World Pipelines June 2007 - Integrity Management

QUALITY PLAN
No. 815-1559
Plug Mill of Plant Rath
Project Name PIPELINE REPLACEMENT PROJECT
Purchaser LEIGHTON / MUMBAI
Customer INDIA
Reference of Purchaser order IO182/PRP2/P0003
Reference of Customer order INO182
Reference of VMD order 815/1559
Dimensions According to P.O.
Inspection by
Grade API 5L, PSL 2 (Grades see item list)
V&M Germany has implemented and maintains a fully documented Quality Management System in accordance
to EN ISO 9001.
Revision 0 … 5 6
Date 15.05.2008 30 July 2008 13 Aug 2008
TWR-SQ/Ra TWR-SQ/Ra TWR-SQ/Ra
Prepared
O. Fitzek O. Fitzek O. Fitzek
TWR-SQ/Ra TWR-SQ/Ra TWR-SQ/Ra
Reviewed/Approved
J. Pfeifenbring J. Pfeifenbring J. Pfeifenbring
Customer Approval
Mill address: V&M Deutschland GmbH

Rather Kreuzweg 106
D 40472 Düsseldorf
Quality
Plant Rath Plug mill 815-1559
Plan No.
TABLE OF CONTENTS Page 1 of 1
VMD Order No. 815/1559 VMD Item No. See item list
Customer INDIA Cust. Order No. INO182
Purchaser LEIGHTON / MUMBAI Purch. Order No. IO182/PRP2/P0003
Project Designation PIPELINE REPLACEMENT PROJECT
Specification/ Material API 5L, PSL 2
Standard (Material see item list)
Revision 0 … 5 6
Date 15.05.2008 30 July 2008 13 Aug. 2008
No. Document Revision / Date Rev.

1 Item List 3 / 10 July 2008
2 List of Specifications 0 / 15 May 2008
3 Manufacturing Procedure Specification 0 / 15 May 2008
4 Manufacturing and Inspection Plan 1 / 16 May 2008
5 Standard Manufacturing and Inspection Plan HKM SMIP-No: R2 0 / 15 May 2008
6 V&M Annex A Chemical Properties (Sour Service) 1 / 15 May 2008
7 V&M Annex B1-1 First Day Production Tests 3 / 30 July 2008
V&M Annex B1-2 First Day Production Tests 3 / 30 July 2008
8 V&M Annex B-1 Production Tests 2 / 30 July 2008
V&M Annex B-2 Production Tests 2 / 30 July 2008
9 V&M Annex C Dimensional Inspection 1 / 12 June 2008
10 V&M Annex D Marking 1 / 2 July 2008
11 V&M Annex F Heat Treatment 1 / 30 July 2008
12 V&M Annex G1 US Testing Parameters 0 / 15 May 2008
13 V&M Annex G6 MPI Parameters Pipe ends 0 / 15 May 2008
14 V&M Annex H Handling, Storage and Shipping 0 / 15 May 2008
15 V&M Annex I Traceability 0 / 15 May 2008
16 V&M Annex L Hydrostatic Test Parameters 1 / 13 Aug. 2008 6
17 V&M Annex M HIC Test Procedure 0 / 15 May 2008
18 V&M Annex N SSC Test Procedure 0 / 15 May 2008
19 V&M Annex T CTOD Test Procedure 0 / 13 May 2008
Quality
Plan No.
MANUFACTURING AND INSPECTION PLAN Page 1 of 3
Revision 0 1
Date 15.05.2008 13.06.2008
Op.
No. Operation Procedure Specification V&M TPI CA Comments Rev
1 Contract review Customer order V&M Sales department

1)
2 HKM Standard SMIP No.: R2 Process BOF
Manufacturing Plan Conticast rounds
3 Billet inspection: V&M Annex A R R Surface, heat analysis 1
1)
Plant HKM
4 Pre-material Mill standard H Identification, quantity
inspection
5 Billet heating: rotary R Temperature, time, rolling
hearth furnace sequence
6 Rolling Plug Mill R Heat traceability
7 Straightening Mill Standard
8 In-house test (EMI) Mill standard R R Longitudinal and transverse 1

-Flux leakage test defects outside, wall thickness
-UT wall thickness
9 Pipe inspection Mill standard R Visual inspection / dimension
control / surface
10 Marking Mill standard R Each pipe:
(inhouse) Heat-no., colour code
11 Heat treatment (Q&T) V&M Annex F, I R Heat traceability, Heat treatment
temperature charts
12 Hot rotary Mill Standard
straightening
13 Marking Mill standard R Each pipe:
(inhouse) Heat-no., order-no., colour code,
Internal Process Pipe No.
Single Pipe Traceability required
14 Stamping and cutting V&M Annex B1-1, B1-2, B1, H W Heat, sample no., Inspector mark 1
of test samples for B2
FDP Tests &
Production Tests
15 Marking transfer no. 1 Traceability: W/R W Prior notice to the inspectors: 1
on the test coupons in Procedure of test lab ref. no.: One working day
the test laboratory V4.0.12
( working day of test lab =
Monday to Saturday )
16 Marking transfer no. 2 Traceability: W/R Prior notice to the inspectors:
on the test specimens Procedure of test lab ref. no.: Two hours if inspectors are
in the test laboratory V4.0.12 available in the area of the
( only if needed ) laboratory or in the Plug Mill of
plant Rath – otherwise one
working day.
________________________________
1) Hüttenwerke Krupp Mannesmann
Quality
Plan No.
Revision 0 1
Date 15.05.2008 13.06.2008
Op.
17 Material tests: V&M Annex A, B, B1 H* W R H* deligated to qualified personal 1

- Product analysis of test house in behalf of V&M/
- Material Tests Rath
- HIC-Test
- SSC-Test
- Hardness Tests
18 Light gag press V&M Annex C
straightening,
if necessary
19 Non Destructive V&M Annex G1 R R R See MPS 1
Examination
Longitudinal and transverse
defects inside & outside,
lamination, minimum/maximum
wall thickness
20 Bevelling V&M Annex C R/W R/W 1
21 MPI of pipe end areas V&M Annex G6 R R Lamination at the bevel and 1
and bevels due to capacity, operation transverse discontinuities inside
may be performed after final & outside
marking
22 Check of residual R R < 20 Gauss, check on random 1
magnetism at pipe basis, three times per shift
ends
23 Final inspection V&M Annex C R R/W Dimensions, surface 1
24 Hydrostatic test V&M Annex L R R/W R Pipe-No. Marked on records 1
25 Weighing and V&M Annex C R R Recorded on Tally-List 1
measuring of length
26 Final marking V&M Annex D R W Marking in metric units 1
27 Pipe end protection Purchase order R R/W Plastic caps suitable for hook 1
loading
28 Document review Purchase order H H R Tally list: 5x in english 1
29 Release of pipes H H R See item list 1
30 Dispatch Purchase order R Pipes loose
31 Inspection certificate 3.2 - EN 10204 R R 5 x in english 1

32 Data Book Purchase order R To be reviewed 1
Quality
Plan No.
Revision 0 1
Date 15.05.2008 13.06.2008
Op.
Abbreviations
V&M V&M QA or Production Representative

H Hold Point Material/Operation cannot proceed without TPI presence. If TPI fails to attend,
production can continue if confirmed with the customer in writing.
W Witness Point TPI invited to witness a specific operation. If TPI fails to attend, production
can continue.
M Monitoring Point TPI to review several operations on a sample basis. If TPI fails to appear,
production can proceed.
R Review Point No invitation to customer / TPI - Records/Reports are available
The fixed times for invitations concerning Witness & Hold Points are as follows:
The first invitation will be pronounced 5 calendar days before starting

production.
During production invitations will be sent to the customer 2 working days

before a testing or production step acc. to this MIP will start.
Unforeseen changes in production sequence must allow a change of invitation

latest 3 PM the working day before a Witness or Hold Point will be carried out.
Invitation for re-processed pipes after repair will be on short time notice and by
agreement with the TPI
Quality
Plan No.
ANNEX B1-1 FIRST DAY PRODUCTION TESTS Page 1 of 2
Specification/ 2020 B Vol-II Material X60 API 5L, PSL 2, Sour
Standard Service (Material see item list)
Revision 0 1 2 3
Date 15.05.2008 13.06.2008 10.07.2008 30 July 2008
Test Requirements Frequency Rev.
Transverse Tensile Test YS min-max 414 – 550 MPa Two specimens per FDP test 3
(flattened strip specimen) UTS ≥ 517 MPa pipe.
YS/UTS ≤ 0,90
Annexure II b) Elongation ≥ 20% for wallthickness ≤ 12,5mm
≥ 22% for wallthickness > 12,5mm
Longitudinal Tensile Test YS min-max 414 – 550 MPa Two specimens per FDP test
pipe.
3
(strip specimen) UTS ≥ 517 Mpa
YS/UTS ≤ 0,90
Transverse Charpy - V Test Size Full size (flattening not permitted) One set (3 specimens) per 3
ASTM A370 Single value min. 31 J FDP test pipe.
Test Temperature : 10°C
Average value min. 41 J
Annexure II b)
Product Analysis See V&M Annex A Each FDP test pipe. 3
CTOD Test Test temperature 10°C One set (3 specimens) per 3

(transverse specimen) FDP test pipe.
BS7448, 1991 CTOD value min. 0,35 mm
Average CTOD for information
Annexure II c) value
All data on fatigue pre-cracking
Supplementary front are required : see
requirement Annexure II c)
Sour Service Tests

NACE standard TM-0284, 96 hours in test solution
3
CSR = 0 %
- HIC Test One set (3specimens) per
4 point bend test specimen acc. to § 9.3.8 and § 8. FDP test pipe.
Annexure II d) (transverse specimen, if possible, otherwise longitudinal
specimen)
- SSC Test Solution acc. to NACE TM 0177-90, 96 hours

No failure at a stress of 72 % SMYS by visual inspection
Annexure II d) and wet MPI
Hardness Test Hardness maximum value : 248 HV10 One test per FDP test pipe. 3
ASTM E92
(Modalities of retest acc. to 9.10) The hardness tests shall be
Annexure II b) carried out on samples of
pipes at locations indicated in
Figure 9.3.6.
Quality
Plan No.
Revision 0 1 2 3
NACE standard tensile test Method A One test on one FDP pipe for
Mill qualification Test 3
Solution acc. to NACE TM 0177-90 the entire order from item 6
and item 20
Annexure II 720 hours
Stress levels of 60,72,80,90 and 100 % SMYS

SSC Test
Minimum stress for failure after 720 hours shall be at

least 72% SMYS.
Remarks FDP test pipes :
Two pipes from one heat (in case of only one heat on first day) or from the first two
heats, i.e. one pipe from each heat, (in case of more than one heat on first day) are
selected on first day production (as per ❸ Annexure II). FDP test pipes to be taken
from the items with the maximum diameter and the minimum wall thickness, so 3
item 3, 16 and 20
Visual inspection of FDP Pipes according to spec. Annexure II a).

Dimensional inspection on each FDP pipe as per Annex C
US-testing on each FDP as per MPS
Quality
Plan No.
Specification/ 2020 A Vol-II Material X52 API 5L, PSL 2, NON Sour
Revision 0 1 2 3
Date 15.05.2008 13.06.2008 10.07.2008 30 July 2008
Transverse Tensile Test YS min-max 359 – 477 MPa Two specimens per FDP test 3
(flattened strip specimen) UTS ≥ 455 MPa pipe.
YS/UTS ≤ 0,90
Longitudinal Tensile Test YS min-max 359 – 477 MPa Two specimens per FDP test
pipe.
3
YS/UTS ≤ 0,90
ASTM A370 Single value min. 27 J FDP test pipe.
Annexure II b)
Product Analysis See V&M Annex A Each FDP test pipe. 3
CTOD Test Test temperature 10°C One set (3 specimens) per 3

(transverse specimen) FDP test pipe.
BS7448, 1991 CTOD value min. 0,35 mm
Average CTOD for information
Annexure II c) value
All data on fatigue pre-cracking
Supplementary front are required : see
requirement Annexure II c)
Hardness Test Hardness maximum value : 248 HV10 One test per FDP test pipe. 3
ASTM E92
(Modalities of retest acc. to 9.10) The hardness tests shall be
Annexure II b) carried out on samples of
Figure 9.3.6.
Remarks FDP test pipes :
Two pipes from one heat (in case of only one heat on first day) or from the first two
heats, i.e. one pipe from each heat, (in case of more than one heat on first day) are
selected on first day production (as per ❸ Annexure II). FDP test pipes to be taken
from the items with the maximum diameter and the minimum wall thickness, so 3
item 6
Visual inspection of FDP Pipes according to spec. Annexure II a).

Dimensional inspection on each FDP pipe as per Annex C
US-testing on each FDP as per MPS
Quality
Plan No.
ANNEX B-1 PRODUCTION TESTS ON MATERIAL Page 1 of 2
Specification/ 2020 b Vol-II Material X60 API 5L, PSL 2 SOUR
Standard SERVICE
(Material see item list)
Revision 0 1 2
Date 15.05.2008 13.06.2008 30 July 2008
Transverse Tensile Test YS min-max 414 – 550 MPa One specimen per inspection 2
(flattened strip specimen) UTS ≥ 517 MPa lot.
YS/UTS ≤ 0,90
§§ 6.2.1 and 9.3.1 Elongation ≥ 20% for wallthickness ≤ 12,5mm
Longitudinal Tensile Test YS min-max 414 – 550 MPa One specimen per inspection
lot.
2
YS/UTS ≤ 0,90
ASTM A370 Single value min. 31 J inspection lot.
§ 9.3.5
Product Analysis See V&M Annex A 2 each heat and additional 2

one pipe for every 100 pipes
or less, if the lot is more than
100 pipes
Hardness Test Hardness maximum value : 248 HV10 One specimen per inspection 2
ASTM E92 lot.
§ 9.3.6 The hardness tests shall be

carried out on samples of
Figure 9.3.6.
CTOD Test Test temperature 10°C Two sets (of 3 specimens) for 2
(transverse specimen) the entire order from the heat
BS7448, 1991 CTOD value min. 0,35 mm with the highest CE based on
Average CTOD for information the heat analysis
§ 9.3.5 value
Sour Service Tests

NACE standard TM-0284, 96 hours in test solution
2
CSR = 0 %
- HIC Test One test for each of the first
three heats, that are not
§ 9.3.7 already covered by the FDP
4 point bend test specimen acc. to § 9.3.8.
pipes and then one test every
(Transverse specimen, if possible, otherwise longitudinal
10 heats.
- SSC Test specimen)
§ 9.3.8 Solution acc. to NACE TM 0177-90, 96 hours
No failure at a stress of 72 % SMYS by visual inspection
and wet MPI
Quality
Plan No.
ANNEX B PRODUCTION TESTS ON MATERIAL Page 2 of 2
Revision 0 1 2
Remarks One inspection lot shall consist of max. 100 pipes of the same heat, size, wall
thickness and heat treatment batch.
Columns 3 and 5 of API 5L, table 3B are not applicable.
Modalities of retest acc. to § 9.10

Quality
Plan No.
ANNEX B-2 PRODUCTION TESTS ON MATERIAL Page 1 of 1
Specification/ 2020 A Vol-II Material X52 API 5L, PSL 2
Standard NON SOUR
(Material see item list)
Revision 0 1 2
Date 15.05.2008 13.06.2008 30 July 2008
Transverse Tensile Test YS min-max 359 - 477 MPa One specimen per inspection 3
(flattened strip specimen) UTS ≥ 455 MPa lot.
YS/UTS ≤ 0,90
Longitudinal Tensile Test YS min-max 359 - 477 MPa One specimen per inspection
lot.
3
YS/UTS ≤ 0,90
ASTM A370 Single value min. 27 J inspection lot.
§ 9.3.5
Product Analysis See V&M Annex A 2 each heat and additional 3

one pipe for every 100 pipes
or less, if the lot is more than
100 pipes
Hardness Test Hardness maximum value : 248 HV10 One specimen per inspection 3
ASTM E92 lot.
§ 9.3.6 The hardness tests shall be

carried out on samples of
Figure 9.3.6.
CTOD Test Test temperature 10°C Two sets (of 3 specimens) for 3
(transverse specimen) the entire order from the heat
BS7448, 1991 CTOD value min. 0,35 mm with the highest CE based on
Average CTOD for information the heat analysis
§ 9.3.5 value
Remarks One inspection lot shall consist of max. 100 pipes of the same heat, size, wall
thickness and heat treatment batch.
Columns 3 and 5 of API 5L, table 3B are not applicable.
Modalities of retest acc. to § 9.10

Quality
Plan No.
ANNEX F HEAT TREATMENT PARAMETERS Page 1 of 1
Revision 0 1
Date 15.05.2008 30 July 2008
Normalizing Solution Annealing Quenching Tempering Rev.
Temperature min. °C 910 610
Temperature max. °C 970 710
Holding Time min. Min. ≥10 >20
Method of Cooling inside and outside still air 1

water-quenched,
inside jet stream / still
air)*
Remarks )* for X52 normalizing 1

Quality
Plan No.
ANNEX L HYDROSTATIC TEST PARAMETERS Page 1 of 2
Revision 0 1
Date 15.05.2008 13 Aug. 2008
V&M D Item 1 3 5 6 7 9 Rev
Dimension 323,90 x 219,10 x 355,60 x 323,90 x 323,90 x 406,40 x

O.D. x w.th nom. mm 14,30 11,10 14,30 15,90 23,80 27,00
Calculated MPa 32,90 37,75 29,97 31,72 54,76 1

Test Pressure
Set Up bar 329 378 300 317 548 491)* 1

Test Pressure
Pressure Tolerance bar -0 / +10 -0 / +10 -0 / +10 -0 / +10 -0 / +10 -0 / +10
Time under ≥ sec. 10 10 10 10 10 10

Pressure
V&M D Item 10 12 13 14 16 17 Rev
Dimension 219,10 x 355,60 x 323,90 x 323,90 x 406,40 x 219,10 x

O.D. x w.th nom. mm 20,60 17,50 20,60 23,80 27,00 20,60
Calculated MPa 70,06 36,67 41,1 54,76 70,06 1

Test Pressure
Set Up bar 701 367 411 548 491)* 701 1

Test Pressure
Pressure Tolerance bar -0 / +10 -0 / +10 -0 / +10 -0 / +10 -0 / +10 -0 / +10
Time under ≥ sec. 10 10 10 10 10 10

Pressure
Quality
Plant 815-1559
Plan No.
ANNEX L HYDROSTATIC TEST PARAMETERS Page 2 of 2
Revision 0 1
V&M D Item 19 20 21 Rev
Dimension 406,40 x 355,60 x 323,90 x

O.D. x w.th nom. mm 11,60 17,50 20,60
Calculated MPa 21,27 36,67 41,1 1

Test Pressure
Set Up bar 213 367 411 1

Test Pressure
Pressure Tolerance bar -0 / +10 -0 / +10 -0 / +10
Time under ≥ sec. 10 10 10

Pressure
Remarks )* Test pressure blocked at 491 bar in accordance to V&M technical comment 15/7677
Calculation acc. to § 9.4.3.1 0,90% of SMYS
Test frequency : all pipes
Pressure gauges:
- The working gauge will be checked against a separate second gauge once per shift.
- The second gauge itself will be checked regularly against a pressure testing instrument in
the gauging department.
- The pressure testing instrument is calibrated regularly by an official independent laboratory.
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QUALITY PLAN

Plug Mill of Plant Rath

Project Name PIPELINE REPLACEMENT PROJECT

Purchaser LEIGHTON / MUMBAI

Reference of Purchaser order IO182/PRP2/P0003

Reference of Customer order INO182

Reference of VMD order 815/1559

Dimensions According to P.O.

Grade API 5L, PSL 2 (Grades see item list)

Mill address: V&M Deutschland GmbH

TABLE OF CONTENTS Page 1 of 1

No. Document Revision / Date Rev.

MANUFACTURING AND INSPECTION PLAN Page 1 of 3

1 Contract review Customer order V&M Sales department

7 Straightening Mill Standard

8 In-house test (EMI) Mill standard R R Longitudinal and transverse 1

MANUFACTURING AND INSPECTION PLAN Page 2 of 3

17 Material tests: V&M Annex A, B, B1 H* W R H* deligated to qualified personal 1

31 Inspection certificate 3.2 - EN 10204 R R 5 x in english 1

MANUFACTURING AND INSPECTION PLAN Page 3 of 3

V&M V&M QA or Production Representative

The first invitation will be pronounced 5 calendar days before starting

During production invitations will be sent to the customer 2 working days

Unforeseen changes in production sequence must allow a change of invitation

ANNEX B1-1 FIRST DAY PRODUCTION TESTS Page 1 of 2

Test Requirements Frequency Rev.

CTOD Test Test temperature 10°C One set (3 specimens) per 3

Sour Service Tests

- SSC Test Solution acc. to NACE TM 0177-90, 96 hours

ANNEX B1-1 FIRST DAY PRODUCTION TESTS Page 2 of 2

Stress levels of 60,72,80,90 and 100 % SMYS

Minimum stress for failure after 720 hours shall be at

Remarks FDP test pipes :

Visual inspection of FDP Pipes according to spec. Annexure II a).

ANNEX B1-2 FIRST DAY PRODUCTION TESTS Page 1 of 1

Test Requirements Frequency Rev.

CTOD Test Test temperature 10°C One set (3 specimens) per 3

Remarks FDP test pipes :

Visual inspection of FDP Pipes according to spec. Annexure II a).

ANNEX B-1 PRODUCTION TESTS ON MATERIAL Page 1 of 2

Test Requirements Frequency Rev.

Product Analysis See V&M Annex A 2 each heat and additional 2

§ 9.3.6 The hardness tests shall be

Sour Service Tests

ANNEX B PRODUCTION TESTS ON MATERIAL Page 2 of 2

Columns 3 and 5 of API 5L, table 3B are not applicable.

Modalities of retest acc. to § 9.10

ANNEX B-2 PRODUCTION TESTS ON MATERIAL Page 1 of 1

Test Requirements Frequency Rev.

Product Analysis See V&M Annex A 2 each heat and additional 3

§ 9.3.6 The hardness tests shall be

Columns 3 and 5 of API 5L, table 3B are not applicable.

Modalities of retest acc. to § 9.10

ANNEX F HEAT TREATMENT PARAMETERS Page 1 of 1

Normalizing Solution Annealing Quenching Tempering Rev.

Temperature min. °C 910 610

Temperature max. °C 970 710

Holding Time min. Min. ≥10 >20

Method of Cooling inside and outside still air 1

Remarks )* for X52 normalizing 1

ANNEX L HYDROSTATIC TEST PARAMETERS Page 1 of 2

V&M D Item 1 3 5 6 7 9 Rev

Dimension 323,90 x 219,10 x 355,60 x 323,90 x 323,90 x 406,40 x

Calculated MPa 32,90 37,75 29,97 31,72 54,76 1