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PIPE SPECIFICATIONS

Cross country pipelines as per the

specifications indicated in API 5L
As per International Institute of Welding
(IIW), Carbon equivalent (CE) should not
exceed 0.43.
API 5L grade pipes will be selected based on
the chemical and mechanical properties.

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 MAJOR COMPONENTS OF A PIPELINE
PROJECT
LINE PIPES - (20% - 35% of the Project Cost)

API – 6D VALVES - (8% - 10% of the Project Cost)

MAINLINE - (5% - 10% of the Project Cost)

PUMPING UNITS

STEEL PLATES - (5% - 7% of the Project Cost)

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 STANDARD LENGTH OF PIPES
NOMINAL MINIMUM AVG. MAX.
LENGTH LENGTH LENGTH

6M 5.33 M 6.86 M
12 M 10.67 M 13.72 M
15 M 13.35 M 16.76 M
18 M 16.00 M 19.81 M
24 M 21.84 M 25.91 M

6 M Lengths are termed as single Random lengths.

12 M Lengths are termed as Double Random Lengths.

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 END CONFIGURATION OF PIPES
Based on Pipe to pipe joints pipe ends are specified as :

BEVELED ENDS - Pipe to pipe/ fitting joints are butt

welded

PLAIN ENDS - Pipe to pipe/ fitting joints are fillet

welded

SCREW ED ENDS - For threaded connections

FLANGED ENDS - For Bolted connection

SPIGOT/SOCKET ENDS - Cemented joints

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STANDARD THICKNESSES OF PIPES

STAINLESS STEEL CARBON STEEL

(Schedule) (Schedule)
5S 10
10S 20
40S 40 (Standard)
80S 80 (Extra Strong)
160 (XXS)
STANDARD THICKNESS AS PER API - 5L CODE
(TYPICAL FOR 18”)
 0.188”
 0.219”
 0.250”
 0.281”
 0.312”
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 0.344”
 STANDARD THCKNESSES OF PIPES
 0.375” (Standard - SCH - 40)
 0.406”
 0.438”
 0.500”(XS - SCH - 80)
 Note- Non-metallic & lined pipes are not covered under this code.
The wall thickness and lining thickness of lined pipes is as per
manufacturer’s standard. However for plastic pipes there are
certain Indian codes.
 Indian code IS-3589 classifies the thickness as Light, Medium &
Heavy. The pipes as per these codes are used for fuel/ water
service. (low pressure)

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 Pipe Specifications and Selection
Criteria for pipe selection are:

 Capacity ( MMTPA or KL / hr)

 Pressure Requirement (P)
 Design Factor (F)
 Weld Joint Factor (E)
 Corrosion Allowance (A)
 Other Considerations ( Ext. Stress like Rly
/Road/River Crossings)

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 Pipe Specifications and Selection
Load consideration:
 In earlier days , pipeline design was done considering the
present load and 15 to 30%
Increment of load.
 Now-a days, the use of Oil/gas increased tremendously. As a
result the concept of pipeline design has also changed.
 Presently pipeline design is being done considering the
present load as well as the assumed Oil/gas load of the that
particular area for the next 20 years (effective life of the
pipeline)

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 DESIGN CONSIDERATIONS FOR PIPES

 Corrosion allowance is added depending on type of service

 Design pressure is taken as 10% higher than anticipated mop
 Design temperature is taken as 250c higher than anticipated Maximum
operating temperature
 Design should meet the requirements of relevant code
 Material should be in accordance with the latest revision of standards

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CALCULATION OF PIPING WALL THICKNESS

 Mainline pipe is designed for 10% higher than the maximum operating
pressure. design factor of 72% SMYS is considered.
 Station piping is designed for higher pressure than mainline to allow for
the pump start-up against shut off and for throttling in order to
compensate for any un-calculable expansion, mechanical, thermal or any
residual stresses. generally 65% of SMYS IS TAKEN AS THE DESIGN
FACTOR.
 FOR SIZING OF THE PIPING A MAXIMUM VELOCITY of 4.5 m/sec is
considered in the design.

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 CALCULATION OF PIPING WALL
THICKNESS
Specified minimum yield stress (SMYS) of pipe is known
from the specification of the pipe

 Hoop Stress (s) = 0.72 x SMYS x E

 Where, E = Weld joint Factor =1.0
 DESIGN PRESSURE = 1.1 X WORKING PRESSURE
 DESIGN PRESSURE =2xSxt/D
 Where, t = thickness of pipe in inch
 D = Outside dia of pipe in inch

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 PIPELINE DESIGN

Weld Joint Factor:

 Weld type ASME B31.8
 Seamless 1
 ERW 1
 SAW 1
 But Welded 0.6

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 PIPELINE DESIGN
 Design and Location Factor
 Canadian Standards association (CSA) suggests design factor of 0.8 While
location factors are:

 Area Class Location ASME CSA

 Deserted 0.72 0.80 1
 Village 0.60 0.72 2
 City 0.50 0.56 3
 Metropolis 0.40 0.44 4

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 PIPELINE DESIGN

 Flow Rate (Kl/Hr) = A x v = 3.14 x (D²/4) x v

 D = √ {(Flow rate x 4)/(3.14 x v)}
 Where A = Pipe Cross Section Area
 D = Design Diameter
 v = Max. Velocity =4.5 m/sec =16.2 km/hr
 Example :
 If we take flow rate = 3000 Kl /Hr
 D = √(3000*4)/(3.14x16200) = 0.4857 m= 485.7 mm
 = 19.12 inch (Say 20” Φ)

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 PIPELINE DESIGN

 P = ( 2 x S x t ) / D or t= (P x D/2xS)
 Where P = Design Pressure(fixed by pump design)
 D = Diameter ( Depends on flow rate)
 S = Allowable Stress ( Depends on Pipe grade)
 t = thickness of pipe
 Example :
 If we take P = 50 Kg / Sq. cm = 710 PSI
 S = 37440 PSI
 t = (710 *20)/2* 37440 = 0.1896 Inch= 4.82 mm

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 PIPELINE DESIGN
Pipeline design (contd.)

 t= DP/2YFJ
 where,
 t=Pipe wall thickness, mm
 P=design pressure ,psig
 D=outside dia of pipe in mm
 Y=minimum yield strength, psig
 F=design factor
 J=welding joint factor

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 CORROSION ALLOWANCE

 Life of Pipeline
 Design of Pipeline
 Environment condition
 On-shore / Off-shore
 Location of the pipeline crossing

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 DIFFERENT CODES USED FOR PIPE
SELECTION
ANSI-36.10 - Carbon steel pipes

ANSI-36.19 - Stainless Steel Pipes

ASTM A 53 - Welded and Seamless Pipes

ASTM A 106 - Seamless CS pipes for high temp.

service

ASTM A 120 - Galvanized Pipe for ordinary use

API 5L - Line Pipes for Petroleum Products

IS – 3589 - Steel Pipe for General Purpose

(Fire Water Service etc.,)

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 PROCESS OF MANUFACTURE
SEAMLESS PROCESS
A process of hot working steel to form a tubular product without a welded
seam. If necessary, the hot worked tubular product may be subsequently
cold finished to produce the desired shape, dimensions & properties.
WELDING PROCESS
1. WITHOUT FILLER METAL
a) Continuous Welding
A process of forming a seam by heating the skelp in a furnace and
mechanically pressing the formed edges together wherein successive coils of
skelp had been joined together to provide a continuous flow of steel for the
welding mill.

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 PROCESS OF MANUFACTURE
b) Electric Welding
A process of forming seam by Electric resistance or Electric induction
welding. Wherein the edges to be welded are mechanically pressed together and
the heat of welding is generated by the resistance to flow of electric current.

2.WITH FILLER METAL

a)Submerged Arc Welding
A welding process that produces coalescence of metals by heating them with an
arc between consumable electrode(s) and the work. The arc and molten metal
are shielded by a blanket of granular, fusible material. Pressure is not applied.
Part or all of the filler metal is obtained from the electrode(s).
b)Gas Metal Arc Welding
Same as SAW, Only shielding is obtained entirely from an externally supplied gas
or gas mixture. Pressure is not used and the filler metal is obtained from the
electrode(s).

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 CHEMICAL COMPOSITION
TYPICAL EXAMPLE OF CHEMICAL COMPOSITION OF API-5LX65

E le m e n t C h e m ic a l R e q u ir e m e n t s ( % )
C 0 .1 6 0 m a x .
Mn 0 .8 0 -1 .5 0
Si 0 .3 5 m a x .
S 0 .0 2 5 M a x .
P 0 .0 2 0 M a x .
AI 0 .0 4 0 M a x .
Nb 0 .0 5 0 M a x .
V 0 .0 8 0 M a x .
Ti 0 .0 2 0 M a x .
Cr 0 .3 0 0 M a x .
Mo 0 .2 5 0 M a x .
Cu 0 .3 5 0 M a x .
Ni 0 .3 0 0 M a x .

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 CHEMICAL COMPOSITION

E le m e n t C h e m ic a l R e q u ir e m e n t s ( % )
N 0 .0 1 0 M a x .
B 0 .0 0 0 3 M a x .
A I ( s o lu b l e ) 2 N m in .
Nb +V 0 .1 0 0 M a x
N b + V + T i+ C u + M o 0 .5 0 0 M a x

 No other element shall be added to the steel without prior permission of purchaser.
 Manufacture of pipe shall be by fully killed fine grain, micro alloyed, calcium treated
and control rolled steel.
 The steel shall be made by continuous casting process only.
 Combination of Nb-V-Ti shall not exceed 0.15%
 - Cu+Ni shall not exceed 0.40%
 HYDRO-TESTING
Each pipe is to be hydro-tested at the works for a minimum duration of 15 sec.

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 CHEMICAL COMPOSITION OF PIPE - AN OVERVIEW
By definition steel is a combination of Iron and Carbon. Steel is alloyed with various
elements to improve physical properties and to produce special properties, such as
resistance to corrosion or heat. Specific effects of the addition of such elements are
outlined below:
 1.0 NICKEL: Nickel raises the strength of steel less than does silicon or manganese. It
ensures good through hardening, especially so when the steel also contains chromium.
Chrome Nickel steels are stainless and resistant to scaling and also heat resistant,
Nickel increases the Notch Impact Value of structural steel considerably.
 2.0 PHOSPHOROUS :Quite generally phosphorous is considered to be detrimental to
steel, so it is endeavored to keep the ‘P’ content in high grade steel at a max. level of
0.03% to 0.05%.
 3.0 SULPHUR: Makes Steel brittle and is therefore harmful. Contents of 0.025% or
0.030% are permitted. Exceptions are for free machining steels to which is added
upto 0.30%.
 4.0 SILICON: It increases the mechanical strength, resistance to scaling and
density. (0.35% approx.)

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 CHEMICAL ANALYSIS
 Chemical Analysis is to be specified as per ASTM A 751 - “Standard
Methods, practices and definitions for chemical analysis of steel products”
 This is to be carried out once for each heat.
Product Analysis
 It is to be specified for two pipes produced from the same heat.
 Where more than 50 pipes are produced from same heat, additional
product analysis of two pipes is to be specified.
 From the results of product analysis Carbon Equivalent to be calculated
using the following formula as indicated in next page :

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 CHEMICAL ANALYSIS

 The C.E. calculated using the above formula shall not exceed 0.38. In addition
the Pcm value based on the product analysis and calculated from the following
formula shall not exceed 0.20.
Mn Cr +Mo+Zr Ti Cb V UTS h
C.E. = C + ----- + -------------- + ---- + ----- + ----- +------- +-----
6 10 15 3 7 900 2
Ni Si Mn+Cu+Cr Mo V
Pcm = C + ----- + -------- + --------------- + ------- + ------- + 5B
60 30 20 15 10
Re-check Analysis :
 If the product analysis shows failure to meet the required composition, either
the whole heat is rejected or each pipe to be fully analyzed so as to confirm
that it meets the chemical composition specified in the P.O.

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 DIMENSIONS, WEIGHTS AND LENGTHS

DIAMETER

1,900” AND SMALLER +0.016”

+0.031”
2 3/8” - 4 ½ “ +1%
4 ½” – 18” + 0.75%
20” – 36”
Non-expanded +1%
Cold expanded + 0.75%
+ 0.25%
Larger than 36”
Non-expanded +1%
Cold expanded + 0.25%
+ 0.125%

At least
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 DIMENSIONS, WEIGHTS AND LENGTHS

WALL THICKNESS

Tolerance in %
NB / TYPE OF PIPE Gr. A, B, A25 X42-X80
2” and smaller, seamless or +20.0 +15.0
welded -12.5 -12.5
3” seamless or welded +18.0 +15.0
-12.5 -12.5
4”-18” seamless or welded +15.0 +15.0
-12.5 -12.5
20” and larger welded +17.5 +19.5
-10.0 -8.0
20” and larger seamless +15.0 +17.5
-12.5 -10.0

However, negative tolerance to be checked w.r.t. the

maximum pressure to be encountered during operation..

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 DIMENSIONS, WEIGHTS AND LENGTHS
If specifying lesser -ve tolerance, +ve tolerance should be increased by an equal
percentage and the plus weight tolerance shall be increased to 22.5 percent less
the wall thickness -ve tolerance.
WEIGHT
Single Lengths
All pipes except Grade A25 +10.0 percent
-3.5 percent
Grade A25 +10.0 percent
-5.0 percent
Truck Loads
All pipes except Grade A25 -1.75 percent
Grade A25 -2.5 percent

Threaded & Beveled ends should be protected by metallic

end protectors.

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 MARKING AND COATING
MARKING
Following information is marked on the pipes
 Purchase Order No.
 Name of manufacturer
 Specifications followed
 Nominal bore of pipe
 Weight/ meter or wall thickness
 Grade of pipe
 Method of manufacture
Example
P.O. No. PLM/HBC/PO-IND/99/46 dt. 24.03.99
ABCO Spec. 5L*14.00 54.57 x 46.S
ABCO - Manufacturer, Spec 5L - Specifications followed
14.00 - Nominal Bore, 54.57 - Weight / meter
x46 - Grade of pipe, S - Seamless

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 MARKING AND COATING

 Location of Stenciling :
 300 mm from the Edge on outside surface for 16” NB and below.
 Min. 150 mm from the Edge on inside surface for 18” NB and above.
 COATING :
 If bare pipes are to be procured Mill standard varnish coating on external
surface is specified to project the pipes against rusting during transit and
storage. This coating should be easily removable by sand blasting.
 If specially coated pipe is desired particular coating specification should be
attached.

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 MECHANICAL TESTS FOR PIPE

A) NON-DESTRUCTIVE TESTS :
 Ultrasonic Testing - for coils, weld seam & bevelled ends.
 Radiography, if specified in specifications
 Chemical Analysis
 Hydro-test (Must for each pipe)
B) DESTRUCTIVE TESTS :
 Tensile test (lower yield pint is noted)
 Fracture Toughness Test
- Charpy V-notch test (Impact Energy Sh. be as specified)
 Charpy V-Notch Impact Test is a Dynamic Test in which a
notched specimen is struck and broken by a single blow in a
specially designed testing machine. The measured test values
may be the energy absorbed, the % shear fracture, the lateral
expansion opposite the notch, or a combination thereof.

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 MECHANICAL TESTS FOR PIPE
Drop weight tear test for pipes 20” or larger, grade 52 or higher:
 At least 80% of the heats shall exhibit a fracture appearance shear
area of 40% or more for the specified temperature.

Flattening Test
 Bend Test (Face Bend & Root Bend) - No Cracks or No Weld Open

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 PIPE - INTERPRETATION

 Important points to be taken care for carrying out the technical evaluation
are as under:
 Technical Evaluation of Pipe:
 The basic idea of carrying out the technical evaluation is to ensure that all
the parties are meeting the technical specifications and there are no
technical deviations.
 Following are the important points to be taken care for carrying out the
technical evaluation of pipe:
 1.0 Supply record of the party.
 2.0 Whether the party is a manufacturer or a trader?
 3.0 Location & Capacity of pipe mill, where pipes will be produced.

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 PIPE - INTERPRETATION

 4.0 Validity of API-Monogram.

 5.0 Whether the party has adequate testing facilities for:
Ultrasonic testing of Plate / Coil
On line, Auto-Flaw Detector, Auto Seam Detector Ultrasonic
Testing Machine (Minimum Body coverage should be 30%).
Ultrasonic testing for bevel ends.
Whether cold expansion facility is there or not ?
Charpy “V” Notch Testing
 6.0 Testing frequency of various tests should be as per specifications.

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