0003-MI20-00S1-0240-0

MODEC International, Inc. FPSO

Materials for Offshore Structures Specification 0003-MI20-00S1-0240, Rev. 0

TABLE OF CONTENTS 1.0

EXECUTIVE SUMMARY .................................................................................................. 3

2.0

BACKGROUND ................................................................................................................ 3

3.0

BASIS ............................................................................................................................... 3 3.1 REFERENCES ...................................................................................................... 3 3.2 DEFINITIONS AND ACRONYMS ......................................................................... 5

4.0

STEEL............................................................................................................................... 6 4.1 TOPSIDES STRUCTURAL STEEL....................................................................... 6 4.2 MISCELLANEOUS STEEL AND OTHER MATERIAL .......................................... 6

5.0

TIMBER ............................................................................................................................ 7

6.0

FIBERGLASS ................................................................................................................... 7

7.0

SUBSTITUTION OF MATERIALS.................................................................................... 7

8.0

STORAGE OF MATERIALS ............................................................................................ 8

9.0

MATERIAL TRACEABILITY ............................................................................................ 8

10.0

INSPECTION AND TESTING ........................................................................................... 8

11.0

MATERIAL TYPES ........................................................................................................... 9

Tables Table 11-1 Material Usage Requirements ................................................................................. 10 Table 11-2 Steel Specifications and Supplemental Requirements ............................................ 11

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1.0


EXECUTIVE SUMMARY This document defines the minimum requirements for the manufacture and supply of steel and miscellaneous materials to be used for offshore structures. Offshore structures include the structural system of topsides modules, skid supported equipment, or packaged supported equipment required for an FPSO. This document covers steel materials required for topsides production / utility modules, pipe rack modules, turret support structure (TSS), pipe rack, and vent/flare boom. It excludes the “hull” steel including the hull, living quarters, helideck, crane pedestals, turret support structure (TSS), module support stools, vent/flare boom foundation, turret mooring system and other structural items attached to the ship’s hull. Special arrangements for each project are covered in particular specifications which supplement or amend this general specification.

2.0

BACKGROUND Company facilities must meet minimum Industry standards to ensure that Quality, Health, Safety, Environmental, and Operations goals are attained. Standard specifications are used to communicate the minimum standards within the Company as well as to Suppliers and Contractors.

3.0

BASIS Industry codes, standards, and practices, as well as Company experience and preferences are the basis for this document. The following references apply only as specified in the body of this document. If the reference is not mentioned within, it is not applicable. Latest reference editions, including addendum, in force at contract award apply. Reference requirement conflicts shall be brought to Company attention for resolution. The most stringent requirement of the following references applies unless otherwise specified in writing by the Company.

3.1

REFERENCES

3.1.1

Company

Number / Identification

Title

None

3.1.2

Client


Title

None

3.1.3

Industry Codes, Standards, Rules, and Regulations


Title

ABS Publication 0002

Rules for Building and Classing Steel Vessels


Guide for Building and Classing Facilities on Offshore Installations

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Materials for Offshore Structures Specification 0003-MI20-00S1-0240, Rev. 0 Title


Guide for Building and Classing Floating Production Installations

API Spec 2H

Carbon Manganese Steel Plate for Offshore Structures

API Spec 2MT1

Carbon Manganese Steel Plate with Improved Toughness for Offshore Structures

API Spec 2W

Specification for Steel Plates for Offshore Structures, Produced by Thermo-Mechanical Control Processing (TMCP)

API Spec 2Y

Specification for Steel Plates, Quenched-and-Tempered, for Offshore Structures

API Spec 5L

Specification for Line Pipe

API Spec RP 2Z

Preproduction Qualification for Steel Plates for Offshore Structures

ASME B1.1

2003 Unified Inch Screw Threads (UN and UNR Thread Form)

ASTM A370-07b

Standard Test Methods and Definitions for Mechanical Testing of Steel Products

ASTM A 490-08a

Standard Specification for Structural Bolts, Alloy Steel, Heat Treated, 150 ksi Minimum Tensile Strength

ASTM A106/A106M-06a

Standard Specification for Seamless Carbon Steel Pipe for High-Temperature Service

ASTM A123/A123M-02

Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products

ASTM A131/A131M-07

Standard Specification for Structural Steel for Ships

ASTM A320/A320M-07a

Standard Specification for Alloy-Steel and Stainless Steel Bolting Materials for LowTemperature Service

ASTM A325-07a

Standard Specification for Structural Bolts, Steel, Heat Treated, 120/105 ksi Minimum Tensile Strength

ASTM A325M-07

Standard Specification for Structural Bolts, Steel, Heat Treated 830 MPa Minimum Tensile Strength [Metric]

ASTM A340

Standard Terminology of Symbols and Definitions Related to Magnetic Testing

ASTM A36/A36M-05

Standard Specification for Carbon Structural Steel

ASTM A490M-04ae1

Standard Specification for High-Strength Steel Bolts, Classes 10.9 and 10.9.3, for Structural Steel Joints [Metric]

ASTM A53/A53M-07

Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated, Welded and Seamless

ASTM A563

Standard Specification for Carbons and Alloy Steel Nuts

ASTM A572/A572M-07

Standard Specification for High-Strength Low-Alloy Columbium-Vanadium Structural Steel

ASTM A578/A578M-07

Standard Specification for Straight-Beam Ultrasonic Examination of Rolled Steel Plates for Special Applications

ASTM A6/A6M-07

Standard Specification for General Requirements for Rolled Structural Steel Bars, Plates, Shapes, and Sheet Piling

ASTM D143

Standard Test Methods for Small Clear Speciments of Timber

ASTM D245

Standard Practice for Establishing Structural Grades and Related Allowable Properties for Visually Graded Lumber

ASTM D2555

Standard Practice for Establishing Clear Wood Strength Values

ASTM E23

Standard Test Methods for Notch Bar Impact Testing of Metallic Materials

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Materials for Offshore Structures Specification 0003-MI20-00S1-0240, Rev. 0 Title

ASTM E-84

Standard Test Method for Surface Burning Characteristics of Burning Materials

ASTM F436

Standard Specification for Hardened Steel Washers

EN 10204

Type of inspection documents

3.2

DEFINITIONS AND ACRONYMS The following definitions apply within the body of this document:

Term

Definition

ABS

American Bureau of Shipping

ANSI

American National Standards Institute

API

American Petroleum Institute

ASME

American Society of Mechanical Engineers

ASTM

American Society for Testing and Materials

CA

Classification Authority

Client

MODEC Client and/or its assigns.

Company

MODEC International Inc and / or its assigns

ERW

Electric-Resistance Welded

Fabricator

Group responsible for the fabrication of the structures

Facility

Supplier or Subcontractor shop and/or any property owned by a Supplier or Subcontractor where any portion of the work shall be performed.

FPSO

Floating, Production, Storage, and Offloading System

FRP

Fiber Reinforced Plastic

HFIW

High Frequecy Induction Welding

HSE

Health, Safety, and Environment

Hull Steel

The steel required for hull, living quarters, helideck, crane pedestals, module support stools, flare/vent tower foundation and any other structural items attached to the ship’s hull excluding Topsides Structural Steel.

Integration Shipyard

Company responsible for integration of all Topsides Modules on the FPSO

Services

Any service or work performed by a Supplier that must comply with the requisition requirements or the contract to procure, design, manufacture, and deliver the work.

Standards

Industry Codes, Standards, Guides, and Recommended Practices referenced herein, meaning the latest issue or edition in force at the end of the Supplier bid validity date or the contract date.

Supplier

At quote stage: any entity invited to provide a quotation for the equipment and/or any Subcontractors thereto. At Purchase stage: any entity contracted for the supply of the equipment and/or any Subcontractors thereto. In all cases, the Supplier is responsible for performance of all Work and shall be the single point of contact for all Work related issues. The Company shall not receive information from nor respond directly to Subsuppliers.

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Term


Definition

Turret Mooring This system is defined as the turret head, chain table, swivel access structure, swivel, mooring lines, System mooring suction piles, etc. required to: maintain vessel on station, allow weathervaning, allow fluid transfer to production facilities and transfer of electrical, hydraulic and other control signals. UV

Ultraviolet

Work

Any material, item, or service listed in the requisition or contract as being in the Supplier’s Scope of Supply

4.0

STEEL

4.1

TOPSIDES STRUCTURAL STEEL Topsides Strutural Steel includes Topsides Pipe Racks, Production/Utility Modules, and Vent/Flare Boom. Unless otherwise accepted in advance by the Company in writing, all structural steel shall be new stock and shall meet the requirements of this specification as well as ABS regulations for Offshore Installations. Mill certificates and traceability documents shall be provided for all steel, and the system of traceability shall be acceptable to both the Company and Classification Authority (CA). The origin of the furnished steel material (plate, pipe shapes, etc.) shall be from Company and CA approved steel manufacturing mills.

4.2

MISCELLANEOUS STEEL AND OTHER MATERIAL

4.2.1

Gratings Steel gratings and stair treads shall be non-skid, serrated and have a bar size of 38mm (1.5 inch) by 6mm (.25 inch) with spacing of 32mm (1 1/4 inch) on centers and cross bars at 102mm (4 inches) on centers. The span length shall not exceed 1200 mm (48 inches) and the grating shall support the design loads. Steel grating steel surfaces shall be heavy-duty galvanized with 518 g/meter² (1.7 ounces of zinc per square foot) in accordance with ASTM A123/A123M. Steel grating treads and the edge of landings at the top of stairs shall be fitted with a non-skid, cast abrasive nosing. Grating Manufacturer, type, method of attaching, etc. shall be submitted to the Company for approval.

4.2.2

Threaded Fasteners (for Structural Attachments) Bolts, studs, and nuts shall be heavy hexagon pattern. Threads shall be Coarse Thread Series conforming to ASME B1.1 or to another standard if approved by the Company Bolts, studs, and nuts 13mm (½ inch) and smaller shall be Type 316 stainless steel (ASTM A320/A320M, Grade B8M). Bolts and studs larger than 13mm (½ inch) shall conform to ASTM A325/A325M or ASTM A490/A490M and shall be hot-dipped galvanized in accordance with ASTM A123/A123M.

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Nuts shall conform to ASTM A563 Grade C for ASTM A325 bolts or studs. For ASTM A490 bolts or studs, nuts shall conform to ASTM A563 Grade DH.

4.2.3

Manufactured Items Manufactured items such as cleats, shackles, wire rope, clips, thimbles, turnbuckles, chain, tie wire, etc. shall be hot-dipped galvanized in accordance with ASTM A123/A123M.

5.0

TIMBER Miscellaneous timber shall be: utility grade hardwood, reasonably flat, straight, and free of splits or loose knots. The maximum moisture content shall be 19%. The minimum timber design values shall be determined in accordance with ASTM D245, ASTM D143, and ASTM D2555, or in accordance with the latest edition of the “Design Value for Wood Construction,” supplement to National Design Specification for Wood Construction, The Nation Forest Products Association. Timber for skid shoes or runners shall have an ultimate compressive strength perpendicular to the grain of at least 2.76 N/mm² (400 psi).

6.0

FIBERGLASS Fiberglass grating shall be Fibergrate type MXFR, or an approved equal. Fiberglass grating for drain troughs shall be Fibergrate 1½ inch Safe-T-Grate (No. I-6015), yellow or grey, or an approved equal

7.0

SUBSTITUTION OF MATERIALS Substitution of materials not meeting this specification and not approved in writing by the Company shall not be accepted. Nonconforming materials shall be removed and replaced with the specified materials at the Fabricator’s expense. Material substitution requests shall be submitted in writing to the Company for approval, allowing reasonable time for evaluation without disruption of the schedule. Material substitution requests shall include: • Nature and extent of the substitution •

Effect on the contract amount

•

Complete material specifications

•

Mechanical and physical properties of proposed substitute

•

Other information requested by the Company

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8.0


STORAGE OF MATERIALS Structural materials, whether plain or fabricated, shall be stored above ground on flat surfaces, platform type skids, or on other Company approved supports. Materials shall be kept free of dirt, grease, paint spray, or other foreign matter and shall be protected from corrosion. Different grades / strength levels of steel shall be identified by a color coding system.

9.0

MATERIAL TRACEABILITY All material shall be identified by coded markings and/or heat numbers and shall be in accordance with ASTM A6 or ASTM A20 where applicable. The Fabricator shall provide the Comapny with a copy of its material identification procedure. The material identification and traceability procedure shall identify each structural member back to the original test certificate, from receipt and storage through subassembly and final erection. The Fabricator shall be responsible for all material identification marking. All identification markings shall be clearly visible and capable of remaining intact through the completion of fabrication. The materials shall be marked for identification as follows: • Pipe: Outside diameter, wall thickness, and steel grade shall be clearly stenciled using an approved color code. •

Steel material other than pipe: The type of material, steel grade, and dimensions such as length, width, height, etc. shall be clearly stenciled using an approved color code.

The Fabricator shall submit details of the marking system to the Company in advance for approval. The Material Identification Procedure shall also meet CA requirements. The Fabricator shall also provide drawings and documents with individual members marked to identify material mill certificate, etc.

10.0

INSPECTION AND TESTING One certified original copy of all Material Certification, Test, and Inspection Reports shall be submitted to the Company within 5 working days of receipt of the material from the Manufacturer. Material test reports shall be furnished to the Company before incorporation of material into any component of the project. Certified Test Reports shall include the following: • Company or Fabricator purchase order number and item number •

Material size and specification

•

Manufacturing process

•

Mill heat numbers and control numbers

•

Chemical composition

•

Carbon equivalent

•

Heat treatment

•

Grain size

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•

Tensile and yield strengths

•

Charpy V-Notch Impact Energy and test temperature(if applicable)

•

Through thickness test results (if applicable)

•

Elongation

•

Impact testing specimen size, orientation, impact values and test temperatures

•

Nondestructive testing performed

•

Other information specifically required by this specification or by referenced specifications

•

Supplemental information relating to manufacturing process

Items with Material Certification, Test, or Inspection Reports that do not satisfy the specifications shall be rejected by the Company and removed from the project storage area. Material testing shall be in accordance with ASTM A370. Refer to Material Type Tables for Mill certificate requirements.

11.0

MATERIAL TYPES Structural materials have been classified into five types depending on application as listed in Table 11-1 Material Usage Requirements. All fabrication drawings shall refer to material types rather than actual material specifications.

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Table 11-1 Material Usage Requirements Material Type 1

Required Usage Special Application Structure (Most Critical) Heavy flanges and deep webs at major load supporting members within the deck that form box or I type supporting structure and receive major concentrated loads Intersection of major bracing members and critical joint nodes Members which receive immediate concentrated loads at intersections of major structural members

2

Primary Application Structure (Intermediate) Plating of lattice legs External shell plating of caissons Deck plating and structure which is not considered special or secondary Main braces, jacket legs, and deck legs, except where considered special Heavy flanges and deep webs of major load supporting members that form box or I type supporting structure and do not receive major concentrated loads Members which provide local reinforcement or continuity of structure in way of intersections, including main deck load plating where the structure is considered special application

3

Secondary Application Structure (Least Critical) Internal structure including bulkheads and girders in legs or columns Deck plating not essential for overall structural integrity Low-stressed deck beams in parallel and bracing, except where structure is considered primary or special application Plating of certain columns with low slenderness ratios, except at intersections

4

Noncritical structural shapes, plates, and fabricated tubulars Deck plating, deck beams, and minor tubular joint chords.

5

Noncritical small tubular members Minor tubular joint chords and handrails etc.

NOTES: 1. For steel specifications and supplementary requirements, see

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Table 11-2 below. 2. API Spec 2B requirements are applicable to fabricated tubulars 3. Noncritical structural members are those members that if an isolated fracture would occur in them, it would not cause a catastrophic failure or pose a threat to the overall survivability of the structure.

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Table 11-2 Steel Specifications and Supplemental Requirements Type 1H Material (Yield Strength 275 MPa (40ksi)
Type 1M Material (Yield Strength fy <275 MPa (40ksi))

General Description:

General description:

High strength plates, shape, and pipes with guaranteed notch toughness and improved through thickness properties

Mild steel plates, shapes, and pipes with guaranteed notch toughness and improved through thickness properties

Specifications: API 2H Grade 50 / API 2W Grade 50T

Specifications:

API 2Y Grade 50T

ASTM A36

ASTM A131 Grade XH 36/40

ASTM A131 Grade B/D/E

ASTM A633 Grade C/D/E

ABS Grades B/D/E

ABS Grades XH 36/40

API 5L Grade B

API 5L X52/ X60

ASTM A53 Grade B ASTM A106 Grade B

Any material standard other than the above shall be subject to Company approval with consideration of following Supplementary requirements: * Ultrasonic Examination shall be per ASTM A 578 Acceptance Std Level B or equivalent. * Through Thickness (Z-Direction) Testing shall be per API 2H S4, or an equivalent. * Low Sulfur Steel for Improved Through-Thickness Propertiesshall be per API 2H S5, or an equivalent. * Material shall be fully killed and fine grained type. * CVN testing shall be according to the requirements of repective standard or design code requirements in line with service temperature and fabrication site temperature, whichever is stricter. * Maximum Carbon and Carbon Equivalent (CE) shall be 0.23% and 0.42% respectively or per the standard, whichever is stricter. * Maximum Sulfur content 0.015% or per the standard, whichever is stricter. *Strain Aged Charpy V-Notch Impact Tests shall be per API 2H S8 shall be applied if the material undergoes more strain 5% or more. * Pre-production Qualification shall be per API 2H S11 (CTOD testing in accordance with API RP 2Z), or an equivalent if thickness ≥ 2 in.

Any material standard other than the above shall be subject to Companyapproval with consideration of following Supplementary requirements: * Ultrasonic Examination shall be per ASTM A 578 Acceptance Std Level B or equivalent. * Through Thickness (Z-Direction) Testing shall be per API 2H S4, or an equivalent. * Low Sulfur Steel for Improved Through Thickness Properties shall be per API 2H S5, or an equivalent. * Material shall be fully killed and fine grained type. * CVN testing shall be according to the requirements of repective standard or design code requirements in line with service temperature and fabrication site temperature, whichever is stricter. * Maximum Carbon and Carbon Equivalent (CE) shall be 0.23% and 0.42% respectively or per the standard, whichever is stricter. * Manufacturer’s certificates shall be supplied with the material. The Constructor shall maintain a material traceability system. Manufacturer shall include shape control of inclusions, and Mill certificates shall comply with EN 10204-3.2.

* Manufacturer’s certificates shall be supplied with the material. The Constructor shall maintain a material traceability system. Manufacturer shall include shape control of inclusions, and Mill certificates shall comply with EN 10204-3.2.

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Type 2H Material (Yield Strength 275 MPa (40ksi)

Type 2M Material (Yield Strength fy <275 MPa (40ksi)



High strength plates, shapes, and pipe with guaranteed notch toughness

Mild steel plates, shapes, and pipes with guaranteed notch toughness

Specifications:

Specifications:

API 2H Grade 50 / API 2W Grade 50T

ASTM A36

API 2Y Grade 50T

ASTM A131 Grade B/D/E


ABS Grades B/D/E

ASTM A633 Grade C /D/E

API 5L Grade B

ABS Grades XH 36/40

ASTM A53 Grade B

API 5L X52/ X60

ASTM A106 Grade B

Any material standard other than the above shall be subject to Company approval with consideration of following Supplementary requirements:

Any material standard other than the above shall be subject to Company approval with consideration of following Supplementary requirements:

* Material shall be fully killed and fine grained type.

* Material shall be fully killed and fine grained type.

* CVN testing shall be according to the requirements of the repective standard or design code requirements in line with service temperature and fabrication site temperature, whichever is stricter.

* CVN testing shall be according to the requirements of the repective standard or design code requirements in line with service temperature and fabrication site temperature, whichever is stricter.

* Maximum Carbon and Carbon Equivalent (CE) shall be 0.23% and 0.42% respectively or a per the standard, whichever is stricter

* Maximum Carbon and Carbon Equivalent (CE) shall be 0.23% and 0.42% respectively or per the standard, whichever is stricter.

*Strain Aged Charpy V-Notch Impact Tests shall be per API 2H S8 and shall be applied if the material undergoes more strain 5% or more.

* Manufacturer’s certificates shall be supplied with the material. The Constructor shall maintain a material traceability system. The Manufacturer shall include shape control of inclusions, and Mill certificates shall comply with EN 10204-3.1.

* Pre-production Qualification shall be per API 2H S11 (CTOD testing in accordance with API RP 2Z), or an equivalent if thickness ≥ 2 in. * Manufacturer’s certificates shall be supplied with the material. The Constructor shall maintain a material traceability system. The Manufacturer shall include shape control of inclusions and Mill certificates shall comply with EN 10204-3.1.

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Type 3H Material (Yield Strength 275 MPa (40ksi)

Type 3M Material (Yield Strength fy <275 MPa (40ksi)



High strength plates, shapes, and pipes

Mild steel plates, shape, and pipes

Specifications:

Specifications:

API 5L Grade X52 (pipe)

ASTM A36


ASTM A 131 Grade A/B/ D

ABS Grades XH 36/40

ASTM A573 Grade 65

ASTM A572 Grade 50 (shapes only)

ASTM A 709 Grade 36

ASTM A992

ASTM A 131 Grade A/B/D/E ABS Grades A/B/D/E

Any material standard other than the above shall be subject to Company approval with consideration of following Supplementary requirements: * Maximum Carbon and Carbon Equivalent (CE) shall be 0.23% and 0.42% respectively, or per the standard, whichever is stricter. * Material shall be fully killed and fine grained type. * Manufacturer’s certificates shall be supplied with the material. Mill certificates shall comply with EN 10204-3.1

0003-MI20-00S1-0240

API 5L-Grade B ASTM A53 Grade B ASTM A106 Grade B Any material standard other than the above shall be subject to Company approval with consideration of following Supplementary requirements: * Manufacturer’s certificates shall be supplied with the material. Mill certificates shall comply with EN 102043.1

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Type 4 Material Yield Strength fy <275 MPa (40ksi) General description: Mild plates, shapes, and pipes Specifications: ASTM A 36 Any material standard other than the above shall be subject to Company approval with consideration of following Supplementary requirements: * Maximum Carbon and Carbon Equivalent (CE) 0.23% and 0.42% respectively or per the standard, whichever is stricter * Fine Austenitic Grain size, if thickness exceeds 1 in. Type 5 Material Yield Strength fy <275 MPa (40ksi) General description: Mild steel pipes and tubes Specifications: ASTM A36 API 5L Grade B (pipe) ASTM A53 Grade B (pipe) ASTM A106 Grade B (pipe) ASTM A500 Grade B (square and rectangular tubes) Maximum thickness: 1 inch for SMLS or SAW ½ inch for ERW Any material standard other than the above shall be subject to Company approval with consideration of following Supplementary requirements: * Maximum Carbon and Carbon Equivalent (CE) 0.23% and 0.42% respectively or per the standard, whichever is stricter.

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