Add the following:

EFC European Federation Of Corrosion

6 Designation

Delete references to PSL 1.

8 Information That Shall Be Supplied By The Purchaser

Add the following:



The complete information shall be provided at the enquiry stage of the purchase order; however, requirements specifically addressed by this DEP need not be repeated.

8.3.2 Additional Information On Mother Pipe

Delete references to SAWH pipe.

9 Manufacturing

9.1 Mother Pipe


Delete paragraphs 1 and 2. Add the following:

Mother pipe shall be manufactured in accordance with DEP 31.40.20.37-Gen.

For manufacturer supplied pipe, evidence of total traceability and suitability for induction bending shall be provided. In addition, manufacturer is required to generate mechanical properties from actual pipe to be used, as required by DEP 31.40.20.37-Gen., for each manufacturer and lot of pipe used for bending.

If the manufacturer proposes to use deliberate high strength TMCP mother pipe to aim for adequate strength after the bending process, Principal shall be notified of this.

Principal shall also be notified in the reverse case, where the manufacturer intends to “upgrade” the mother pipe material through post bend heat treatment.

9.2 Qualification Test Bend

Delete paragraph1. Add the following:

The manufacture of test bends shall be carried out in accordance with an MPS that shall be qualified in accordance with Clause 9 before commencement of production.

9.4 Post-Bending Heat Treatment

Delete paragraph 1. Add the following:

Unless the manufacturer can demonstrate otherwise, pipe grades of L450 (X65) and higher, the pipe bender shall provide a quench and temper heat treatment of the entire joint.

Annex C gives the minimum requirements for heat treatment of bends.

9.5 Forming And Sizing After Bending

Add the following to Table 1:

Bend equipment, including coil None

9.7 Jointers And Girth Welds

Add the following:

The use of jointers is permitted in order to manufacture bends; however, on completion of the bend, the joiner shall be removed such that no effects from the joiner shall remain (including HAZ).

9.8 End Preparation

Add the following:

Cutting of the ends by thermal techniques or any other method that may result in a variance to the properties compared to that of the bulk material shall not be permitted.



10 Testing And Inspection

10.1 General requirements


Add the following:

Principal shall select or approve selection of the pipe to be used for the procedure qualification.

Principal shall be given the option to witness all qualification operations, including mechanical testing, NDE and dimensional analysis. Sufficient notice (at least 14 days) shall be given of the start of qualification test bending.

A timetable as to the various stages of qualification bends and production bends shall be supplied to the Principal.

The bending procedure shall be re-qualified if there are any changes in essential variables as listed in Table 1 (9.5).

10.2.1 Qualification Test Bends

Delete final paragraph.

10.2.3 Production Test Bends

Delete paragraph. Add the following:

Where the bend quantity for a given size and grade exceeds 25, a production test shall be performed for each batch of 25 bends produced. The production testing shall consist of those tests performed during the MPS. Failure of any production test shall be investigated with all production put on hold until the cause of the failure can be determined. Prior to commencement of production, it shall be shown that bends previously produced and future production is not susceptible to the same reduction of properties.

10.3 Chemical composition


10.4 Physical Testing

10.4.1 Test Pieces General


10.4.2 Tensile Testing

10.4.2.1 Test Pieces


Two (2) samples shall be removed and tested from each of the shown locations.

The manufacturer shall supply for approval the type of test bar to be used, round or flat.

Modify Table 2 as follows:


Delete reference to PSL 1

Modify Table 3 as follows:


Delete reference to PSL 1

Delete notes b, d and e



10.4.2.2 Test Method


10.4.3 Charpy V-Notch Impact Testing

10.4.3.1 Test Pieces


In addition to transverse specimens, a set of longitudinal specimens shall be taken in the tangent region of the base material.

Amended per

Circular 102/11

For all bends with a mother pipe nominal wall thickness greater than 35mm (1.378 in), test pieces shall be taken in the same locations as those of material less than 35mm (1.378 in) plus additional samples in the equivalent locations no more than 2 mm (0.08 in) from the bore of the material.



The test temperature shall be lower than or equal to that specified in the table below.

Nominal wall thickness, t

(mm)

Test Temperature

(°C)

Maximum test temperature

(°C)

t ≤ 20 Tmin 0

20 < t ≤ 30 Tmin-10 0

30 < t ≤ 40 Tmin-20 0

t > 40 To be advised by the Principal

Tmin is the minimum design temperature, which shall be specified in the purchase order.

Nominal wall thickness, t

(in)

Test Temperature

(°F)

Maximum test temperature

(°F)

t ≤ 0.8 Tmin 32

0.8 < t ≤ 1.2 Tmin-50 32

1.2 < t ≤ 1.5 Tmin-70 32

t > 1.5 To be advised by the Principal

Tmin is the minimum design temperature, which shall be specified in the purchase order.

10.4.3.3 Requirements




10.4.4 Through-Thickness Hardness Testing


Delete paragraph. Add the following:

Through thickness hardness testing shall be performed using Vickers hardness method in accordance with ISO 6507 or ASTM E92. Hardness indent locations shall be in accordance with DEP 31.40.20.37.Gen.

10.4.4.2 Requirements

Replace first paragraph with:

Hardness readings shall not exceed 275HV10 in the OD or mid wall regions and 250HV10 in the ID.

10.4.6 Metallographic Examination

10.4.6.1 Test method

Replace 3rd paragraph with:

The micrographic examination shall be made at a distance of 2.0 mm (0.08 in) from the external and internal surfaces and at a mid-wall position. For a wall thickness of 10 mm (0.4 in) and smaller, the micrographic examination shall be made at the mid-wall position only.

10.4.7 Drop-weight tear testing

Delete paragraphs and replace with:

For DSAW pipe with outside diameter ≥ 406.4 mm (16 in), two drop weight tear specimens representing each test location shall be tested. Testing shall be performed in accordance with API RP 5L3. For each test (of a set of two test pieces), the average shear fracture shall be ≥ 85 %. The test shall be performed at the minimum design temperature specified by the Principal in the purchase order. Where it is not possible to test a full thickness specimen, the test temperature shall be adjusted in accordance with API RP 5L3.

10.4.9 Guided Bend Test



10.4.10 Flattening Tests


10.5 Non-Destructive Testing

10.5.1 Visual Inspection


10.5.7 Repairs


Repair by welding shall not be permitted.

10.6 Dimensions

Delete Table 4. Add the following:

As a minimum, 100 % wall thickness inspection shall be conducted over an area of at least 45º on both sides of the extrados. This area shall be broken into grids not larger than



75 mm (3 in) and the lowest reading for that grid shall be reported. Alternatively, a continuous scan using a procedure approved and qualified by Principal is acceptable. The continuous scan shall be made at a calibrated rate and is alarmed for minimum wall thickness plus uncertainty of the equipment. Any area causing an alarm shall be investigated by a point inspection method and witnessed by the Principal’s Representative.

Table 4 Permissible dimensional tolerances

Dimension Permissible tolerance

Linear dimensions a ±3 mm (0.12 in)

Minimum wall thickness Zero

Maximum wall thickness Zero

Inside diameter of bend ends In accordance with DEP 31.40.20.37-Gen.

Inside diameter of bend arc and tangents See (10.7)

Bend angle ±1°

Bend radius for bends with rb ≥ 1 000 mm ( 39.5 in) ±1 %

Bend radius for bends with rb < 1 000 mm (39.5 in) ±10 mm (0.39 in)

End out-of-squareness 3 mm (0.12 in) max.

Out-of-planeness 1 % Of OD

Out-of-roundness at ends In accordance with DEP 31.40.20.37-Gen.

Out-of-roundness in bend body rb ≥ 5D; 2.5% max.

3D ≤ rb < 5D; 3 % max. a Such as centre-to-end, offsets, chord lengths.

10.7 Gauging

Add:

The inside diameter of each finished bend shall permit the passage of a drift mandrel consisting of two (2) parallel circular metal disks, each at least 6 mm (1/4 in) thick, rigidly connected and separated by a distance of one (1) nominal pipe diameter. The disk diameter shall be at least 95% of the specified nominal pipe inside diameter or 97.5 % of the pipe’s original inside diameter unless otherwise stated in the purchase order.

11 Inspection Document


The purchaser shall supply ISO 10474 3.1B (or equivalent) inspection documents which shall include, as a minimum, procedure qualification test bend data results, reports of the individual bend data including non-destructive test results, dimensional reports and confirmation that the bends were manufactured in accordance with the MPS, this DEP and ISO 15590-1.



Annex A Manufacturing Procedure Specification

A.1 Introduction

Delete first paragraph and replace with:

This annex specifies the requirements for the manufacturing procedure specification for PSL 2 level bends.

A.2 Manufacturing Procedure Specification


A manufacturing procedure specification shall be produced for all bends. Test bends shall be manufactured in accordance with a preliminary MPS documented before commencement of test bending. The preliminary MPS shall be modified as necessary, based on the parameters recorded during test bending, prior to commencing production bending. The manufacturing shall not proceed until the MPS has been accepted by the purchaser.



Annex B PSL2 Bends Ordered For Sour Service

B.2 Additional Information To Be Supplied By The Purchaser


B.3.2 Pipe Manufacturing


B.4.1 Chemical Composition

Delete paragraphs and replace with: Amended per

Circular 102/11

For bends with t≤ 35.0 mm (1.378 in), the chemical composition for standard grades shall be as given in DEP 31.40.20.37-Gen., Table H.1.

For pipe with t >35.0 mm (1.378 in), the chemical composition shall be as agreed, with the requirements given in DEP 31.40.20.37-Gen., Table H.1 being amended as appropriate.

B.4.3 HIC/SWC Test

B.4.3.2 Test Method


Unless otherwise specified, HIC/SWC tests shall be carried out and reported in accordance with NACE TM0284 in a medium complying with NACE TM0284:2003 solution A.

HIC/SWC testing may be omitted if the mother pipe has passed HIC/SWC testing.

B.4.3.3 Requirements

Delete final paragraph.

B.4.4 SSC Test

B.4.4.1 Test Pieces


One (1) sample shall be taken from the extrados of the bend body, in the longitudinal direction for each test bend provided for manufacturing procedure qualification; three (3) test pieces shall be taken from each sample. For welded pipe, test pieces shall also be extracted transverse to the weld and contain a section of the longitudinal at its centre.

Test pieces for four (4)-point bending SSC tests shall be at least 115 mm (4.5 in) long x 20 mm (0.79 in) wide x 15 mm (0.59 in) thick. For test pieces containing welds, the distance between the inner supports shall be equal to, or greater than, the width of the weld plus 50 mm (2 in) (25 mm (1 in) each side of the weld).

B.4.4.2 Test Method


Unless otherwise specified, testing shall be carried out at 90% of the actual yield of the parent material with the internal surface in tension as described in EFC 16, Appendix 2. The applied strain shall be verified by the direct application of strain gauges.

Test solution A, EFC 16 Annex A3, shall be used adjusted to a starting pH of 3.5. 1 bar (14.5 psi) (pure) H2S shall be used. The test duration shall be 720 h.




Add the following:

In addition, all SSC test specimens are to be evaluated for resistance to SOHIC in accordance with ISO 15156-2, Clause B.4.2.3: Two longitudinal metallographic sections shall be taken from each SSC specimen. No ladder-like HIC features or cracks exceeding a length of 0.5 mm (0.02 in) in the through thickness direction are to be permitted

B.4.5 Hardness Test

B.4.5.1 Test Pieces




For test pieces subjected to hardness testing, the maximum acceptable hardness shall be 230 HV10 in the pipe body, weld and HAZ.

The maximum acceptable hardness of an unexposed weld cap and external surface HAZ and base metal shall not exceed 250 HV10 if:

a) the parent bend wall thickness is greater than 9 mm (0.35 in);

b) the weld cap is not exposed directly to the sour environment.

B.7 Non-destructive Inspection

B7.1 Laminar Imperfections At The Pipe Ends


For pipe with wall thickness, t, equal to or greater than 5.0 mm (0.197 in), ultrasonic inspection in accordance with ISO 11496 shall be used to verify that the 100 mm (4.0 in) wide zone at each pipe end is free of such laminar defects.

B.7.2 Ultrasonic Testing On Bend Body


All pipe to be used in the manufacture of induction bends shall be purchased in accordance with DEP 31.40.20.37-Gen. including full body ultrasonic testing stated in DEP 31.40.20.37-Gen. Annex K.

B.7.3 Ultrasonic Testing Adjacent To Weld Seam


All pipe to be used in the manufacture of induction bends shall be purchased in accordance with DEP 31.40.20.37-Gen. including ultrasonic testing of weld seam edges as stated in DEP 31.40.20.37-Gen. Annex K.

B.7.4 Non-Destructive Inspection Of HFW Weld Seams


The full length of the weld seam shall be ultrasonically inspected for the detection of longitudinal imperfections, in accordance with DEP 31.40.20.37-Gen., Annex K.4.1.

B.7.5 Ultrasonic Inspection Of SAW Seam Welds




The full length of the weld seam shall be ultrasonically inspected for the detection of longitudinal and transverse imperfections, in accordance with DEP 31.40.20.37-Gen., K.5.1.

Annex C Heat Treatment Requirements

C.1 Furnaces

Furnaces shall be adequately sized for the load to be heat-treated. The load shall fit entirely within the calibrated working zone. The furnace shall be capable of bringing the load up to temperature within a reasonable time period. The furnace shall be adequately insulated to prevent heat loss and maintain temperature uniformity.

Furnaces shall have automatic temperature indicating, controlling, and recording devices. The controlling and recording instruments used for heat-treating shall posses an accuracy of ±1% of their full-scale range.

Furnaces shall be properly calibrated no less than once a year to an internationally recognized standard such as AMS H 6875 or Appendix H of API 6A. Furnaces shall be capable of maintaining a uniform temperature within the working zone of ± 15°C (5°F-60°F) of the set point temperature for austenitizing and stress relieving, and ± 10°C (15°F-50°F) of the set point temperature for tempering. A calibration of the furnace to be used shall be available for review.

Temperature controlling and recording instruments shall be calibrated at least once every three months. Thermocouples also shall be calibrated or replaced at least once every three months.

Equipment used to calibrate production equipment shall have an accuracy of ±0.25% and shall be traceable to an industry-recognized industry standard such as NIST, the National Institute for Standards and Technology or equivalent.

Parts shall not be placed directly on the furnace hearth (floor).

C.2 Quenching Facilities

Quench tanks shall be located in close proximity to the austenitizing furnace and be easily accessible. The transfer time from the austenitizing furnace to the quench tank shall be minimized.

Quench tanks shall be adequately sized for the loads. In the case of water quenching, the volume of water quench tanks shall be such that the temperature of the water does not exceed 38°C (100°F) at the start of the quench, and does not exceed 50°C (122°F) at the end of the quench.

Quench tanks shall have some means (propellers, pumps, etc) of circulating the quench media to optimize the cooling rate. In the case of water quenching, agitation shall be sufficient to break up the steam blanket that forms at the surfaces of the hot, immersed part. Agitators shall be placed so that good circulation is maintained throughout the quench tank when a load is being quenched and shielding of one bend by another does not occur.

Oil quench media shall be maintained at the manufacturers’ recommended temperature. Polymer quench media shall be maintained at the manufacturers’ recommended temperature, and the concentration of the polymer shall be routinely monitored and adjusted as necessary.

A thermocouple shall be attached to the surface of at least one bend in each heat treatment load. The specified austenitizing or tempering time at temperature begins when the surface thermocouple reaches the desired set point temperature.

Sufficient space shall be allowed between parts when loading a furnace to insure that all surfaces of the parts are evenly heated and to insure a good, even quench.

Bends shall not be quenched with the cavity opening or bore oriented downwards.



Annex D Additional Requirements For CRA Clad Overlay Bends

Susceptibility to intergranular corrosion testing in accordance with ASTM A262 Methods A and E shall be performed on the CRA region of pipe with CRA overlays.

For pipe with CRA overlay, the purchase order shall state if mechanical properties are required for the CRA from the qualification test bend. If testing is required, the pipe bender shall supply with their proposal the test procedures that would be used (including sample size and geometry) for Principal approval.

For pipe with CRA overlay the Vickers hardness testing of the qualification bend shall be determined using three (3) readings at each of the following locations:

1) 1.5 mm (0.06 in) (+0.5 mm (0.02 in), -0.0 mm (-0.0 in)) from outside pipe surface

2) Mid-wall (half nominal base wall thickness ± 1.0 mm (0.04 in)). 0.5 mm (0.02 in) spacing into base. 0.5 mm (0.02 in) spacing into CRA

3) Fusion line of base/CRA into base at 0.5 mm (0.02 in) spacing until two (2) readings are ± 5 units of mid-wall reading

4) Fusion line of base/CRA into CRA at 0.5 mm (0.02 in) spacing.

All CRA overlay pipe bends shall have inspection to determine wall thickness for both the carbon steel pipe and CRA. This testing shall be conducted to provide the thickness of as-bent pipe and to establish that minimum wall thickness requirements of the pipe are met. As a minimum, inspection shall be conducted over an area of at least 45º on both sides of the extrados. The lowest reading for the examination region shall be reported for both the liner and the base metal.

The completed CRA surface of the completed bends shall be inspected for iron contamination.



Annex E Additional Requirements For Duplex and 6Mo Bends

E.1 Introduction

This Appendix covers additional requirements for the manufacture and testing of forged 6Mo austenitic, 22Cr duplex stainless steel and 25Cr super duplex stainless steel induction bends for use as piping or pipeline components.

All bends shall be manufactured in accordance with this DEP. Although the above Standard is intended for carbon and low alloy steel bends it shall also be applied to 6Mo austenitic, 22Cr duplex stainless steel and 25Cr super duplex stainless steel. All testing and inspection shall be carried out as per this standard. Additional guidance on MPQ and production testing are given in this annex.

Where any conflict exists the most onerous condition shall apply. The Principal shall be consulted where clarification is required on any aspect of manufacturing, testing or inspection.

E.2 Manufacturing Procedure Qualification

In addition to the testing requirements as stated in (10) of this DEP, the test bend shall be subject corrosion testing and metallographic examination for each of the locations shown in Table 3, appropriate to the mother pipe type.

Unless otherwise specified in the PO, corrosion testing shall be performed using ASTM G48 method A at the same temperature as the original mother pipe.

The metallographic examination shall consist of a confirmation that there shall be no obvious indications of sigma or other detrimental secondary phases. For duplex materials, the metallographic determination shall also consist of a ferrite determination using ASTM E562.

Material properties shall meet the requirements of the Standard used for the mother pipe.

E.3 Production Testing

Portable hardness readings shall be made on each production bend in the finished condition. The Purchaser shall approve the method and procedure to be used.

Readings shall be taken on the tangent ends remote from the bending transition zone, on the bending transition zone, and on the extrados and intrados of the body of the bend. A minimum of five (5) readings shall be taken at each location. The results shall meet the requirements specified in standard used for the mother pipe, and shall be consistent with the results recorded for the test band. If there is a large variation between the production test results and the test bend the Purchaser may require additional metallographic examination to provide assurance that the production bends meet all the requirements of this Standard.



PART III REFERENCES

In this DEP, reference is made to the following publications: NOTES: 1. Unless specifically designated by date, the latest edition of each publication shall be used,

together with any amendments/supplements/revisions thereto.

2. The DEPs and most referenced external standards are available to Shell staff on the SWW (Shell Wide Web) at http://sww.shell.com/standards/.

SHELL STANDARDS

Line pipe for critical service (amendments/supplements to ISO 3183) DEP 31.40.20.37-Gen.

AMERICAN STANDARDS

Recommended practice for conducting drop-weight tear tests on line pipe

API RP 5L3

Standard practices for detecting susceptibility to intergranular attack in austenitic stainless steels

ASTM A262

Issued by: American Petroleum Institute Publications and Distribution Section 1220 L Street Northwest, Washington DC 20005, USA

Standard Test Method for Vickers Hardness of Metallic Materials ASTM E92

Issued by: American Society for Testing and Materials 1916 Race Street, Philadelphia Pa 19103, USA

EUROPEAN STANDARDS

A Working Party report on guidelines on materials requirements for carbon and low allow steels for H2S-containing environments in oil and gas production

EFC 16

Issued by: The Institute Of Materials 1 Carlton House Terrace, London SW1Y 5DB, UK

INTERNATIONAL STANDARDS

Metallic materials – Vickers hardness test – Part 1: Test method ISO 6507

Quality systems – Model for quality assurance in design, development, production, installation and servicing

ISO 9001

Steel and Steel Products – Inspection documents ISO 10474

Seamless and welded steel tubes for pressure purposes - Ultrasonic testing of tube ends for the detection of laminar imperfections

ISO 11496

Petroleum and natural gas industries — Induction bends, fittings and flanges for pipeline transportation systems — Part 1: Induction bends

ISO 15590-1



Petroleum and natural gas industries – Materials for use in H2S-containing environments in oil and gas production – Part 2: Cracking-resistant carbon and low alloy steels, and the use of cast irons

ISO 15156-2

Issued by: ISO Central Secretariat 1, ch. de la Voie-Creuse Case postale 56, CH-1211 Genève 20, Switzerland


DEP 31.40.20.33-Gen. Specification Feb 2011

Documents

Transcript of DEP 31.40.20.33-Gen. Specification Feb 2011