SUBMARINE PIPELINE SYSTEMS

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OFFSHORE STANDARD DNV-OS-F101 SUBMARINE PIPELINE SYSTEMS 2000 DET NORSKE VERITAS FOREWORD DET NORSKE VERITAS (DNV) is an autonomous and independent foundation with the objectives of safeguarding life, property and the environment, at sea and onshore. DNV undertakes classification, certification, and other verification and consultancy services relating to quality of ships, offshore units and installations, and onshore industries worldwide, and carries out research in relation to these functions. DNV Offshore Codes consist of a three level hierarchy of documents: — Offshore Service Specifications. Provide principles and procedures of DNV classification, certification, verification and consultancy services. — Offshore Standards. Provide technical provisions and acceptance criteria for general use by the offshore industry as well as the technical basis for DNV offshore services. — Recommended Practices. Provide proven technology and sound engineering practice as well as guidance for the higher level Offshore Service Specifications and Offshore Standards. DNV Offshore Codes are offered within the following areas: A) Qualification, Quality and Safety Methodology B) Materials Technology C) Structures D) Systems E) Special Facilities F) Pipelines and Risers G) Asset Operation Amendments April 2002 This Code has been amended, but not reprinted in April 2002. The changes are incorporated in the Web, CD and printable (pdf) versions. The amendments are shown in red colour in the Web and CD versions. All changes affecting DNV Offshore Codes that have not been reprinted, are published separately in the current Amendments and Corrections, issued as a printable (pdf) file. Comments may be sent by e-mail to rules@dnv.com For subscription orders or information about subscription terms, please use distribution@dnv.com Comprehensive information about DNV services, research and publications can be found at http://www.dnv.com, or can be obtained from DNV, Veritasveien 1, N-1322 Høvik, Norway; Tel +47 67 57 99 00, Fax +47 67 57 99 11. © Det Norske Veritas. All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means, including photocopying and recording, without the prior written consent of Det Norske Veritas. Computer Typesetting (FM+SGML) by Det Norske Veritas. Printed in Norway by GCS AS. If any person suffers loss or damage which is proved to have been caused by any negligent act or omission of Det Norske Veritas, then Det Norske Veritas shall pay compensation to such person for his proved direct loss or damage. However, the compensation shall not exceed an amount equal to ten times the fee charged for the service in question, provided that the maximum compensation shall never exceed USD 2 million. In this provision "Det Norske Veritas" shall mean the Foundation Det Norske Veritas as well as all its subsidiaries, directors, officers, employees, agents and any other acting on behalf of Det Norske Veritas. Acknowledgement This Offshore Standard has been developed in close co-operation with the industry. In order to ensure constructive and effective feedback at an early stage of the development, working groups for design, material, installation and operation were established. The following companies were members of working groups: — — — — — — Statoil Norsk Hydro Saga Petroleum Phillips Petroleum J.P.Kenny A/S Reinertsen Engineering The Standard has been circulated on extensive internal and external hearing. The following organisations have made major contributions to the hearing process: Allseas Engineering Andrew Palmer & Associates BP Amoco Exploration British Steel Brown & Root BHP Steel Coflexip Stena Offshore DSND DST EMC Exxon Prod. Research Company ITOCHU JP Kenny Ltd Kawasaki Steel Mentor Project Eng. Niras Norsk Hydro Navion Phillips Petroleum Rambøll Oil & Gas Røntgen Technische Dienst bv Reinertsen Engineering Seaflex Shaw Pipeline Services Ltd. Stolt Comex Seaway Salzgitter Saga Petroleum Shell Vallourec & Mannesmann Vallourec & Mannesman Tubes DNV is grateful for the valuable co-operations and discussions with the individual personnel of these companies. DET NORSKE VERITAS DET NORSKE VERITAS Offshore Standard DNV-OS-F101, 2000 Contents – Page 5 CONTENTS Sec. 1 General................................................................. 11 A. General.................................................................................. 11 A A A A 100 200 300 400 Introduction..................................................................... 11 Objectives ....................................................................... 11 Scope and Application .................................................... 11 Other codes ..................................................................... 11 B. Normative References .......................................................... 11 B B B B B B B 100 200 300 400 500 600 700 Offshore Service Specifications...................................... 11 Offshore Standards ......................................................... 11 Recommended practices ................................................. 11 Rules ............................................................................... 11 Certification notes and Classification notes.................... 12 Guidelines ....................................................................... 12 Other references.............................................................. 12 C. Definitions ............................................................................ 12 C 100 C 200 C 300 Verbal forms ................................................................... 12 Definitions ...................................................................... 12 Definitions (continued) ................................................... 15 D. Abbreviations and Symbols.................................................. 16 D D D D 100 200 300 400 Abbreviations.................................................................. 16 Symbols .......................................................................... 16 Greek characters ............................................................. 17 Subscripts........................................................................ 17 Sec. 2 Design Philosophy ............................................... 18 A. General.................................................................................. 18 A 100 A 200 Objective......................................................................... 18 Application...................................................................... 18 B. Safety Philosophy ................................................................. 18 B B B B B B 100 200 300 400 500 600 General............................................................................ 18 Safety objective............................................................... 18 Systematic review ........................................................... 18 Safety class methodology ............................................... 18 Quality assurance............................................................ 19 Health, safety and environment ...................................... 19 D 900 E. External and Internal Pipe Condition ...................................24 E 100 E 200 E 300 External operational conditions ...................................... 24 Internal installation conditions ....................................... 24 Internal operational conditions ....................................... 24 F. Documentation......................................................................25 F F F F 100 200 300 400 F F F F 500 600 700 800 General............................................................................ 25 Conceptual and detail engineering.................................. 25 Linepipe and pipeline component manufacturing .......... 25 Corrosion control system and weight coating manufacturing ................................................................. 25 Installation and commissioning ...................................... 26 DFI Résumé .................................................................... 26 Operation ........................................................................ 26 Filing of documentation.................................................. 26 Sec. 4 Loads.................................................................... 27 A. General..................................................................................27 A 100 A 200 A 300 Objective......................................................................... 27 Application ..................................................................... 27 Loads............................................................................... 27 B. Functional Loads ..................................................................27 B 100 B 200 General............................................................................ 27 Characteristic load effects............................................... 27 C. Environmental Loads............................................................27 C C C C C C 100 200 300 400 500 600 General............................................................................ 27 Wind loads ...................................................................... 28 Hydrodynamic loads ....................................................... 28 Wave and current loads .................................................. 28 Ice loads .......................................................................... 28 Characteristic load effects............................................... 28 D. Construction Loads...............................................................29 D 100 General............................................................................ 29 E. Accidental Loads ..................................................................29 E 100 C. Design Format ...................................................................... 19 Marine growth ................................................................ 24 General............................................................................ 29 100 200 300 400 500 600 General............................................................................ 19 Categorisation of fluids................................................... 19 Location classes .............................................................. 19 Safety classes .................................................................. 19 Partial Safety Factor methodology ................................. 19 Reliability analysis.......................................................... 20 F. Other loads............................................................................29 Sec. 3 Design Premises and Documentation................ 21 A 100 A 200 C C C C C C A. General.................................................................................. 21 A A A A 100 200 300 400 Objective......................................................................... 21 Concept development ..................................................... 21 Execution plan ................................................................ 21 Installation, operation and abandonment ........................ 21 B. System Design Principles ..................................................... 21 B 100 B 200 B 300 System integrity .............................................................. 21 Monitoring/inspection during operation ......................... 21 Pressure Control System................................................. 22 C. Pipeline Route....................................................................... 22 C 100 C 200 C 300 Location .......................................................................... 22 Route survey ................................................................... 22 Seabed properties............................................................ 23 F 100 F 200 Trawling loads ................................................................ 29 Earthquake ...................................................................... 30 Sec. 5 Design Criteria.................................................... 31 A. General..................................................................................31 Objective......................................................................... 31 Application ..................................................................... 31 B. Design Principles and Materials ...........................................31 B B B B B B B 100 200 300 400 500 600 700 Pipeline layout ................................................................ 31 Mill pressure test and system pressure test..................... 31 In-service inspection....................................................... 32 Minimum wall thickness................................................. 32 Materials selection .......................................................... 32 Characteristic material properties ................................... 33 Corrosion allowance ....................................................... 34 C. Load and Resistance Calculations ........................................34 C C C C 100 200 300 400 Load conditions .............................................................. 34 Load effect calculation ................................................... 34 Characteristic wall thickness .......................................... 35 Stress and strain calculations .......................................... 35 D. Environmental Conditions.................................................... 23 D. Limit States...........................................................................36 D D D D D D D D D D D D D D D D 100 200 300 400 500 600 700 800 General............................................................................ 23 Collection of environmental data.................................... 23 Wind................................................................................ 23 Tide ................................................................................. 24 Waves.............................................................................. 24 Current ............................................................................ 24 Ice.................................................................................... 24 Air and sea temperatures................................................. 24 100 200 300 400 500 600 700 800 General............................................................................ 36 Limit state format ........................................................... 36 Load effect factors and load combinations..................... 37 Pressure containment (bursting) ..................................... 37 Local buckling ................................................................ 38 Global buckling .............................................................. 39 Fatigue ............................................................................ 40 Ovalisation...................................................................... 40 DET NORSKE VERITAS Offshore Standard DNV-OS-F101, 2000 Page 6 – Contents D D D D 900 1000 1100 1200 Ratcheting .......................................................................41 Accumulated plastic strain ..............................................41 Fracture ...........................................................................41 Accidental limit state ......................................................42 E. Special Considerations ......................................................... 42 E E E E E E E E 100 200 300 400 500 600 700 800 General ............................................................................42 Pipe soil interaction.........................................................42 Spanning risers/pipelines ................................................43 On bottom stability..........................................................43 Trawling interference ......................................................43 Third party loads, dropped objects..................................44 Insulation.........................................................................44 Pipe-in-pipe and bundles.................................................44 F. Pipeline Components and Accessories ................................. 44 F 100 General ............................................................................44 G. Supporting Structure............................................................. 44 G G G G 100 200 300 400 General ............................................................................44 Riser supports..................................................................44 J-tubes .............................................................................44 Stability of gravel............................................................44 H. Installation and Repair.......................................................... 45 H 100 H 200 H 300 General ............................................................................45 Pipe straightness..............................................................45 Coating ............................................................................45 Sec. 6 Linepipe............................................................... 46 A. General.................................................................................. 46 A A A A 100 200 300 400 Scope ...............................................................................46 Material specification......................................................46 Pre-qualification of materials and manufacturers ...........46 Process of manufacture ...................................................46 Sec. 7 Components and Assemblies............................. 66 A. General..................................................................................66 A 100 A 200 Scope...............................................................................66 Quality assurance ............................................................66 B. General requirements for Design of Pipeline Components ..66 B B B B B B B B B B B B 100 200 300 400 500 600 700 800 900 1000 1100 1200 General ............................................................................66 Material selection............................................................66 Flanged and mechanical connections..............................67 Bolting............................................................................67 Valves..............................................................................67 Pressure vessels..............................................................67 Components fabricated by welding.................................67 Insulating joints...............................................................67 Pipeline fittings ...............................................................68 Anchor flanges ................................................................68 Other components ...........................................................68 Structural items ...............................................................68 C. Material and Manufacturing Specifications for Components .......................................................................... 68 C 100 Material and manufacturing specifications .....................68 D. Material for Hot Formed, Forged and Cast Components .....69 D 100 D 200 D 300 D 400 General ............................................................................69 Components made of low alloy C-Mn steel....................69 Components made of ferritic-austenitic (duplex) steel, other stainless steel and nickel based corrosion resistant alloy (CRA).....................................................................70 Delivery condition...........................................................70 E. Hot Forming, Forging, Casting and Heat Treatment............ 70 B. Linepipe Designations .......................................................... 46 E E E E B 100 B 200 B 300 F. Manufacturing of Components, Equipment and Structural Items .....................................................................................71 Linepipe NDT levels .......................................................46 Supplementary requirements...........................................46 Designations....................................................................47 C. Material Properties ............................................................... 47 C C C C 100 200 300 400 C 500 C 600 General ............................................................................47 Carbon Manganese (C-Mn) steel linepipe ......................47 Ferritic-austenitic (duplex) steel .....................................50 Other stainless steel and nickel based corrosion resistant alloy (CRA) linepipe.........................................51 Clad/lined steel linepipe..................................................51 Weldability......................................................................52 D. Supplementary Requirements............................................... 52 D 100 D 200 D 300 D 400 D 500 Supplementary requirement, sour service (S) .................52 Supplementary requirement, fracture arrest properties (F)...................................................................53 Supplementary requirement, linepipe for plastic deformation (P) ...............................................................55 Supplementary requirement, dimensions (D) .................55 Supplementary requirement, high utilisation (U) ...........56 E. Manufacture.......................................................................... 56 E 100 E 200 E 300 General ............................................................................56 Quality Assurance ...........................................................56 Manufacturing Procedure Specification and Qualification....................................................................56 E 400 Steel making....................................................................57 E 500 Manufacture of plate and strip ........................................57 E 600 Linepipe manufacture .....................................................57 E 700 Chemical analysis ...........................................................59 E 800 Mechanical and corrosion tests .......................................59 E 900 Non-destructive testing ...................................................59 E 1000 Visual inspection, workmanship and correction of defects .........................................................................61 E 1100 Mill pressure test .............................................................62 E 1200 Dimensions, weight and lengths .....................................62 F. Marking and Protection ........................................................ 65 F 100 General ............................................................................65 F F F F 100 200 300 400 100 200 300 400 F 500 F 600 F 700 Hot forming.....................................................................70 Forging ............................................................................70 Casting ............................................................................70 Heat treatment .................................................................70 General ............................................................................71 Manufacture of flanges ...................................................71 Manufacture of valves.....................................................71 Manufacture of pressure-containing equipment and components fabricated by welding .................................72 Manufacture of other equipment and components..........72 Fabrication of structural items ........................................72 Mechanical testing of hot formed, cast and forged components .....................................................................72 G. Manufacture of Bends...........................................................72 G G G G G G G G G G G 100 200 300 400 500 600 700 800 900 1000 1100 General ............................................................................72 Mother pipe for seawater service ....................................74 Supplementary requirements to mother pipe ..................74 Requirements to pipe other than dedicated mother pipe.74 Required post bending heat treatment.............................74 Bending procedure qualification.....................................74 Bending and post bend heat treatment ............................75 Non-destructive testing and visual inspection ................76 Production testing of bends.............................................76 Dimensions, tolerances and marking ..............................76 Repair ..............................................................................77 H. Fabrication of Risers, Expansion Loops, Pipe Strings for Reeling and Towing..............................................................77 H 100 H 200 H 300 H H H H H H H General ............................................................................77 Quality Assurance ...........................................................77 Materials for risers, expansion loops, pipe strings for reeling and towing...........................................................77 400 Fabrication procedures and planning ..............................77 500 Material receipt, identification and tracking ...................77 600 Cutting, forming, assembly, welding and heat treatment78 700 Hydrostatic testing ..........................................................78 800 Non-destructive testing and visual examination .............78 900 Dimensional verification.................................................79 1000 Corrosion protection .......................................................79 G. Documentation, Records and Certification .......................... 65 I. Documentation, Records, Certification and Marking...........79 G 100 I General ............................................................................65 100 Documentation, records, certification and marking........79 DET NORSKE VERITAS Offshore Standard DNV-OS-F101, 2000 Contents – Page 7 Sec. 8 Corrosion Protection and Weight coating ........ 80 A. General.................................................................................. 80 A 100 A 200 A 300 Objective......................................................................... 80 Application...................................................................... 80 Definitions ...................................................................... 80 B. General Principles for Corrosion Control During Design .... 80 B 100 B 200 General............................................................................ 80 Evaluation of options for corrosion control.................... 80 C. Pipeline External Coatings ................................................... 81 C 100 C 200 General............................................................................ 81 Coating materials, surface preparation and application.. 81 D. Special Riser Coatings.......................................................... 81 D 100 D 200 General............................................................................ 81 Coating materials, surface preparation and application.. 82 E. Field Joint Coatings .............................................................. 82 E 100 E 200 General............................................................................ 82 Coating materials, surface preparation and application.. 82 F. Concrete Weight Coating ..................................................... 82 F 100 F 200 F 300 General............................................................................ 82 Concrete materials and coating manufacturing .............. 82 Inspection and testing ..................................................... 83 D D D D 400 500 600 700 D 800 essential variables and validity ....................................... 90 Operating limit conditions .............................................. 91 Installation procedures.................................................... 91 Contingency procedures ................................................. 91 Layvessel arrangement, laying equipment and instrumentation ............................................................... 91 Requirements for installation.......................................... 92 E. Additional Requirements for Pipeline Installation Methods Introducing Plastic Deformations .........................................93 E E E E E 100 200 300 400 500 General............................................................................ 93 Installation Manual ......................................................... 93 Qualification of the Installation Manual......................... 93 Installation procedures.................................................... 93 Requirements for installation.......................................... 93 F. Pipeline Installation by Towing............................................94 F F F F F F F F 100 200 300 400 500 600 700 800 General............................................................................ 94 Installation Manual ......................................................... 94 Qualification of Installation Manual............................... 94 Operating limit conditions .............................................. 94 Installation procedures.................................................... 94 Contingency procedures ................................................. 94 Arrangement, equipment and instrumentation ............... 94 Pipestring tow and installation........................................ 94 G. Other Installation Methods ...................................................94 G. Cathodic Protection Design .................................................. 83 G 100 G 100 G 200 H. Shore Pull..............................................................................95 General............................................................................ 83 Design parameters and calculations................................ 83 H. Manufacturing and Installation of Sacrificial Anodes.......... 84 H 100 H 200 Anode manufacturing ..................................................... 84 Anode installation ........................................................... 84 I. Design and Manufacturing/Fabrication of Internal Corrosion Protection.............................................................................. 84 I I I 100 200 300 I 400 I 500 General............................................................................ 84 Internal corrosion protection by fluid processing ........... 84 Internal corrosion protection by use of linepipe in Corrosion Resistant Alloys (CRAs)................................ 85 Internal corrosion protection by organic coatings or linings ......................................................................... 85 Internal corrosion protection by chemical treatment ...... 85 Sec. 9 Installation........................................................... 86 A. General.................................................................................. 86 A 100 A 200 A 300 A A A A A A 400 500 600 700 800 900 Objective......................................................................... 86 Application...................................................................... 86 Failure Mode Effect Analysis (FMEA) and Hazard and Operability (HAZOP) studies .................................. 86 Installation and testing specifications and drawings....... 86 Installation Manuals........................................................ 86 Quality Assurance........................................................... 86 Welding........................................................................... 86 Non-destructive testing and visual examination............. 87 Production tests............................................................... 87 B. Pipeline Route, Survey and Preparation ............................... 87 B B B B 100 200 300 400 Pre-installation route survey ........................................... 87 Seabed preparation.......................................................... 88 Pipeline and cable crossings ........................................... 88 Preparations for shore approach ..................................... 88 C. Marine Operations ................................................................ 88 C 100 C 200 C 300 C C C C C 400 500 600 700 800 General............................................................................ 88 Vessels ............................................................................ 88 Anchoring systems, anchor patterns and anchor positioning ...................................................................... 88 Positioning systems ........................................................ 89 Dynamic positioning....................................................... 89 Cranes and lifting equipment.......................................... 89 Anchor handling and tug management ........................... 89 Contingency procedures ................................................. 89 D. Pipeline Installation .............................................................. 89 D 100 D 200 D 300 General............................................................................ 89 Installation Manual ......................................................... 90 Review and qualification of the installation manual, H H H H H H H H 100 200 300 400 500 600 700 800 General............................................................................ 94 General............................................................................ 95 Installation Manual ......................................................... 95 Qualification of Installation Manual............................... 95 Operating limit conditions .............................................. 95 Installation procedures.................................................... 95 Contingency procedures ................................................. 95 Arrangement, equipment and instrumentation ............... 95 Requirements for Installation ......................................... 95 I. Tie-in Operations ..................................................................95 I I I I I I I I 100 200 300 400 500 600 700 800 General............................................................................ 95 Installation Manual ......................................................... 95 Qualification of Installation Manual............................... 95 Operating limit conditions .............................................. 95 Tie-in procedures ............................................................ 95 Contingency procedures ................................................. 96 Tie-in operations above water ........................................ 96 Tie-in operations below water ........................................ 96 J. As-Laid Survey.....................................................................96 J J J J 100 200 300 400 General............................................................................ 96 Specification of as-laid survey........................................ 96 As-laid survey................................................................. 96 As-laid survey of corrosion protection systems.............. 96 K. Span Rectification and Pipeline Protection ..........................96 K K K K K K 100 200 300 400 500 600 General............................................................................ 96 Span rectification and protection specification............... 96 Span rectification ............................................................ 97 Trenching........................................................................ 97 Post-installation gravel dumping .................................... 97 Grout bags and concrete mattresses................................ 97 L. Installation of Protective and Anchoring Structures.............97 L 100 General............................................................................ 97 M. Installation of Risers .............................................................98 M M M M M M 100 200 300 400 500 600 General............................................................................ 98 Installation Manual ......................................................... 98 Qualification of the Installation Manual......................... 98 Operating limit conditions .............................................. 98 Contingency procedures ................................................. 98 Requirements for Installation ......................................... 98 N. As-Built Survey ....................................................................98 N N N N 100 200 300 400 General............................................................................ 98 Specification of as-built survey ...................................... 98 As-built survey requirements.......................................... 98 Inspection of impressed current cathodic corrosion protection system ............................................................ 99 DET NORSKE VERITAS Offshore Standard DNV-OS-F101, 2000 Page 8 – Contents O. Final Testing and Preparation for Operation ........................ 99 F. Design Criteria.................................................................... 111 O 100 O 200 F F F F F F 100 200 300 400 500 600 F F F F F F F F 700 800 900 1000 1100 1200 1300 1400 O 300 O O O O O O 400 500 600 700 800 900 General ............................................................................99 Specification of final testing and preparation for operation ....................................................................99 Procedures for final testing and preparation for operation ....................................................................99 Cleaning and gauging......................................................99 System pressure testing...................................................99 Cleaning, de-watering and drying .................................100 Systems testing..............................................................101 Product filling ...............................................................101 Operational verification (start-up inspection) ...............101 P. Documentation.................................................................... 101 P 100 General ..........................................................................101 Sec. 10 Operation, Inspection, and Repair ................. 102 A. General................................................................................ 102 A A A A A A 100 200 300 400 500 600 Objective .......................................................................102 Procedures .....................................................................102 In-Service file................................................................102 Operation.......................................................................102 Inspection and monitoring philosophy..........................102 Special inspections ........................................................102 B. Pipeline Configuration Survey ........................................... 102 B 100 B 200 General ..........................................................................102 Periodic survey..............................................................102 C. Inspection and Monitoring of External Corrosion.............. 103 C 100 C 200 C 300 General ..........................................................................103 Risers in the Splash zone and the Atmospheric Zone ...103 Pipelines and Risers in the Submerged Zone................103 D. Inspection and Monitoring of Internal Corrosion............... 104 D 100 D 200 D 300 General ..........................................................................104 Corrosion inspection .....................................................104 Corrosion monitoring....................................................104 E. Defects and Repair.............................................................. 104 E E E E E E E 100 200 300 400 500 600 700 General ..........................................................................104 Global buckling.............................................................105 Grooves, gouges, cracks and notches............................105 Metal loss defects..........................................................105 Dents .............................................................................105 Leaks .............................................................................105 Repair by welding .........................................................105 Sec. 11 Requalification.................................................. 106 A. General................................................................................ 106 A 100 A 200 Objective .......................................................................106 Application....................................................................106 B. Design Criteria.................................................................... 106 B 100 B 200 B 300 General ..........................................................................106 System Pressure Test ....................................................106 Deterioration .................................................................106 Sec. 12 Commentary (Informative) ............................. 107 General ..........................................................................111 Material de-rating..........................................................111 Condition load effect factors.........................................111 Pressure containment - equivalent format.....................111 Calculation of nominal thickness..................................111 Pressure containment criterion, incidental pressure less than 10% above the design pressure. ............................111 Local buckling - Collapse .............................................112 Local buckling - Moment..............................................112 Local buckling - Girth weld factor................................112 Local buckling - Propagating pressure..........................112 Local buckling - Buckle arrestors .................................113 Local buckling - Allowable stress design format..........113 Local buckling - Adding moments................................113 Ovalisation ....................................................................113 G. Fracture Mechanics.............................................................114 G 100 G 200 G 300 Engineering Criticality Assessment (ECA) - Strain based design ..................................................................114 ECA - Cyclic loading into the plastic regime ...............114 Fracture toughness testing.............................................114 H. API Material Grades ........................................................... 115 H 100 API material grades.......................................................115 I. Components and assemblies ...............................................115 I I I 100 200 300 Bends.............................................................................115 Riser Supports ...............................................................115 J-tubes ...........................................................................115 J. Material and Design Links.................................................. 116 J J J J 100 200 300 400 General ..........................................................................116 Supplementary requirements.........................................116 Links based on accumulated strain ...............................116 Material data sheet ........................................................117 K. Installation ..........................................................................117 K K K K 100 200 300 400 Safety class definition ...................................................117 Coating ..........................................................................117 Simplified laying criteria ..............................................118 Reeling ..........................................................................118 L. References...........................................................................119 App. A Supplementary Requirements to ISO ............ 120 A. General................................................................................120 A 100 General ..........................................................................120 B. Differences observed ..........................................................120 B B B B B B B B B B 100 200 300 400 500 600 700 800 900 1000 Chemical composition and mechanical properties........120 Weldability....................................................................120 Samples and test pieces.................................................120 Frequency of testing during manufacture .....................120 NDT ..............................................................................120 Dimensions....................................................................120 Documentation ..............................................................120 Special requirements for sour service ...........................120 Special requirements for fracture arrest ........................120 Mill pressure test...........................................................120 App. B Mechanical Testing and Corrosion testing .... 122 A. General................................................................................ 107 A 100 Objective .......................................................................107 B. Cross References ................................................................ 108 C. Design Philosophy.............................................................. 109 C 100 C 200 C 300 Safety Class discussion .................................................109 Structural reliability analyses........................................109 Characteristic values .....................................................110 D. Design Premise ................................................................... 110 D 100 D 200 Monitoring ....................................................................110 Air and sea temperatures...............................................110 A. Mechanical Testing.............................................................122 A A A A A A A A A A A 100 200 300 400 500 600 700 800 900 1000 1100 General ..........................................................................122 Selection and preparation of samples and test pieces ...122 Chemical analysis .........................................................122 Tensile test ....................................................................122 Bend test........................................................................122 Charpy V-notch impact test ..........................................123 Drop weight tear test (DWTT)......................................123 Fracture toughness testing.............................................123 Shear strength test .........................................................124 Metallographic examination and hardness testing ........124 Strain ageing test...........................................................124 E. Loads .................................................................................. 110 B. Corrosion Testing ............................................................... 125 E 100 E 200 E 300 B 100 B 200 B 300 Local pressure ...............................................................110 Conversion of pressures ................................................110 Flow velocity around cylindrical members...................111 General ..........................................................................125 Pitting corrosion test .....................................................125 Hydrogen Pressure Induced Cracking test ...................125 DET NORSKE VERITAS Offshore Standard DNV-OS-F101, 2000 Contents – Page 9 B 400 Sulphide Stress Cracking test ....................................... 125 A. Application ......................................................................... 130 B B B B B A 100 A 200 A 300 C. Manual Non-destructive testing of Base Materials and Weld Overlay ...............................................................................148 App. C Welding .............................................................. 130 General.......................................................................... 130 Welding processes ........................................................ 130 Quality Assurance......................................................... 130 B. Welding Equipment, Tools and Personnel ......................... 130 B 100 B 200 Welding equipment and tools ....................................... 130 Personnel....................................................................... 130 C. Welding Consumables........................................................ 131 C C C C C 100 200 300 400 500 General.......................................................................... 131 Chemical composition .................................................. 131 Mechanical properties................................................... 131 Batch testing – Girth welds........................................... 131 Handling and storage of welding consumables ............ 132 D. Welding Procedures............................................................ 132 D D D D D D 100 200 300 400 500 600 General.......................................................................... 132 Preliminary welding procedure specification ............... 132 Welding procedure qualification record ....................... 132 Welding procedure specification .................................. 132 Welding procedure specification for repair welding .... 133 Essential variables for welding procedures .................. 133 E. Qualification of Welding Procedures ................................. 133 E 100 E 200 E 300 E 400 E 500 E 600 E 700 E 800 E 900 General.......................................................................... 133 Qualification of repair welding procedures .................. 134 Qualification of longitudinal and spiral welds in linepipe and linepipe components................................. 134 Qualification of girth welds in risers, expansion loops and pipe strings for towing.................................. 134 Qualification of girth welds for installation and tie-in . 135 Qualification of girth welds exposed to accumulated plastic strain .................................................................. 136 Qualification of underwater welding for tie-in ............. 136 Qualification of overlay welding .................................. 137 Qualification of welding procedures for structures ...... 137 F. Examination and Testing .................................................... 137 F F F F F F 100 200 300 400 500 600 General.......................................................................... 137 Visual examination and non-destructive testing........... 137 Destructive testing of butt joints................................... 137 Sulphide stress cracking test ......................................... 139 Corrosion Testing and Microstructure Examination .... 139 Testing of weld overlay ................................................ 139 G. Fabrication and Welding Requirements ............................. 140 G G G G G G 100 200 300 400 500 600 G 700 General.......................................................................... 140 Production welding ....................................................... 140 Repair welding.............................................................. 140 Post weld heat treatment ............................................... 140 Welding of linepipe and linepipe components ............. 141 Fabrication of risers, expansion loops, pipe strings for towing...................................................................... 141 Installation and tie-in welding ...................................... 141 H. Material and Process Specific Requirements ..................... 141 H 100 H 200 H 300 Internally clad/lined carbon steel.................................. 141 Duplex stainless steel.................................................... 142 Martensitic (13% Cr) stainless steel ............................. 142 App. D Non-Destructive Testing (NDT)....................... 143 A. General................................................................................ 143 A A A A A A A A 100 200 300 400 500 600 700 800 Scope............................................................................. 143 Codes and standards...................................................... 143 Quality Assurance......................................................... 144 Non-destructive testing methods .................................. 144 Non-destructive testing procedures .............................. 144 Personnel qualifications................................................ 144 Reporting ...................................................................... 144 Timing of NDT ............................................................. 144 B. Manual Non-destructive Testing and Visual Examination of Welds .................................................................................. 145 B 100 B 200 General.......................................................................... 145 Radiographic testing ..................................................... 145 C C C C C 300 400 500 600 700 100 200 300 400 500 Manual ultrasonic testing.............................................. 145 Manual magnetic particle testing.................................. 146 Manual liquid penetrant testing .................................... 147 Manual eddy current testing ......................................... 147 Visual examination ....................................................... 148 General.......................................................................... 148 Plate and pipe................................................................ 148 Forgings ........................................................................ 148 Castings......................................................................... 148 Weld overlay................................................................. 148 D. Automated Non-Destructive Testing.................................. 148 D 100 D 200 General.......................................................................... 148 Automated ultrasonic testing ........................................ 149 E. Non-Destructive Testing Acceptance Criteria....................149 E 100 E 200 General.......................................................................... 149 Acceptance criteria based on Engineering Critical Assessment (ECA)........................................................ 150 F. Non-Destructive Testing of Plate and Strip at Mill ............ 150 F 100 F 200 F 300 F 400 General.......................................................................... 150 Ultrasonic testing of C-Mn and duplex steel plate and strip................................................................ 150 Ultrasonic testing of clad plate and strip ...................... 151 Visual examination of plate and strip ........................... 151 G. Non-Destructive Testing of Linepipe at Pipe Mills............ 151 G G G G G G G G G G 100 200 300 400 500 600 700 800 900 1000 General.......................................................................... 151 Untested pipe ends........................................................ 151 Suspect pipe .................................................................. 151 Non-destructive testing applicable to all pipe .............. 151 Non-destructive testing of seamless pipe ..................... 152 Non-destructive testing of HFW, LBW and EBW pipe152 Non-destructive testing of SAW pipe........................... 154 Manual NDT................................................................. 156 Non-destructive testing of weld repairs in pipe............ 157 Visual examination of welds in linepipe ...................... 157 H. Testing of Installation Girth Welds, Component Welds and other Pressure Containing Welds........................................157 H H H H 100 200 300 400 General.......................................................................... 157 Non-destructive testing and visual examination........... 157 Acceptance criteria ....................................................... 157 Repair of welds ............................................................. 158 I. Acceptance Criteria for Pipeline Components, Equipment, Structural Items, Base Materials and Weld Overlay ..........159 I I 100 200 I I I 300 400 500 General.......................................................................... 159 Manual Non-destructive Testing Acceptance criteria for Plate and Pipe ............................................. 160 Acceptance criteria for forgings ................................... 160 Acceptance criteria for castings.................................... 160 Acceptance criteria for weld overlay............................ 160 App. E Automated Ultrasonic Girth Weld Testing.... 161 A. General................................................................................161 A 100 A 200 Scope............................................................................. 161 References..................................................................... 161 B. Basic Requirements ............................................................161 B B B B B B B B B B B B B 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 General.......................................................................... 161 Documentation.............................................................. 161 Qualification ................................................................. 161 Ultrasonic system equipment and components............. 161 Recorder set-up............................................................. 163 Circumferential scanning velocity................................ 163 Gate settings.................................................................. 163 Recording Threshold .................................................... 163 Power supply ................................................................ 163 Software........................................................................ 163 System Log Book ......................................................... 163 Spares............................................................................ 163 Slave monitors .............................................................. 163 C. Procedure ............................................................................163 C 100 General.......................................................................... 163 DET NORSKE VERITAS Offshore Standard DNV-OS-F101, 2000 Page 10 – Contents D. Calibration .......................................................................... 164 I. Validity of Qualification.....................................................167 D 100 D 200 I I Initial static calibration..................................................164 Dynamic calibration......................................................164 E. Field Inspection .................................................................. 164 E 100 E 200 Inspection requirements ................................................164 Operational checks ........................................................165 F. Re-examination................................................................... 165 F 100 General ..........................................................................165 G. Evaluation and Reporting ................................................... 165 G 100 G 200 G 300 Evaluation of indications ..............................................165 Examination reports ......................................................165 Inspection records .........................................................165 H. Qualification ....................................................................... 165 H H H H H H H H H H 100 200 300 400 500 600 700 800 900 1000 General ..........................................................................165 Scope .............................................................................165 Requirements ................................................................165 Qualification programme ..............................................166 Variables .......................................................................166 Test welds .....................................................................166 Qualification testing.....................................................166 Validation testing ..........................................................166 Analysis.........................................................................167 Reporting.......................................................................167 100 200 Validity..........................................................................167 Essential variables.........................................................167 J. Annex A. Transducer requirements....................................167 J J J J J J J J J J J J J J 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 A.1 Identification ..........................................................167 A.2 Beam angle.............................................................167 A.3 Beam size ...............................................................167 A.4 Overall gain............................................................167 A.5 Index point .............................................................167 A.6 Squint .....................................................................167 A.7 Longitudinal angle beam........................................167 A.8 Surface waves.........................................................167 A.9 Side lobes ...............................................................167 A.10 Subsidiary maxima...............................................167 A.11 Pulse shape ...........................................................167 A.12 Frequency.............................................................168 A.13 Pulse length ..........................................................168 A.14 Signal to noise ......................................................168 K. Annex B. Determination of shear wave velocity in pipe steels .......................................................................168 K K K K K K 100 200 300 400 500 600 B.1 General ...................................................................168 B.2 Equipment ..............................................................168 B.3 Specimens...............................................................168 B.4 Test method ............................................................168 B.5 Accuracy.................................................................168 B.6 Recording ...............................................................168 DET NORSKE VERITAS
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