API 5L PSL2 X46 DSAW Steel Pipe
Basic Overview
API 5L PSL2 Grade X46 DSAW (Double-Sided Submerged Arc Welded) steel pipe is a medium-strength line pipe manufactured to the American Petroleum Institute specification for pipeline transportation systems. The "X46" designation indicates a minimum yield strength of 46,000 psi (317-320 MPa), positioning it between X42 and X52 in the API 5L grade ladder.
PSL2 (Product Specification Level 2) is the enhanced quality level with stricter requirements than PSL1, including tighter chemistry controls (lower carbon and sulfur), mandatory Charpy impact testing, maximum strength limits, yield-to-tensile ratio control, and full traceability.
The DSAW manufacturing process-also known as LSAW (Longitudinal Submerged Arc Welding) or SSAW (Spiral Submerged Arc Welding)-is a high-integrity welding method where both inside and outside welds are applied, forming a single high-quality weld nugget. This process is specifically designed for large-diameter, thick-wall pipes used in demanding pipeline applications.
Name Explanation
| Part | Meaning |
|---|---|
| API | American Petroleum Institute |
| 5L | Specification for line pipe used in pipeline transportation systems |
| PSL2 | Product Specification Level 2 – enhanced quality level with stricter requirements (mandatory impact testing, tighter chemistry, max strength limits) |
| X46 | Grade designation: "X" indicates pipeline grade, "46" represents minimum yield strength in ksi (46,000 psi / 317-320 MPa) |
| DSAW | Double-Sided Submerged Arc Welding – both inside and outside welds are applied; the welding arc is submerged in granular flux during welding |
Key Specifications
| Attribute | Description |
|---|---|
| Standard | API 5L (46th Edition, aligned with ISO 3183) |
| Product Specification Level | PSL2 – enhanced quality level |
| Grade | X46 (L320 in ISO notation) |
| Minimum Yield Strength | 317-320 MPa (46,000-46,400 psi) |
| Maximum Yield Strength | 524-525 MPa (76,000-76,100 psi) – PSL2 specifies both min and max |
| Minimum Tensile Strength | 434-435 MPa (63,000-63,100 psi) |
| Maximum Tensile Strength | 758-760 MPa (110,000-110,200 psi) |
| Yield-to-Tensile Ratio (max) | 0.93 – ensures adequate ductility |
| Manufacturing Process | DSAW (Double-Sided Submerged Arc Welding) / LSAW / SSAW |
| Size Range (DSAW/LSAW/SSAW) | 219 mm to 4064 mm (8" to 160") OD – typical for DSAW |
| Wall Thickness | 5.0 mm to 40 mm (up to 60 mm for special applications) |
| Length | 6 m to 12 m standard; up to 18 m available |
| End Finishes | Plain ends, beveled ends (30° bevel angle), threaded, grooved |
| Delivery Condition | X46M (Thermomechanical rolled/TMCP) – most common; X46N (Normalized), X46Q (Quenched and tempered) available |
Chemical Composition (PSL2 Requirements)
Chemical Composition for PSL2 X46 (Welded Pipe)
| Element | Maximum % | PSL1 Comparison |
|---|---|---|
| Carbon (C) | 0.22% | PSL1 X46: 0.26-0.28% – tighter control |
| Silicon (Si) | 0.45% | Not specified for PSL1 |
| Manganese (Mn) | 1.40% | PSL1 X46: 1.40% – similar range |
| Phosphorus (P) | 0.025% | PSL1: 0.030% – stricter |
| Sulfur (S) | 0.015% | PSL1: 0.030% – 50% reduction |
| Vanadium (V) | 0.07% max | Micro-alloying for grain refinement |
| Niobium (Nb) | 0.05% max | Micro-alloying for strength |
| Titanium (Ti) | 0.04% max | Micro-alloying for grain refinement |
| Carbon Equivalent (CEIIW) | 0.43% max | Required and controlled for weldability |
*Note: The total content of micro-alloying elements (Nb+V+Ti) does not exceed 0.15%. PSL2 requires carbon equivalent (CE) calculation and control to ensure good field weldability.*
Mechanical Properties
| Property | PSL2 Requirement | PSL1 Comparison |
|---|---|---|
| Yield Strength (min) | 317-320 MPa (46,000-46,400 psi) | Same minimum |
| Yield Strength (max) | 524-525 MPa (76,000-76,100 psi) | Not specified |
| Tensile Strength (min) | 434-435 MPa (63,000-63,100 psi) | Same minimum |
| Tensile Strength (max) | 758-760 MPa (110,000-110,200 psi) | Not specified |
| Yield-to-Tensile Ratio | 0.93 max | Not specified |
| Elongation | Per API 5L formula (varies by wall thickness) | Same formula |
| Charpy Impact (CVN) | Mandatory – typically 27J at 0°C or -20°C | Not required |
| Hardness (max) | 250 HV10 (sour service: 248 HV10) | Not specified |
X46 vs. Adjacent Grades Comparison (PSL2)
| Grade | Yield Strength (min) | Yield Strength (max) | Tensile Strength (min) | Typical Application |
|---|---|---|---|---|
| X42 | 290 MPa (42 ksi) | 496 MPa (72 ksi) | 414 MPa (60 ksi) | Gathering lines, distribution |
| X46 | 317-320 MPa (46 ksi) | 524-525 MPa (76 ksi) | 434-435 MPa (63 ksi) | Higher-pressure transmission |
| X52 | 359 MPa (52 ksi) | 531 MPa (77 ksi) | 455 MPa (66 ksi) | General transmission |
| X56 | 386 MPa (56 ksi) | 545 MPa (79 ksi) | 490 MPa (71 ksi) | Higher-pressure transmission |
| X60 | 414 MPa (60 ksi) | 565 MPa (82 ksi) | 517 MPa (75 ksi) | High-pressure transmission |
*X46 offers approximately 10% higher yield strength than X42 and serves as a cost-effective intermediate option when X42 is under-strength but X52 would be over-specified.*
Delivery Conditions (Heat Treatment Suffixes)
PSL2 X46 DSAW pipes are supplied with suffixes indicating heat treatment condition:
| Suffix | Condition | Typical Application |
|---|---|---|
| X46N | Normalized | General transmission, improved grain structure |
| X46Q | Quenched and tempered | Maximum strength uniformity |
| X46M | Thermomechanical rolled (TMCP) | Most common – enhanced toughness and weldability |
| X46QS | Quenched and tempered + Sour service | H₂S environments with NACE compliance |
| X46MS | Thermomechanical rolled + Sour service | H₂S environments with enhanced toughness |
Note: Suffix "S" indicates Sour Service application per NACE MR0175.
Dimensional Specifications
| Parameter | Range / Tolerance |
|---|---|
| Outside Diameter | 219 mm to 4064 mm (8" to 160") – typical DSAW/SSAW range |
| Wall Thickness | 5.0 mm to 40 mm (up to 60 mm for special applications) |
| Diameter Tolerance | ±0.75% of specified OD (typical); ±1% for larger diameters |
| Wall Thickness Tolerance | +15% / -12.5% of nominal (typical) |
| Length | 6 m to 12 m standard; up to 18 m available |
| Out-of-Roundness | ≤ 1% of specified OD |
Typical Size Availability (API 5L Grade X46 DSAW/SSAW):
| OD (inch) | OD (mm) | Wall Thickness Range (mm) |
|---|---|---|
| 16" | 406 | 6.0 - 14.0 |
| 20" | 508 | 6.0 - 16.0 |
| 24" | 610 | 6.0 - 18.0 |
| 30" | 762 | 7.0 - 21.0 |
| 36" | 914 | 8.0 - 24.0 |
| 40" | 1016 | 8.0 - 26.0 |
| 48" | 1219 | 9.0 - 28.0 |
| 56" | 1422 | 10.0 - 29.0 |
| 60" | 1524 | 10.0 - 29.0 |
| 64" | 1626 | 10.0 - 30.0 |
| 72" | 1829 | 10.0 - 30.0 |
DSAW/SSAW/LSAW Manufacturing Process
Double-Sided Submerged Arc Welding (DSAW), also known as Spiral Submerged Arc Welding (SSAW) or Longitudinal Submerged Arc Welding (LSAW), is a high-efficiency process used primarily for large-diameter steel pipes.
Process Description
Welding arc is submerged in granular flux during welding, protecting the weld from atmospheric contamination
Both inside and outside welds are required, usually accomplished in separate processes
The separate welds consume a portion of the other, resulting in a single high-quality weld nugget
Forming Methods
| Method | Description | Typical Diameters |
|---|---|---|
| SSAW (Spiral) | Steel strip is continuously formed into a cylindrical shape at a specific helix angle; most economical for large diameters | 219-4064 mm (8"-160") |
| LSAW (Longitudinal/JCOE) | Progressive J-C-O forming steps (J-shape → C-shape → O-shape), expanded after welding | 406-1626 mm (16"-64") |
| UOE | Plate pressed into U-shape, then O-shape, expanded after welding | 508-1118 mm (20"-44") |
Process Steps
Plate/Coil Selection – Steel plates/coils meeting API 5L PSL2 X46 requirements (fully killed, fine grain steel)
Edge Preparation – Edges are beveled to create a V-shaped groove
Forming – Steel plates/coils are formed into cylindrical shapes using JCOE/UOE/Spiral forming methods
Tack Welding – Formed plates are tack-welded to maintain shape
Double Submerged Arc Welding – Pipe seam welded on both interior and exterior surfaces
Cold Expansion – Pipe may be expanded up to 1.5% to achieve final OD dimension
Ultrasonic Inspection – Seam inspected by continuous ultrasonic automatic flaw detection
Hydrostatic Pressure Test – Each pipe undergoes hydrostatic pressure testing
Finishing – End processing, beveling, coating, and marking according to specifications
Testing & Inspection Requirements (PSL2)
| Test Type | Requirement | Notes |
|---|---|---|
| Chemical Analysis | Per heat lot | Tighter PSL2 limits |
| Tensile Test | Per lot | Verifies both min and max limits |
| Yield-to-Tensile Ratio | ≤ 0.93 | Mandatory verification |
| Charpy Impact Test (CVN) | Mandatory | Required for all PSL2 grades; typically 27J at 0°C or -20°C |
| Flattening Test | Required | Checks ductility and weld integrity |
| Bend Test | Required | Verifies weld integrity |
| Hydrostatic Test | Each pipe | Pressure integrity verification |
| Ultrasonic Inspection (UT) | 100% of weld seam | Mandatory for PSL2 |
| X-ray Inspection (RT) | When specified | For critical applications; 100% available upon request |
| Hardness Testing | For sour service | Hardness mapping required; ≤250 HV10 (≤248 HV10 for sour) |
| HIC/SSC Testing | For sour service | Per NACE MR0175/ISO 15156 |
| DWTT (Drop Weight Tear Test) | For critical applications | Fracture toughness verification |
| Dimensional Inspection | 100% | Per standard tolerances |
| Mill Test Certificate | EN 10204 Type 3.1B | Provided with full test results |
PSL1 vs. PSL2 Comparison for X46
| Feature | PSL1 X46 | PSL2 X46 | Significance |
|---|---|---|---|
| Carbon (C) max | 0.26-0.28% | 0.22% | Tighter control for better weldability |
| Sulfur (S) max | 0.030% | 0.015% | 50% reduction – critical for toughness and HIC resistance |
| Phosphorus (P) max | 0.030% | 0.025% | Improved toughness and weldability |
| Yield Strength | 317-320 MPa min only | 317-524 MPa range | Prevents over-strength materials |
| Tensile Strength | 434-435 MPa min only | 434-758 MPa range | Ensures consistent mechanical properties |
| Yield-to-Tensile Ratio | Not specified | ≤ 0.93 | Ensures adequate ductility |
| Charpy Impact Testing | Not required | Mandatory | Guarantees low-temperature toughness |
| Carbon Equivalent (CE) | Not required | Calculated and controlled | Ensures good field weldability |
| NDT Requirements | Standard | 100% UT mandatory for PSL2 | Better defect detection |
| Traceability | Batch level | Pipe-by-pipe full traceability | Complete quality documentation |
| Hardness Control | Not specified | ≤250 HV10 (sour: ≤248 HV10) | Essential for sour service applications |
| Typical Use | General service, water lines, non-critical | Critical service, sour service, low temperature |
Common Applications
| Application | Description |
|---|---|
| Oil and Gas Transmission | Medium-to-high pressure pipelines for crude oil and natural gas |
| Natural Gas Gathering Lines | Connecting wells to processing facilities for urban or regional gas distribution |
| Water Transmission Mains | Large-diameter municipal and industrial water pipelines |
| Industrial Process Piping | Refineries, chemical plants, power generation |
| Gathering and Flow Lines | Upstream oil and gas operations |
| Pipeline Station and Terminal Piping | Compressor stations, pump stations, metering facilities |
| Sour Service | H₂S environments (with X46MS/X46QS grades) |
| Offshore Pipelines | Subsea applications requiring enhanced toughness |
Key Advantages of PSL2 X46 DSAW Pipe
| Advantage | Description |
|---|---|
| Higher Strength than X42 | 10% higher yield strength (320 MPa vs. 290 MPa) allows higher operating pressures or reduced wall thickness |
| Cost-Effective Intermediate Grade | Economical alternative when X42 is under-strength but X52 would be over-specified |
| Guaranteed Low-Temperature Toughness | Mandatory Charpy impact testing ensures reliable performance in cold climates |
| Stricter Chemistry Controls | 50% lower sulfur content (0.015% vs. 0.030%) improves weldability and HIC resistance |
| Controlled Strength Range | Maximum yield strength (524 MPa) prevents over-strength materials that can cause welding issues |
| Full Traceability | Pipe-by-pipe traceability for complete quality documentation |
| 100% Ultrasonic Inspection | Mandatory NDT ensures weld seam integrity |
| Micro-alloyed with TMCP | Fine grain structure for excellent impact properties |
| Sour Service Capability | Available with NACE MR0175/ISO 15156 compliance (X46MS/X46QS grades) |
| Large Diameter Capability | DSAW/SSAW produces pipes from 8" to 160" OD – ideal for large-diameter applications |
| High Weld Integrity | Double-sided welding creates a single high-quality weld nugget |
Coating Options
API 5L PSL2 X46 DSAW pipe can be supplied with various coatings for corrosion protection:
| Coating Type | Best For | Key Features |
|---|---|---|
| 3LPE (3-layer polyethylene) | Buried pipelines | Most common; excellent corrosion protection, high impact resistance |
| FBE (Fusion Bonded Epoxy) | Oil & gas pipelines | Strong adhesion, chemical resistance |
| Coal Tar Epoxy | Marine environments | Heavy-duty protection |
| CWC (Concrete Weight Coating) | Offshore/subsea pipelines | Negative buoyancy and mechanical protection |
| 3LPP (3-layer polypropylene) | Offshore pipelines | High temperature resistance (up to 140°C) |
| Varnish / Anti-rust oil | Temporary protection | Short-term corrosion protection during transport |
| Bitumen Coating | Buried service | Cost-effective protection |
| Black Oil Coating | Standard mill finish | Temporary protection |
| IPN8710 | Water pipelines | High resistance to water corrosion |
| TPEP (3PE + Internal Epoxy) | Dual protection | Internal epoxy + external 3PE |
End Finishes
Available end treatments include:
Plain ends (PE) – standard for most applications
Beveled ends (BE) – for field welding (30° bevel angle)
Threaded ends – for mechanical connections
Grooved ends – for mechanical couplings
International Approximations
| Standard | Equivalent Grade | Notes |
|---|---|---|
| ISO 3183 | L320 | International standard equivalent |
| GB/T 9711 | L320 | Chinese equivalent |
| EN 10208-2 | L320MB | European equivalent |
| DIN 17172 | StE 320.7 TM | Historical German equivalent |
Important Considerations
1. PSL2 is the Standard for Critical X46 Applications
PSL2 is required for low-temperature service (especially below 0°C), sour service (H₂S environments), regulated pipelines (FERC, DOT), and critical applications
PSL1 is suitable for general service, water lines, non-critical applications where low-temperature toughness is not required
2. X46 vs. Lower/Higher Grades
X42: Medium-pressure transmission (42 ksi yield)
X46: Higher-pressure transmission (46 ksi yield)
X52: General transmission (52 ksi yield)
X56/X60: Higher-pressure transmission, offshore
3. Impact Testing Temperature
Standard Charpy impact testing is at 0°C with 27J minimum for PSL2
For arctic applications, impact testing at -20°C or -45°C can be specified with higher energy requirements
4. Sour Service Capability
PSL2 X46 with additional requirements can be used for sour service (H₂S environments):
X46MS/X46QS grades specifically designed for sour service
Hardness testing (≤ 248 HV10)
HIC and SSC testing per NACE TM0284 and NACE TM0177
Sulfur content may be further limited to ≤ 0.002%
5. Delivery Conditions
PSL2 X46 DSAW pipes are typically supplied in the following conditions:
X46M – Thermomechanical rolled (TMCP) – most common for enhanced toughness and weldability
X46Q – Quenched and tempered – for maximum strength uniformity
X46N – Normalized – for improved grain structure
6. Manufacturing Method Selection
SSAW (Spiral) – Most economical for very large diameters (24" to 160"+); suitable for most transmission applications
LSAW (Longitudinal) – Better dimensional accuracy for heavy wall and high-pressure applications; typical range 16" to 64"
UOE – Highest dimensional accuracy; typical range 20" to 44"
7. Weldability
Low carbon content (≤0.22%) ensures good weldability
Suitable for all standard welding methods (SMAW, GTAW, GMAW, SAW)
Preheat may be required for thicker sections (typically 100-150°C)
For sour service applications, low hydrogen practices are required
Qualified welding procedures with impact-tested filler metals essential
8. NDT Requirements
100% ultrasonic inspection (UT) of weld seam is mandatory for PSL2
X-ray inspection (RT) is available upon request, especially for critical applications
For sour service, additional NDT may be required
9. Third-Party Inspection
Available inspection services include SGS, BV, Lloyds, DNV, TÜV
10. Mill Test Certificate
Typically provided as EN 10204 Type 3.1B with full test results
Third-party inspection available upon request
11. Regulatory Compliance
PSL2 is required for pipelines regulated by:
FERC (Federal Energy Regulatory Commission)
DOT (Department of Transportation)
FEMSA (Federal Environmental, Management and Safety Agency)
PED (Pressure Equipment Directive) for Europe
Summary
API 5L PSL2 Grade X46 Double-Sided Submerged Arc Welded (DSAW/SSAW/LSAW) steel pipe is a medium-strength line pipe that fills the gap between X42 and X52 in the API 5L grade ladder. With minimum yield strength of 46,000 psi (317-320 MPa) – approximately 10% higher than X42 – and guaranteed Charpy impact toughness, this material offers a cost-effective intermediate option for higher-pressure transmission applications where X42 is under-strength but X52 would be over-specified.
Key features:
Material standard: API 5L PSL2 X46 – medium-strength grade for critical service
Yield strength: 317-320 MPa (46,000 psi) minimum – 10% higher than X42
Tensile strength: 434-435 MPa (63,000 psi) minimum
PSL2 quality level: Mandatory impact testing, 50% lower sulfur (0.015% vs. 0.030%), maximum strength limits (≤524 MPa), yield-to-tensile ratio ≤0.93, and full traceability
DSAW/SSAW manufacturing produces pipes from 8" to 160" OD with wall thickness up to 40 mm
Double-sided welding creates a single high-quality weld nugget
JCOE, UOE, or Spiral forming methods ensure cost-effective large-diameter production
100% ultrasonic inspection of weld seam is mandatory
Excellent weldability with low carbon content (≤0.22%)
Sour service capable with NACE MR0175/ISO 15156 compliance (X46MS/X46QS grades)
TMCP delivery (X46M) provides enhanced toughness and weldability
Common applications include:
Medium-to-high pressure oil and gas transmission pipelines
Natural gas gathering and distribution networks
Water transmission mains and industrial process piping
Pipeline station and terminal piping
Sour service applications (with X46MS/X46QS grades)
Offshore and subsea pipelines
When ordering, specify: API 5L PSL2 Grade X46M (or X46Q), DSAW/SSAW/LSAW (as applicable), Size (OD x WT), Length, End Finish (plain/beveled), Coating Requirements, Impact Test Temperature (e.g., 0°C, -20°C, -45°C), and Mill Test Certificate to EN 10204 Type 3.1B.
For sour service applications, specify X46MS or X46QS with NACE MR0175/ISO 15156 compliance. For the most demanding projects, consider specifying DNV Type Approval, EN 10204 3.2 certification, and third-party surveillance to ensure full compliance with international standards.
