5890-000-SP-5103-001_A.pdf

PTSC Lam Son FPSO

MuhammadKhafif ZolAzlan 2012.10.11 18:08:15 +08'00'

A

10.10.2012 Issued for Review

PTSC rev.

Date

Reason for issue

JP Race 2012.10.23 15:23:18 +08'00'

Sadok 2012.10.16 11:21:08 +08'00'

MKZ

SCH

JPR

Prep.

Checked

Accepted

Contract no. / Purchase order no.: Technip Malaysia. 5th Floor Wisma JCorp, 249 Jalan Tun Razak 50400 Kuala Lumpur Malaysia

PTSCAP-2012-CO-021 Doc. title according to SMDR:

STRUCTURAL EQUIPMENT MANUFACTURING SPECIFICATION Tag no.:

Project code

TLDD

PO no.

TN sub-contractor document TN document no._Rev.: no._Rev.: 5890-000-SP-5103_A LSJOC document number Unit code Disc. code Doc. type Sequence no.

8100

-

SFI code:

-

0003

-

1AAV

-

A09

Rev.

-

PTSC document number Project no.

0909

Orig. code

-

TN

-

Disc. code

Doc. type

Sequence no.

Total no. of Pages

Rev.

X

X

X

164

A

TECHNIP FAR EAST SDN. BHD. 2nd Floor, Wisma Technip, 241 Jalan Tun Razak 50400 Kuala Lumpur

Tel: +603-21167888 Fax: +603-21167999

CLIENT:

PTSC LAMSON JOC

PROJECT TITLE:

PTSC LAMSON FOR FPSO CONVERSION PROJECT

PROJECT NO:

5690

MuhammadKhaf if ZolAzlan 2012.10.11 18:08:53 +08'00'

Sadok 2012.10.16 11:21:29 +08'00'

Yvan Jacobzone 2012.10.18 11:46:40 +08'00'

A

10/10/12

Issued for Review

MKZ

SCH

YJA

JPR

REV #

DATE

REASON FOR ISSUE

PREPARED BY

DISCIPLINE CHECK

TECHNICAL INTEGRITY

PROJECT APPROVAL

DOCUMENT TITLE:

STRUCTURAL EQUIPMENT MANUFACTURING SPECIFICATION

DOCUMENT NO:

5890-000-SP-5103-001

DOCUMENT CONFIDENTIALITY RATING CONFIDENTIAL – NOT TO DISCLOSE WITHOUT AUTHORISATION CLIENT REF:

N/A

THIS DOCUMENT CONTAINS CONFIDENTIAL INFORMATION. ALL RIGHTS (INCLUDING COPYRIGHT, CONFIDENTIAL INFORMATION, TRADE SECRETS AND DESIGN RIGHTS) ARE OWNED BY TECHNIP FAR EAST SDN BHD. NO USE OR DISCLOSURE IS TO BE MADE WITHOUT THE WRITTEN PERMISSION OF TECHNIP FAR EAST SDN BHD. COPYRIGHT TECHNIP FAR EAST SDN BHD. ALL RIGHTS RESERVED.

5890-000-SP-5103-001_A.docx

PTSC LAMSON FOR FPSO CONVERSION PROJECT STRUCTURAL EQUIPMENT MANUFACTURING SPECIFICATIONS

Doc. No : 5890-000-SP-5103-001 Rev : A Page : 3 of 15

RECORD OF AMENDMENT It is certified that the amendments listed below have been incorporated in this copy of the publication.

AMDT NO

AMENDED SECTION

PARA NO

DESCRIPTION OF CHANGES

Property of Technip Far East Sdn. Bhd. Copyright Technip Far East Sdn. Bhd. All rights reserved

5890-000-SP-5103-001_A.docx



HOLDS STATUS SHEET This revision has the following HOLDs

SECTION

PARA NO

DESCRIPTION OF HOLD


5890-000-SP-5103-001_A.docx



TABLE OF CONTENTS 1.0

INTRODUCTION .................................................................................................................... 6

1.1

Project Description ................................................................................................................. 6

2.0

SCOPE ................................................................................................................................... 7

2.1

Purpose .................................................................................................................................. 7

3.0

MATERIAL DATA SHEET ..................................................................................................... 7

4.0

WELDING SPECIFICATIONS ............................................................................................... 7

5.0

PAINTING SPECIFICATIONS ............................................................................................... 7

6.0

FASTENER MATERIAL SPECIFICATIONS ......................................................................... 7

7.0

BOLT COATING SPECIFICATIONS ..................................................................................... 7

8.0

FORGED MATERIAL SPECIFICATIONS ............................................................................. 7

9.0

PAINTING OF INSTALLATION AIDS SPECIFICATIONS .................................................... 7

10.0

WELDING AND NDE REQUIREMENT FOR PRESSURE VESSELS ACCORDING TO ASME SPECIFICATIONS ...................................................................................................... 7


5890-000-SP-5103-001_A.docx


1.0

INTRODUCTION

1.1

Project Description


Thang Long is geographically located in the south-western part of Block 01/97 and 02/97 in the Cuu Long Basin (see figure 1.1) approximately 120 km east of Vung Tau, 26 km south of Ruby Field and 35 km northeast of Su Tu Vng Field. Dong Do is approximately located 5 km southeast of Thang Long Field. There are total 6 wells drilled in Thang Long Dong Do field.

Figure 1-1: Thang Long Dong Do Location Map The development plan calls for a central processing facility located on an FPSO with production from the two fields via dry trees only. As such two wellhead platforms will be tied back; one located on Thang Long and the other on Dong Do delivering full well stream transfer to the FPSO as shown in the figure below.

Figure 1-2: Preliminary Field Layout


5890-000-SP-5103-001_A.docx

PTSC LAMSON FOR FPSO CONVERSION PROJECT STRUCTURAL EQUIPMENT MANUFACTURING SPECIFICATIONS 2.0

SCOPE

2.1

Purpose


This document defines the technical requirements for the specifications to be applied for fabrication of structural components. 3.0

MATERIAL DATA SHEET Refer to Appendix A.

4.0

WELDING SPECIFICATIONS Refer to Appendix B.

5.0

PAINTING SPECIFICATIONS Refer to Appendix C.

6.0

FASTENER MATERIAL SPECIFICATIONS Refer to Appendix D.

7.0

BOLT COATING SPECIFICATIONS Refer to Appendix E.

8.0

FORGED MATERIAL SPECIFICATIONS Refer to Appendix F.

9.0

PAINTING OF INSTALLATION AIDS SPECIFICATIONS Refer to Appendix G.

10.0

WELDING AND NDE REQUIREMENT FOR PRESSURE VESSELS ACCORDING TO ASME SPECIFICATIONS Refer to Appendix H.


5890-000-SP-5103-001_A.docx



APPENDIX A MATERIAL DATA SHEET


5890-000-SP-5103-001_A.docx

Project n° - Unit

XXXX

Material code Serial n°

SP

5103

0002

Rev.

Page

3

1 / 16

SURF WELDED STRUCTURES MATERIAL DATA SHEET

JOB SPECIFICATION SURF WELDED STRUCTURES MATERIAL DATA SHEET

Pages modified under this revision: pages 1 to 4, 6 to 16

3

04/05/12

Issue For Implementation

JB. HUBERT

R. KARNAFEL

S. ROUTEAU

2

02/04/12

Issue For Implemenation

JB. HUBERT

R. KARNAFEL

S. ROUTEAU

1

27/07/11

A. MUSTO

S. ROUTEAU

S. ROUTEAU

0

02/09/08

J.EMERY

B.SANCHEZ

S.ROUTEAU

Rev

Date DD/MM/YY

WRITTEN BY (name & visa)

CHECKED BY (name & visa)

APPROVED BY (name & visa)

STATUS

DOCUMENT REVISIONS Sections changed in last revision are identified by a vertical line in the margin

JSD 1 - ANG - rev. 2

Project n° - Unit

XXXX


SP

5103

0002

Rev.

Page

3

2 / 16


SUMMARY

1. SCOPE

3

2. REFERENCES

3

3. MDS MATRIX

5

4. MILL CERTIFICATE

6

5. DELIVERY CONDITION

6

6. MATERIAL DATA SHEETS

7

6.1 MDS A1

7

6.2 MDS A2

9

6.3 MDS A3

10

6.4 MDS A4

11

6.5 MDS B1

12

6.6 MDS B2

13

6.7 MDS B3

14

6.8 MDS C1

15

6.9 MDS C2

16


Project n° - Unit

XXXX


SP

5103

0002

Rev.

Page

3

3 / 16


1.

SCOPE This document defines the technical requirements for the weldable structural steels for the fabrication of structural components delivered in the form of plates, bars, shapes and tubulars. Structural components include, but shall not be limited to the followings:  Structural steelwork of Pipeline in-line Structures, Manifolds, etc.  Flexible pipe ancillary equipment  Hang off collars  Mid water arche structures  Anchor bases, Mudmats  Suction piles  Installation aids

2.

REFERENCES The following standards latest edition are used in the present document:


EN 10025-1 EN 10025-2 EN 10025-3 EN 10025-4

Hot rolled product of structural steel Part 1 Hot rolled product of structural steel Part 2 Hot rolled product of structural steel Part 3 Hot rolled product of structural steel Part 4

EN 10225

Weldable Structural Steels for fixed offshore structures – Technical delivery conditions

EN 10219-1

Cold formed welded structural hollow sections of non alloy and fine grain steel

EN 10210-1

Hot finished structural hollow sections of non alloy and fine grain steel

ISO 8501-1

Preparation of steel substrates before application of paints and related products Part 1

ISO 10893

Non-destructive testing of steel tubes

EN 10160

Ultrasonic testing of steel flat product of thickness equal or greater than 6 mm

EN 10164

Steel products with improved deformation properties perpendicular to the surface of the product

EN 10204 / ISO 10474

Metallic products - Inspection documents

API spec 2H

Specification for Carbon Manganese Steel Plate for Offshore Structures

API spec 2W

Specification for Steel Plates for Offshore Structures, produced by TMCP

API spec 2Y

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

API spec 2MT1

Specification for Carbon Manganese Steel Plate with Improved Toughness for Offshore Structures

API spec 2MT2

Rolled Shapes with Improved Notch Toughness

API spec 5L

Specification for Line Pipe

API spec 2B

Specification for the Fabrication of Structural Steel Pipe

ASTM A36

Standard Specification for Carbon Structural Steel

ASTM A106

Seamless Carbon Steel Pipe for High-Temperature Service

ASTM A131

Standard Specification for Structural Steel for Ships

ASTM A500

Standard Specification for Cold-Formed Welded and Seamless Carbon Steel

Project n° - Unit

XXXX


SP

5103

0002

Rev.

Page

3

4 / 16


Structural Tubing in Rounds and Shapes ASTM A501

Standard Specification for Hot-Formed Welded and Seamless Carbon Steel Structural Tubing

ASTM A992

Standard Specification for Structural Steel Shapes

ASTM A6

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

ASTM A370

Standard Test Methods and Definitions for Mechanical Testing of Steel Products

ASTM A578

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

ASTM A770

Standard Specification for Through-Thickness Tension Testing of Steel Plates for Special Applications

“latest revision” for all references


Project n° - Unit

XXXX


SP

5103

Rev.

Page

3

5 / 16

0002


3.

MDS MATRIX Each Material Data Sheet (MDS) shall be chosen according to the structural category of the component. There are 3 structural categories A, B, C depending of the criticality of the component. For one structural category, several MDS can be chosen according to the yield strength or to particular requirements (Through Thickness Testing, additional NDT, etc.). MDS apply only for weldable steel Plates, Round and Shaped Bars, Rolled Sections/Shapes and Hollow Structural Sections – Round or Shaped tubing. In particular, it can not be applied to forged components. It is the responsibility of the structural draughtsman or engineer to determine the structural category of each component. These steels can be used for non welded structures. In this case, chemical composition additional requirements as specified in the MDS may be released for procurement. These MDS are usable for the fabrication of SURF structures with design temperature above 0°C (32°F) and with limited wall thickness depending on the considered MDS and product. For greater thickness or design temperature below 0°C (32°F), specific considerations shall be given for procurement of material with agreement of design/material engineer. For thicknesses above 50mm or project specific requirement, tensile tests and impact tests are to be performed at mid thickness.

Structural category

Definition

A (Critical)

Critical component

B (Standard) C (Auxiliary)

Standard component Auxiliary component

Nominal Yield Strength 355 MPa 355 MPa 420 MPa 460 MPa 235 MPa 355 MPa 355 MPa 235 MPa 355 MPa

Particular Use / Requirement / Through Thickness Testing High strength material High strength material / / verification of edge/internal defects * / /

MDS number A1 A2 A3 A4 B1 B2 B3 C1 C2

(*) MDS-B3 is mainly to be used for Plates of cans for suction piles for welding without prior cutting. Material designation shall be reported on the drawings bill of materials. For this purpose, the following method shall be adopted: S"Yield strength" as per MDS-"number". For example, the steel for critical application of yield stress equal to 355MPa, with the Through Thickness Test shall be designated: “S355 as per MDS-A2”. Any MDS number can be substitute by another MDS number according to the following table without prior agreement. Substitution A1 can be A2


Table A2 replaced -

for MDS A3 by -

number A4 -

B1

B2

B3

C1

C2

B2

A1, A2, B3

-

B1, C2

B2

Project n° - Unit

XXXX


SP

5103

0002

Rev.

Page

3

6 / 16


4.

MILL CERTIFICATE Mill certificates shall indicate, as a minimum, the following:  Rolling technique/delivery condition of base material and temperature of heat treatment  Type of tubular (e.g. seamless, welded) together with manufacturing process  Ladle analysis and/or product chemical analysis including Carbon Equivalent (CEV)  Mechanical test results including impact test with reference to product No.  Non-Destructive Tests performed with acceptance  Any supplementary tests and inspections carried out  Certificate No. and date of issue. IIW formula for CEV calculation shall be used: CEV = C + Mn/6 + (Cr+Mo+V)/5 + (Ni+Cu)/15

Structural materials shall be supplied with Mill inspection certificates in accordance with EN 10204 / ISO 10474 standard:  3.2 Mill certificate for Critical Category steels. See below.  3.1 Mill certificate for Standard Category steels.  2.2 Mill certificate for Auxiliary Category steels. When material is ordered from a Stockist, the Stockist may have selected material that has only been certified by the manufacturer using a type 3.1 certificate. However, it is accepted that material covered by type 3.1 certification can be upgraded to material to “meeting the intent of type 3.2” by the Stockist employing an independent third party inspector. This involves visiting the Stockist to identify the material to be verified, visual examination, sample dimensional checks and confirmation that the material is traceable back to the ladle chemical analysis which may be in the form of a EN10204 type 3.1 certificate. Following confirmation of traceability the material certificate is checked against the intended specification to confirm compliance for chemical analysis, mechanical properties, heat treatment condition, corrosion and structure requirements, NDT performed as determined by the applicable material standard and present MDS. The third party inspector shall also visit the test house to witness all additional testing of the material that is applicable. The acceptability of the type 3.2 (or meeting the intent of 3.2) shall be confirmed with the purchaser.

5.

DELIVERY CONDITION Where standards permit more than one delivery condition, the delivery condition shall be agreed at the time of placement of order and shall not be subject to change. Thermo-mechanically rolled process (TMCP) condition is recommended. Quenched and Tempered (QT) condition shall be limited to S420 as per MDS A3 and S460 as per MDS A4 excepted otherwise agreed in the Purchase Order.


Project n° - Unit

XXXX


SP

5103

0002

Rev.

Page

3

7 / 16


6.

MATERIAL DATA SHEETS

The “description to be reported on the drawings” as described in each sub paragraphs covers all standards that are listed.

6.1

MDS A1

MATERIAL DATA SHEET

MDS A1

TYPE OF MATERIAL: Critical Category, 355 MPa PRODUCT STANDARD GRADE EN 10025-2 S355J2 * Plates and shapes EN 10025-2 EN 10025-3 EN 10025-4 EN 10225

Tubulars / Hollow sections

SCOPE and USAGE

STEEL GRADE DESCRIPTION TO BE REPORTED ON THE DRAWINGS

S355K2 S355N/NL S355M/ML All S355 grades

STANDARD

GRADE

API spec 2H API spec 2W ASTM A131 ASTM A131 API spec 2MT1 API spec 2MT2 API spec 5L PSL2

grade 50 grade 50 DH36 * EH36 2MT1 Class A X52N / X52M

EN 10210-1 S355J2H * EN 10219-1 S355J2H * EN 10210-1 S355K2H/NH/NLH API spec 2B as Plates grade EN 10219-1 S355K2H/NH/NLH EN 10219-1 S355MH/MLH EN 10225 All S355 grades This MDS specifies the selected options in the referred standard and modified requirements which shall supersede the corresponding requirements in the referred standard. - Thickness ≤100mm (4”) for Plates or ≤50mm (2”) for shapes and tubulars (*) : grades S355J2/S355J2H/DH36 permitted only for Thickness ≤16mm (5/8”) - Design temperature ≥0°C (32°F) The steel grades defined here above are the minimum requirements S355 as per MDS A1

QUALIFICATION; STEEL Basic oxygen converter or basic oxygen furnace. Fully killed steel. MAKING PROCESS As per standards HEAT TREATMENT/ DELIVERY CONDITION Cold formed hollow sections: CHEMICAL COMPOSITION TENSILE TESTING ADDITIONAL REQUIREMENTS

SURFACE CONDITION


- if welded with the ERW process, the weld seam shall be heat treated. - if cold forming strain exceeds 5%, stress relieving heat treatment shall be carried out. As per standards, excepted EN 10025-2 S355K2 : CEV ≤ 0.45% EN 10210 S355K2H : CEV ≤ 0.45% Maximum YS/UTS: 0.88 Minimum Elongation: 20% API spec 5L PSL2 – CVN impact test: * temperature shall be -30°C (-22°F) and energy as per table 8, or * temperature shall be -20°C (-4°F) and energy 40J(30ft.lbf) up to D 762mm(30”) API spec 2B – supplementary requirement SR2 with CVN impact test values as above for API 5L. For thicknesses above 50mm (2”) or project specific requirement, tensile tests and impact tests are to be performed at mid thickness. The surface of the material shall comply to Rustgrade A or B or better according to ISO 8501-1.

Project n° - Unit

XXXX


SP

5103

0002

Rev.

Page

3

8 / 16


MATERIAL DATA SHEET

MDS A1

TYPE OF MATERIAL: Critical Category, 355 MPa - EN 10025-2/-3/-4: Option 6 or 7 is required (as per EN 10160 class S1, E1) - EN 10225: Option 19 is required (as per EN 10160 class S1, E1) - EN 10219-1, EN 10210-1: Welds shall be inspected by ultrasonic test (as per ISO 10893-11, with acceptance level U3) - EN 10219-1, EN 10210-1: Seamless hollow section shall be inspected by ultrasonic test (as per ISO 10893-10, acceptance level U2/C) - API spec 2H / 2W / 2MT1: Supplementary requirement S1 - API spec 2MT2: Supplementary requirement S8 - ASTM A131: additional requirement for level A in accordance with ASTM A578 SURFACE PROTECTION Bare or as specified in the purchase order As specified in relevant standard MARKING EN 10 204 / ISO 10474 Type 3.2 CERTIFICATE

NDT


Project n° - Unit

XXXX


SP

5103

0002

Rev.

Page

3

9 / 16


6.2

MDS A2

MATERIAL DATA SHEET

MDS A2

TYPE OF MATERIAL: Critical Category, 355 MPa, Z35/TTT PRODUCT STANDARD GRADE EN 10025-2 S355K2 Plates and shapes EN 10025-3 EN 10025-4 EN 10225

Tubulars / Hollow sections SCOPE and USAGE

S355N/NL S355M/ML All S355 grades

STANDARD

GRADE

API spec 2H API spec 2W ASTM A131 API spec 2MT2 API spec 2B

grade 50 grade 50 EH36 class A As Plates grade

This MDS specifies the selected options in the referred standard and modified requirements which shall supersede the corresponding requirements in the referred standard. Improved deformation properties (Z35) For plates or rolled sections of thickness greater of equal to 25mm (1”) which are heavily stressed in the through thickness direction due to large welding shrinkage or heavy service stresses, cross assemblies with full or deep penetration with possibility of inducing lamellar tearing, Z 35 quality of standard EN 10164 or Through Thickness Testing as per ASTM A770 is required.


QUALIFICATION; STEEL MAKING PROCESS HEAT TREATMENT/ DELIVERY CONDITION CHEMICAL COMPOSITION TENSILE TESTING

- Thickness ≤100mm (4”) for Plates or 50mm (2”) for shapes and tubulars - Design temperature ≥0°C (32°F) The steel grades defined here above are the minimum requirements S355 as per MDS A2

Basic oxygen converter or basic oxygen furnace. Fully killed steel. As per standards

As per standards, excepted EN 10025-2 S355K2 : CEV ≤ 0.45% Maximum YS/UTS: 0.88 Minimum Elongation: 20% - EN 10025-2: option 4 is required for Improved deformation properties EN 10164 Class ADDITIONAL Z35 REQUIREMENTS - EN 10225: option 13 is required for Through Thickness Testing including EN 10164 Class Z35 - API spec 2H / 2W: Supplementary requirement S3, and S4 or S5 for Through Thickness Testing or improved Properties - API spec 2MT2: Supplementary requirement S4, and S44 for TTT - ASTM A131: additional requirements of ASTM A770 are required for TTT For thicknesses above 50mm (2”) or project specific requirement, tensile tests and impact tests are to be performed at mid thickness. SURFACE CONDITION The surface of the material shall comply to Rustgrade A or B or better according to ISO 8501-1. - EN 10025-2/-3/-4: Option 6 or 7 is required (as per EN 10160 class S1, E1) NDT - EN 10225: Option 19 is required (as per EN 10160 class S1, E1) - API spec 2H / 2W: Supplementary requirement S1 - API spec 2MT2: Supplementary requirement S8 - ASTM A131: additional requirement for level A in accordance with ASTM A578 SURFACE PROTECTION Bare or as specified in the purchase order As specified in relevant standard MARKING EN 10 204 / ISO 10474 Type 3.2 CERTIFICATE JSD 1 - ANG - rev. 2

Project n° - Unit

XXXX


SP

5103

0002

Rev.

Page

3

10 / 16


6.3

MDS A3

MATERIAL DATA SHEET

MDS A3

TYPE OF MATERIAL: Critical Category, 420 MPa PRODUCT STANDARD GRADE EN 10025-3 S420N or NL Plates and shapes Tubulars / Hollow sections SCOPE and USAGE


STANDARD

GRADE

API spec 2W API spec 2Y

grade 60 EN 10025-4 S420M or ML grade 60 EN 10225 All S420 grades EN 10210-1 S420NH or NLH API spec 5L PSL2 X60M/X60N/X60Q EN 10219-1 S420MH or MLH API spec 2B as Plates grade EN 10225 All S420 grades This MDS specifies the selected options in the referred standard and modified requirements which shall supersede the corresponding requirements in the referred standard. - Thickness ≤50mm (2”) - Design temperature ≥0°C (32°F) The steel grades defined here above are the minimum requirements S420 as per MDS A3

QUALIFICATION; STEEL Basic oxygen converter or basic oxygen furnace. Fully killed steel. MAKING PROCESS As per standards HEAT TREATMENT/ DELIVERY CONDITION Cold formed hollow sections:

- if welded with the ERW process, the weld seam shall be heat treated. - if cold forming strain exceeds 5%, stress relieving heat treatment shall be carried out. As per standards, excepted CHEMICAL EN 10210 S420NH : CEV ≤ 0.45% COMPOSITION For API 5L PSL2 X60N: CEV ≤ 0.43% Maximum YS/UTS: 0.88 TENSILE TESTING Minimum Elongation: 20% API spec 5L PSL2 – CVN impact test: ADDITIONAL * temperature shall be -30°C (-22°F) and energy as per table 8, or REQUIREMENTS * temperature shall be -20°C (-4°F) and energy 40J(30ft.lbf) up to D 762mm(30”) API spec 2B – supplementary requirement SR2 with CVN impact test values as above for API 5L. SURFACE CONDITION The surface of the material shall comply to Rustgrade A or B or better according to ISO 8501-1. - EN 10025-2: Option 6 or 7 is required (as per EN 10160 class S1, E1) NDT - EN 10225: Option 19 is required (as per EN 10160 class S1, E1) - EN 10219-1, EN 10210-1: Welds shall be inspected by ultrasonic test (as per ISO 10893-11, with acceptance level U3) - EN 10219-1, EN 10210-1: Seamless hollow section shall be inspected by ultrasonic test (as per ISO 10893-10, acceptance level U2/C) - API spec 2W : Supplementary requirement S1 - API spec 2Y : Supplementary requirement S1 SURFACE PROTECTION Bare or as specified in the purchase order As specified in relevant standard MARKING EN 10 204 / ISO 10474 Type 3.2 CERTIFICATE


Project n° - Unit

XXXX


SP

5103

0002

Rev.

Page

3

11 / 16


6.4

MDS A4

MATERIAL DATA SHEET

MDS A4

TYPE OF MATERIAL: Critical Category, 460 MPa PRODUCT STANDARD GRADE EN 10025-3 S460N or NL Plates and shapes Tubulars / Hollow sections SCOPE and USAGE


STANDARD

GRADE

API spec 2W API spec 2Y

grade 60 * EN 10025-4 S460M or ML grade 60 * EN 10225 All S460 grades EN 10210-1 S460NH or NLH API spec 5L PSL2 X65M/X65Q EN 10219-1 S460MH or MLH API spec 2B as Plates grade EN 10225 All S460 grades This MDS specifies the selected options in the referred standard and modified requirements which shall supersede the corresponding requirements in the referred standard. - Thickness ≤50mm (2”) - Design temperature ≥0°C (32°F) The steel grades defined here above are the minimum requirements S460 as per MDS A4

QUALIFICATION; STEEL Basic oxygen converter or basic oxygen furnace. Fully killed steel. MAKING PROCESS As per standards HEAT TREATMENT/ DELIVERY CONDITION Cold formed hollow sections: CHEMICAL COMPOSITION TENSILE TESTING

- if welded with the ERW process, the weld seam shall be heat treated. - if cold forming strain exceeds 5%, stress relieving heat treatment shall be carried out. As per standards, excepted EN 10210 S460NH : CEV ≤ 0.45% EN 10219 S460NH : CEV ≤ 0.45% Maximum YS/UTS: 0.90 Minimum Elongation: 18%

(*) API spec 2W / 2Y – minimum Yield Strength: - 450 MPa (65ksi) for thk less or equal to 40mm (1.5”) and - 430 MPa (62ksi) for thk greater than 40mm (1.5”) - API spec 5L PSL2 – CVN impact test: ADDITIONAL * temperature shall be -30°C (-22°F) and energy as per table 8, or REQUIREMENTS * temperature shall be -20°C (-4°F) and energy 40J(30ft.lbf) up to D 762mm(30”) - API spec 2B – supplementary requirement SR2 with CVN impact test values as above for API 5L. SURFACE CONDITION The surface of the material shall comply to Rustgrade A or B or better according to ISO 8501-1. - EN 10025-2: Option 6 or 7 is required (as per EN 10160 class S1, E1) NDT - EN 10225: Option 19 is required (as per EN 10160 class S1, E1) - EN 10219-1, EN 10210-1: Welds shall be inspected by ultrasonic test (as per ISO 10893-11, with acceptance level U3) - EN 10219-1, EN 10210-1: Seamless hollow section shall be inspected by ultrasonic test (as per ISO 10893-10, acceptance level U2/C) - API spec 2W : Supplementary requirement S1 - API spec 2Y : Supplementary requirement S1 SURFACE PROTECTION Bare or as specified in the purchase order As specified in relevant standard MARKING EN 10 204 / ISO 10474 Type 3.2 CERTIFICATE


Project n° - Unit

XXXX


SP

5103

0002

Rev.

Page

3

12 / 16


6.5

MDS B1

MATERIAL DATA SHEET

MDS B1

TYPE OF MATERIAL: Standard Category, 235 MPa PRODUCT STANDARD GRADE EN 10025-2 S235J0 * Plates and shapes EN 10025-2



S235J2

STANDARD

GRADE

ASTM A131 ASTM A131 ASTM A36 API spec 5L PSL2

grade B * grade D grade BR / BN

EN 10210-1 S275J0H * EN 10219-1 S275J0H * EN 10210-1 S275J2H ASTM A500 grade A EN 10219-1 S275J2H ASTM A501 grade A This MDS specifies the selected options in the referred standard and modified requirements which shall supersede the corresponding requirements in the referred standard. - Thickness ≤50mm (2”), and ≤25mm (1”) for shapes and tubulars (*) : grades S235J0/S275J0H/B permitted only for Thickness ≤25mm (1”) - Design temperature ≥0°C (32°F) ASTM A500 is only for Shaped Structural Tubing (ASTM A500 for Round Structural Tubing is not allowed) The steel grades defined here above are the minimum requirements S235 as per MDS B1


- if welded with the ERW process, the weld seam shall be heat treated. - if cold forming strain exceeds 5%, stress relieving heat treatment shall be carried out. For ASTM A36, A500 and A501 : C% ≤ 0.22% For ASTM A131, A106, A500 and A501 : CEV ≤ 0.45% Maximum YS/UTS: 0.88 Minimum Elongation: 20% - API spec 5L PSL2 – CVN impact test: * temperature shall be -20°C (-4°F) and energy as per table 8 of API spec 5L

- ASTM A36 supplementary requirement S5 for impact test: - ASTM A500 and ASTM A501 additional requirement for impact test: * to be as per requirements of ASTM A131 Grade D SURFACE CONDITION The surface of the material shall comply to Rustgrade A or B or better according to ISO 8501-1. As per standards NDT SURFACE PROTECTION Bare or as specified in the purchase order As specified in relevant standard MARKING EN 10 204 / ISO 10474 Type 3.1 CERTIFICATE


Project n° - Unit

XXXX


SP

5103

0002

Rev.

Page

3

13 / 16


6.6

MDS B2

MATERIAL DATA SHEET

MDS B2

TYPE OF MATERIAL: Standard Category, 355 MPa PRODUCT STANDARD GRADE EN 10025-2 S355J0 * Plates and shapes EN 10025-2



S355J2

STANDARD

GRADE

API spec 2H API spec 2W ASTM A131 ASTM A131 ASTM A992 API spec 5L PSL2

grade 50 grade 50 grade AH36 * grade DH36 X52N / X52M

EN 10210-1 S355J0H * EN 10219-1 S355J0H * EN 10210-1 S355J2H ASTM A500 grade C EN 10219-1 S355J2H ASTM A501 grade B This MDS specifies the selected options in the referred standard and modified requirements which shall supersede the corresponding requirements in the referred standard. - Thickness ≤50mm (2”), and ≤25mm (1”) for shapes and tubulars (*) : grade S355J0/S355J0H/AH36 permitted only for Thickness ≤25mm (1”) - Design temperature ≥0°C (32°F) ASTM A500 is only for Shaped Structural Tubing (ASTM A500 for Round Structural Tubing is not allowed) The steel grades defined here above are the minimum requirements S355 as per MDS B2


- if welded with the ERW process, the weld seam shall be heat treated. - if cold forming strain exceeds 5%, stress relieving heat treatment shall be carried out. CEV ≤ 0.45% For ASTM A500 and A501 : C% ≤ 0.22% Maximum YS/UTS: 0.88 Minimum Elongation: 20% - API spec 5L PSL2 – CVN impact test: * temperature shall be -20°C (-4°F) and energy as per table 8 of API 5L

- ASTM A992 Supplementary requirement S5 for impact test: - ASMT A500 and ASTM A501 additional requirement for impact test: * to be as per requirements of ASTM A131 Grade DH36 SURFACE CONDITION The surface of the material shall comply to Rustgrade A or B or better according to ISO 8501-1. As per standards NDT SURFACE PROTECTION Bare or as specified in the purchase order As specified in relevant standard MARKING EN 10 204 / ISO 10474 Type 3.1 CERTIFICATE


Project n° - Unit

XXXX


SP

5103

0002

Rev.

Page

3

14 / 16


6.7

MDS B3

MATERIAL DATA SHEET

MDS B3

TYPE OF MATERIAL: Standard Category, 355 MPa, with verification of edge and internal defects PRODUCT STANDARD GRADE STANDARD GRADE EN 10025-2 S355J2 API spec 2H grade 50 Plates and shapes EN 10025-2 EN 10025-3 EN 10025-4 EN 10225

SCOPE and USAGE


QUALIFICATION; STEEL MAKING PROCESS HEAT TREATMENT/ DELIVERY CONDITION CHEMICAL COMPOSITION TENSILE TESTING ADDITIONAL REQUIREMENTS SURFACE CONDITION

S355K2 S355N/NL S355M/ML All S355 grades

API spec 2W ASTM A131

grade 50 grade DH36

This MDS specifies the selected options in the referred standard and modified requirements which shall supersede the corresponding requirements in the referred standard. - Thickness ≤50mm (2”) - Design temperature ≥0°C (32°F) The steel grades defined here above are the minimum requirements S355 as per MDS B3

Basic oxygen converter or basic oxygen furnace. Fully killed steel. As per standards As per standards Maximum YS/UTS: 0.88 Minimum Elongation: 20% none

The surface of the material shall comply to Rustgrade A or B or better according to ISO 8501-1. - EN 10025-2/-3/-4 Option 6 or 7: Ultrasonic testing as per EN 10160 class S1, E2 NDT - EN 10225: Option 19 is required (as per EN 10160 class S1, E2) - API spec 2H / 2W: Supp. requirement S1 level C in accordance with ASTM A578 - ASTM A131: additional requirement for level C in accordance with ASTM A578 SURFACE PROTECTION Bare or as specified in the purchase order As specified in relevant standard MARKING EN 10 204 / ISO 10474 Type 3.1 CERTIFICATE


Project n° - Unit

XXXX


SP

5103

0002

Rev.

Page

3

15 / 16


6.8

MDS C1

MATERIAL DATA SHEET

MDS C1

TYPE OF MATERIAL: Auxiliary Category, 235 MPa PRODUCT STANDARD GRADE Plates and shapes EN 10025-2 S235JR S235JRH S235JRH

STANDARD ASTM A131 ASTM A36 API spec 5L ASTM A500 ASTM A501 ASTM A106

GRADE grade A or B grade B grade A grade A grade B


EN 10210-1 EN 10219-1

SCOPE and USAGE

This MDS specifies the selected options in the referred standard and modified requirements which shall supersede the corresponding requirements in the referred standard. ASTM A500 is only for Shaped Structural Tubing (ASTM A500 for Round Structural Tubing is not allowed)


QUALIFICATION; STEEL MAKING PROCESS HEAT TREATMENT/ DELIVERY CONDITION CHEMICAL COMPOSITION TENSILE TESTING ADDITIONAL REQUIREMENTS

- Thickness ≤ 25mm (1”) - Design temperature ≥0°C (32°F) The steel grades defined here above are the minimum requirements S235 as per MDS C1 No specific requirements As per standards

For ASTM A106, A500 and A501, and API spec 5L : C% ≤ 0.24% For ASTM A131, A106, A500 and A501, and API spec 5L: CEV ≤ 0.45% As per standards - API spec 5L additional requirement for impact test: - ASTM A36 supplementary requirement S5 for impact test: - ASTM A131 grade A, A106, A500 and ASTM A501 additional requirement for impact test: * temperature shall be 20°C (68°F) and energy 27J (20 ft.lbf) SURFACE CONDITION The surface of the material shall comply to Rustgrade A or B or better according to ISO 8501-1. NDT No specific requirements SURFACE PROTECTION Bare or as specified in the purchase order MARKING As specified in relevant standard CERTIFICATE EN 10 204 / ISO 10474 Type 2.2


Project n° - Unit

XXXX


SP

5103

0002

Rev.

Page

3

16 / 16


6.9

MDS C2

MATERIAL DATA SHEET

MDS C2

TYPE OF MATERIAL: Auxiliary Category, 355 MPa PRODUCT STANDARD GRADE Plates and shapes EN 10025-2 S355J0

S355J0H S355J0H

STANDARD API spec 2MT2 ASTM A131 ASTM A992 API spec 5L ASTM A500 ASTM A501

GRADE class A grade AH36 X52 grade C grade B


EN 10210-1 EN 10219-1

SCOPE and USAGE

This MDS specifies the selected options in the referred standard and modified requirements which shall supersede the corresponding requirements in the referred standard. ASTM A500 is only for Shaped Structural Tubing (ASTM A500 for Round Structural Tubing is not allowed)


QUALIFICATION; STEEL MAKING PROCESS HEAT TREATMENT/ DELIVERY CONDITION CHEMICAL COMPOSITION TENSILE TESTING ADDITIONAL REQUIREMENTS

- Thickness ≤ 25mm (1”) - Design temperature ≥0°C (32°F) The steel grades defined here above are the minimum requirements S355 as per MDS C2 No specific requirements No specific requirements

CEV ≤ 0.45% For ASTM A500 and A501 : C% ≤ 0.22% No specific requirements - API spec 5L additional requirement for impact test: - ASTM A992 Supplementary requirement S5 for impact test: - ASMT A500 and ASTM A501 additional requirement for impact test: * temperature shall be 0°C (-4°F) and energy 27J (20 ft.lbf) SURFACE CONDITION The surface of the material shall comply to Rustgrade A or B or better according to ISO 8501-1. NDT No specific requirements SURFACE PROTECTION Bare or as specified in the purchase order MARKING As specified in relevant standard CERTIFICATE EN 10 204 / ISO 10474 Type 2.2




APPENDIX B WELDING SPECIFICATIONS


5890-000-SP-5103-001_A.docx

Project n° - Unit

XXXXX


SP

5103

001

Rev.

Page

1

2 / 34

SUBSEA STRUCTURAL WELDING SPECIFICATION

This is an electronically generated document which has been reviewed and approved in accordance with Technip France Management System. An audit trail of review and approval is available within the system. The screen version of this document is the CONTROLLED COPY at all times. When printed, it is considered as a “FOR INFORMATION ONLY” copy, and it is the holder’s responsibility that he / she holds the latest valid version.

VERSION RECORD SHEET Revision

Issue Date

Purpose

0

27/03/09

AFC

1

01/07/10

AFC

List of updated/modified sections if any

All pages

Project n° - Unit

XXXXX


SP

5103

001

Rev.

Page

1

3 / 34


CONTENTS 1. SCOPE 2. REQUIREMENTS 3. DEFINITIONS 4. ABBREVIATIONS 5. REFERENCES, APPLICABLE CODES AND STANDARDS 6. VENDOR QUALITY MANAGEMENT 7. STRUCTURAL STEEL FOR SUBSEA APPLICATION 8. STRUCTURAL CRITICALITY APPENDIX A: SUBSEA STRUCTURE WELDS SPECIFICATION, AWS Standards APPENDIX B: SUBSEA STRUCTURE WELDS SPECIFICATION, EN/ISO Standards

Project n° - Unit

XXXXX


SP

5103

001

Rev.

Page

1

4 / 34


1. SCOPE This document defines the technical requirements for the fabrication welding and Non Destructive Testing program of structural components. Structural components are those designated as non-pressure containing and shall include, but shall not be limited to the following: Structural steelwork of ITA, FLET, FTA… Flexible pipe ancillary equipment Hang off collar Mid water arches structure Anchor bases Suction piles Installation aids and sea fastenings 2. REQUIREMENTS Two distinct specifications are given in appendix A and B: -Appendix A specification follows the AWS standards. -Appendix B specification follows the EN/ISO standards. VENDOR is requested to inform CONTRACTOR about the selected Standard corpus (Appendix A or Appendix B) before starting work and shall not change the selected route throughout the project. 3.

DEFINITIONS For the purpose of this specification, the following definitions shall apply COMPANY: CONTRACTOR’s Client CONTRACTOR: TECHNIP France. VENDOR: means MANUFACTURER /SUPPLIER, which is the party that manufactures or supplies equipment and services, to perform the duties specified by the CONTRACTOR. The word "Shall" is to be understood as mandatory.

4.

ABBREVIATIONS CE Carbon Equivalent CJP Complete Joint Penetration CVN Charpy V- notch DPI Dye penetrant inspection EN European standard FCAW Flux Core Arc Welding FCAW-GS Gas Shielded Flux Core Arc Welding FCAW-SS Self Shielded Flux Core Arc welding FTA Flow Line Termination Assembly GMAW Gas Metal Arc Welding GTAW Gas Tungsten Arc Welding HAZ Heat Affected Zone ILT In-Line Tee Assembly LAST Lowest Anticipated Service Temperature MPI Magnetic Particle Inspection NDE Non-Destructive Examination NDT Non-Destructive Test PJP Partial Joint Penetration PQR Procedure Qualification Test QCP Quality Control Plan QT Quenched and Tempered RT Radiographic Testing SAW Submerged Arc Welding

Project n° - Unit

XXXXX


SP

5103

001

Rev.

Page

1

5 / 34


SMAW TMCP UT WPS 5.

Shielded Metal Arc Welding Thermo-Mechanical Controlled Process Ultrasonic Testing Welding Procedure Specification

REFERENCES, APPLICABLE CODES AND STANDARDS 5.1 General The VENDOR shall ensure that all materials, workmanship and inspection conform to the requirements of this specification. Any conflict between the requirements placed by this specification and referenced codes, standards, datasheets or drawings shall be referred to CONTRACTOR for clarification. VENDOR shall list and fully describe all deviations from this specification and the other relevant documents. VENDOR shall have fully experienced supervisory personnel in charge of all aspects of the work and shall employ only experienced workers to carry out the work. CONTRACTOR shall approve all sub-contractors to VENDOR prior to the placement of order. VENDOR shall demonstrate that any chosen sub-contractor is capable of producing work to the required standard. VENDOR shall make no substitution of materials and/or modification of details without prior approval by CONTRACTOR. VENDOR shall submit in writing all changes duly documented with description of the benefits of such changes to CONTRACTOR for approval. It is an obligation of VENDOR to check all the contract documents and drawings and to notify CONTRACTOR of any errors or omissions. 5.2 Application of contractual documents In case of conflict between documents the following order of precedence shall govern. 1. Purchase order 2.

Scope of work and material requisition

3.

Data sheets

4.

Project specifications

5.

General project specifications

6. Applicable codes and standards All exceptions to the specifications and data sheets requirements must be brought to the attention of CONTRACTOR in writing and shall require prior approval before any action is taken by the VENDOR. 5.3 References Unless otherwise specifically indicated in writing, the VENDOR shall work in accordance with the requirements of the latest editions of the referenced codes and standards in time of contract award. When this specification states no overriding requirements, the referenced codes and standards shall apply in full. If there is any conflict between this specification and any other specification and/or related data sheets or with any applicable codes, standards and regulations, VENDOR shall inform CONTRACTOR in writing. Written clarification must be given by CONTRACTOR before VENDOR commences work. Otherwise the most stringent requirements shall apply. VENDOR shall keep copies of all referenced specifications referred to in this specification and shall make them readily available to all fabrication, testing, and inspection personnel involved in the work. The codes, standards and specifications with their latest published amendments shall apply.

6.

VENDOR QUALITY MANAGEMENT Compliance with ISO 9001shall be demonstrated to CONTRACTOR.

Project n° - Unit

XXXXX


SP

5103

001

Rev.

Page

1

6 / 34


VENDOR shall be required to demonstrate that the control of their operations involving welding is in compliance with the principles of ISO 3834-1 and as a minimum with the “standard quality” requirements of ISO 3834-3. Before commencement of work VENDOR shall submit for approval a detailed step by step Quality Control Plan (QCP) where all applicable fabrication and test procedures including the acceptance criteria are referred to. The Quality Control Plan shall include all fabrication, inspection and test operations as well as prior operations before fabrication. The Quality Control Plan shall show all planned witness, hold and review points for VENDOR quality control personnel. Columns shall also be provided for CONTRACTOR, to specify the witness and hold points. The Quality Control Plan and the procedures to which it makes reference shall be approved by CONTRACTOR before commencement of fabrication. Within the certified quality system of the manufacturer the welding activities need a special attention. The quality assurance with respect to the welding in general shall meet the requirements of ISO 14731. 7.

STRUCTURAL STEEL FOR SUBSEA APPLICATION 7.1 Material definition Material to be used for construction are indicated on construction drawings supplied to SUPPLIER. 7.2 Substitution of Steel grades If VENDOR wishes to use other steel grades, the request shall be submitted to CONTRACTOR for review and approval prior to commencement of work. 7.3 Certification All material shall be delivered with minimum certificates EN 10204 2.2 or more stringent requirement from project specifications, Purchase order or codes. All certificates shall be either originals or verified copies. 7.4 Identification of material The VENDOR shall also ensure that the Mill markings and identification on all materials are maintained throughout and transferred to all surplus and scrap. The markings and identification shall be visibly clear and recognized as being correct by the Inspector.

8.

STRUCTURAL CRITICALITY The structure is divided into different structural categories. These structures criticality is usually defined in the design codes and design drawings, but in general the definition of each area is as follows: Cat I: Applicable for highly loaded joints and members with limited structural redundancy, and where failure will have substantial consequences. Mainly applicable to lift points and fatigue sensitive areas. Cat II: Applicable for joints and members submitted to high tensile stress, and where failure is without dramatic consequences, due to a certain level of structural redundancy. Cat III: Applicable for joints and members submitted to high shear stress, and where failure is without dramatic consequences, due to a certain level of structural redundancy. Cat IV: Applicable for joints and members submitted to compressive stress or low stress level. Cat V: Applicable for joints and members submitted to marginally loaded ancillary components.

Project n° - Unit

XXXXX


SP

5103

001


APPENDIX A: SUBSEA STRUCTURE WELDS SPECIFICATION, AWS Standards

Rev.

Page

1

7 / 34

Project n° - Unit

XXXXX


SP

5103

001

Rev.

Page

1

8 / 34


TABLE OF CONTENTS

1. CODES AND STANDARDS

Page 9

2. WELDING REQUIREMENTS

Page 9

3. WELDING PROCEDURE QUALIFICATIONS

Page 10

4. ESSENTIAL VARIABLES

Page 12

5. WELDING PROCESSES

Page 12

6. WELDING CONSUMABLES

Page 13

7. QUALIFICATION OF WELDERS & WELDING OPERATORS

Page 14

8. PRODUCTION WELDING

Page 14

9. WELD INSPECTION

Page 16

10. WELD REPAIRS

Page 20

Project n° - Unit

XXXXX


SP

5103

001

Rev.

Page

1

9 / 34


1. CODES AND STANDARDS American Petroleum Institute (API) API RP 2X Recommended Practice for Ultrasonic and Magnetic Examination of Offshore Structural Fabrication and Guidelines for Qualifications of Technicians ASTM A 370 Standard Test Methods and Definitions for Mechanical Testing Steel Products American Society of Mechanical Engineers (ASME) ASME Section V Non-destructive examination ASME Section II, Part C Welding Rods, electrodes, and Filler Metal American welding Society (AWS) AWS D1.1 Structural welding code AWS A2.4 Symbols for welding and Non destructive testing AWS A5.01 Filler Metal Procurement Guidelines. European Standards EN 10204 EN 10225 EN 29000 EN 29001 Other documents: ISO 9001

EN 10204 Certificate of Metallic Products Non-alloy steel tubes suitable for welding or threading. Quality systems – Guide to selection and use Quality systems – Model for quality assurance in design development, production, installation and servicing. Quality management and systems – Requirements

2. WELDING REQUIREMENTS 2.1 General All structural welding shall be in accordance with AWS D1.1, amended and supplemented by this specification. CONTRACTOR shall develop and qualify welding procedure specifications, including repair welding and tack welding procedure specifications, for all structural welding. This shall be done prior to commencement of the work according to the AWS D1.1 code, and the requirements of this specification. 2.2 Welding Book The VENDOR shall submit a detailed Welding Data Book to the CONTRACTOR at the time of WPS/PQR submittal. Fabrication shall not start until the Welding Data Book is returned with agreement to proceed. The Welding Data Book shall include the following documents: ♦

A cover sheet with title block dedicated to the Project.

♦

A Weld map / Weld Key Form.

♦

Welding Procedure Specifications (WPS).

♦

Procedure Qualification Records (PQR).

♦

A NDE map with extensions of each NDE examination

2.2.1 Weld map The Weld map / Weld Key form shall contain as a minimum the following information: ♦

Sketch of the structural part.

♦

Material type(s) and grade(s) for each type of structural component.

♦

WPS to be used for each type of joint of same design and similar thickness.

♦

Actual thickness where each WPS is to be used.

Project n° - Unit

XXXXX


SP

5103

001

Rev.

Page

1

10 / 34


♦

P.W.H.T. requirements (project specification or code as applicable).

2.2.2 Welding procedure specification (WPS) Welding Procedure Specifications (WPS) and their supporting Procedure Qualification Records (PQR) shall conform to the requirements of AWS D1.1 and to the requirements of this specification Welding Procedure Specifications together with Procedure Qualification Records shall be submitted to the CONTRACTOR prior to the start of fabrication. Welding shall not proceed until these documents are returned by the CONTRACTOR with agreement to proceed. All Welding Procedure Specifications and Procedure Qualification Records for purchased items subcontracted by the VENDOR shall be reviewed by the VENDOR for content and contract compliance prior to submittal to the CONTRACTOR. Each WPS shall be identified by a unique number and shall be identified on the welding map. Pre-qualified welding procedures as defined in AWS D 1.1 code chapter 3 may be used without qualification test subject to prior approval by the CONTRACTOR. However, such procedures shall meet the requirements of this specification. This paragraph is only applicable for structural categories IV and V. 3. WELDING PROCEDURE QUALIFICATIONS 3.1 General Welding procedure qualifications tests shall be carried in accordance with AWS D1.1: -Each applicable WPS shall be qualified by tests prior to commencement of the work as directed by the AWS D 1.1 code, and the requirements of this specification. -Qualified welding procedures from previous orders approved by an international and CONTRACTOR recognized inspection agency may be accepted without further tests provided that acceptable documentation is supplied as regard to the requirements of present specification and subject to prior approval of the CONTRACTOR/COMPANY. - T, K, Y welds. Testing shall be as per the relevant original qualification scheme, unless otherwise specified by CONTRACTOR. -Shop welding procedure qualification for site application may be acceptable provided site machine and associated equipment are identical to those used for qualification and will require CONTRACTOR / COMPANY written approval. 3.2 Mechanical testing requirements Mechanical tests for procedure qualification shall be in accordance with AWS D1.1 Section 4 and the additional requirements as specified in the following Sections. 3.2.1 Hardness Hardness survey is only applicable for structural category I,II and III and shall be performed on weld macro cross section according to the Vickers hardness test method defined in the ASTM E 92 or other standards approved by CONTRACTOR / COMPANY. The series of readings shall include unaffected base material, Heat affected Zone, weld deposit at 1 to 2 mm from the surface as per below sketch. In the HAZ the first indentation shall be located as close as possible of the fusion line. A minimum of three impressions shall be made in each area (weld metal, HAZ, and base metal on each side). Hardness values requirements are: - TMCP and Q/T steels: 325 HV10 max. -Normalized and forged steels: 350 HV10 max.

Project n° - Unit

XXXXX


SP

5103

001

Rev.

Page

1

11 / 34


Examples of hardness survey locations are shown on below sketches: 2mm max

2mm max

0.5 to 1mm

2mm max

3.2.2 Charpy V-notch impact testing Charpy impact toughness testing of the weld metal and heat affected zone (HAZ) shall be performed for welding of CJP joints. Locations for CVN test specimens shall be weld metal, Fusion Line, Fusion Line + 2mm and Fusion Line + 5mm. Test to be performed as per AWS D1.1 Part D at LAST-20°C for structural category I and at LAST for Structural Cat II. Test is not required for structural categories Cat III, IV and Cat V.

Project n° - Unit

XXXXX


SP

5103

001

Rev.

Page

1

12 / 34


Acceptance criteria are as a minimum 30J average and 27J individual. Location of samples shall be in compliance with Figure 4-40 of AWS D1.1. Full size specimens shall be used where possible in the case of sub-size specimens the reduction factors shall be as follows: Specimen Size 10 mm 7.5 mm 5.0 mm

Energy Reduction Factor None 5/6 2/3

3.2.3 Retest: Should a qualification test weld fail any of the required tests or permitted re-tests, the cause of the failure shall be established and reported to CONTRACTOR. A revised WPS shall be submitted for CONTRACTOR approval prior to re-testing. 3.2.4 NDT: Results of non-destructive testing shall be completed and confirmed to be in compliance with the specified requirements before mechanical testing is carried-out. Failure to meet the acceptance criteria for non-destructive testing shall result in failure of the qualification test.

4. ESSENTIAL VARIABLES Changes beyond the limitations of PQR essential variables for all welding methods shown in AWS D1.1, Tables 4-5 and 4-6 and the following additional requirements shall require re-qualification of the WPS: Variables Base Material Carbon Equivalent Base Material

PWHT

Limitations Carbon equivalent of base material used in production shall not exceed the carbon equivalent of the base material of the welding qualification + 0.03%. The following limits shall apply for welding procedure when Charpy Vee Notch testing is required (a change in an essential variable beyond the specified limits requires a new qualification): - A change in the process of manufacture for the base material, outside the following groups: 1. Quenched and Tempered steels 2. TMCP or Controlled-rolled steels 3. Normalized or as-rolled steels - An increase of more than 10°C over the maximum interpass temperature attained on the procedure qualification. Welds qualified with PWHT shall be PWHT in production.

• When weld-through primers are used during fabrication, they shall be included in the weld procedure qualifications. The specific primer shall be an essential variable. Weld through primers containing Deoxaluminite are preferred, 5. WELDING PROCESSES Acceptable methods of welding are SMAW, SAW, GMAW, FCAW, and GTAW processes. Combinations of processes may be qualified and used providing the following conditions are met: • The welding process has been explicitly stated for each pass (e.g. optional passes are not permitted); • The combination of processes has been fully tested with supporting PQR documentation;

Project n° - Unit

XXXXX


SP

5103

001

Rev.

Page

1

13 / 34


• Single welding processes qualified individually cannot be combined with another welding process unless tested in that combination. • Self-shielded flux cored arc welds shall not be followed by any other process, including weld repairs, unless specifically qualified. 6. WELDING CONSUMABLES 6.1 General Low hydrogen welding consumables shall be used for all welds. Low hydrogen consumables are those capable of producing weld metal with less than 10 ml of diffusible hydrogen per 100 g of deposited metal using the mercury or gas chromatography methods when stored and baked according to the manufacturer's recommendation. The COMPANY may request additional testing of consumables during construction, at COMPANY’s expense. Welding consumables shall be selected such as: -The tensile strength of deposited weld metal is at least equal to the specified minimum mechanical properties of the materials being welded in production. -The principal elements in the deposited weld metal are similar to the nominal composition of the base metal. Solid wires for automatic welding processes shall contain the principal elements required for the deposited weld metal. Welds deposited by the submerged arc process shall not derive any principal elements from the flux. Manufacturer’s storage and baking requirements must be adhered to. Fluxes that the flux Manufacturer recommends for single pass welds shall not be used for multiple pass welds. Active fluxes are not permitted. 6.2 Welding consumable classification and certification Filler metal shall be as specified in ASME Section II Part C or equivalent AWS Specification. Welding consumables shall be purchased from Manufacturer’s operating a quality system based on ISO 9001 or EN 12074. All FCAW consumables (either for FCAW-SS or FCAW-GS) shall be low hydrogen type, as tested and certified by the consumable manufacturer and shall conform to AWS A5.20 and AWS A5.29 Alloy fluxes as defined by ASME section II, Part C SFA 5.17 or 5.23 shall not be used. Welding consumables shall be delivered with certificates EN 10204: -type 2.2 for structural categories III, IV and V otherwise more stringent requirement from project specifications if any. -type 3.1 for chemical analysis and mechanical tests for structural categories I and II otherwise more stringent requirement from project specifications if any. 6.3 Consumable storage Welding consumables shall be stored with care, under dry conditions in their original unopened packing. After opening shipping containers of electrodes, fluxes and other welding materials, storage and handling shall be as specified in the Manufacturer's recommendations. Electrodes, filler wires or fluxes that are damaged, damp, greasy or oxidized shall not be used. All electrodes, which have been in direct contact with water, shall be definitely rejected. VENDOR’s facilities shall include a temperature and humidity controlled welding consumable and flux store, including holding and drying ovens. Low hydrogen electrodes and fluxes shall be dried at 250°C/300°C for two hours prior to use, unless otherwise recommended by the electrodes manufacturer. Welding electrodes shall then be stored in ovens at a minimum temperature of 80 °C. When used for production they shall be placed in heated quivers capable of maintaining a minimum temperature of 75 °C.

Project n° - Unit

XXXXX


SP

5103

001

Rev.

Page

1

14 / 34


Above drying conditions do not apply to electrodes supplied in vacuum conditioning boxes unless unproperly stored and handled after opening. When using vacuum packed electrodes, each box shall be ink stamped with date and hour at opening. Electrodes shall be used within 4 hours after box opening unless otherwise recommended by the electrodes manufacturer. Submerged arc flux shall be clearly identified in moisture-proof containers and shall be stored in a dry location at a temperature recommended by manufacturer. Submerged arc, gas metal arc and flux-cored wire shall be clearly identified and shall be stored in a dry location at a temperature recommended by manufacturer. The identification shall state manufacturer, grade and batch number. Unidentifiable wire shall not be used. 6.4 Shielding Gases Shielding gases and gas mixtures shall be in accordance with AWS A5.32 / EN 439 unless otherwise specified in project specification. 7. QUALIFICATION OF WELDERS & WELDING OPERATORS VENDOR shall use only properly trained and qualified welders and welding operators. The ability of welder and operators shall be determined by qualification in accordance with AWS D.1.1. VENDOR shall maintain records of the results of all welder qualification tests and make them available to CONTRACTOR upon request. Where feasible, existing current welder qualifications which comply with the requirements of the code and this specification may be proposed by the VENDOR and in this case, it is preferable (although not mandatory) that the certificates have been endorsed by an independent 3rd party. Welders and welding operators shall be qualified for each process used. However within the range for characteristics of GMAW and FCAW process, the significant characteristics ( i.e. GMAW spray arc vs. short circuiting or FCAW inner-shielded vs. outer shielded ) shall be considered essential variable for performance qualification. 8. PRODUCTION WELDING 8.1 General All structural welding shall be performed in accordance with qualified WPS’s. WPS’s that are approved for construction shall be posted at each applicable work location and shall be readily available to each welder and welding operator. All structural welding shall be performed by qualified welders and with welding equipment that has been calibrated prior to the commencement of production welding. All welding shall be continuous whenever possible. If welding is interrupted, the weld shall be covered by lagging and allowed to cool naturally. Preheat, when specified in the approved WPS, shall be reinstated before further welding is allowed. All butt joints shall be full penetration welds with welding from both sides wherever possible. Partial penetration welds shall not be acceptable. Fillet welds shall be made with a minimum of two passes. Special attention shall be given to any items that may be adversely affected by being in close proximity to welding activities e.g. valves, ROV connection points and instrumentation panels. The proposed methodology for installation, fit-up and welding of such items shall be subject to review by CONTRACTOR All welds shall exhibit good workmanship and shall be free of cracks, overlap, excessive undercut and other injurious defects. All production welding shall be executed as per the applicable qualified welding procedures. Prior to commencement of work VENDOR shall develop a weld sequence procedure for control of fabrication tolerances within the acceptable limits. VENDOR shall ensure through adequate supervision that the suggested sequence is followed throughout the fabrication.

Project n° - Unit

XXXXX


SP

5103

001

Rev.

Page

1

15 / 34


T joints: fillet welds shall be always continuous in order to avoid crevices. Except for fillet welds used to reinforce groove welds, the minimum fillet weld size (leg length) shall be equal to the thinner member thickness if not specified on the drawings. The maximum inter-pass temperature during welding shall not exceed 250 deg. C. Weld dressing shall be performed only by grinding without reduction of the material thickness. 8.2 Preparation & Fit-Up The weld joint and adjacent base metal shall be free of moisture, grease, loose mill scale, rust and paint prior to and during welding. Machining, oxygen cutting, air carbon arc gouging, chipping or grinding can be used for joint preparation, back gouging or removal of unacceptable work or metal, except that oxygen gouging shall not be used on Q&T steels. Surfaces showing carbon deposits or slag due to arc-air gouging, oxy-fuel cutting or heating shall be dressed by sandblasting, grinding or brushing as required to remove carbon residue. All members shall be well fitted and firmly tacked into place before welding. Tack welding shall be performed according to a qualified and approved welding procedure and shall only be performed by qualified tack welders or qualified welders. All other welding, including welding of temporary attachments, such as scaffolding supports and tie downs, shall be performed by qualified welders. All tack welds which will form part of the permanent weld shall be cleaned, ground down to a feather edge at both ends. Permanent backup bars shall not be used except as specifically approved by CONTRACTOR. Any deviation from welding procedure specifications (e.g. fit-up, weld preparations, inadequate preheat, etc) shall be rectified prior to welding. Where the fit-up of a groove weld joint results in root openings that exceed those specified in the WPS, the fit-up shall be corrected to bring the opening to within the dimensions allowed by the WPS prior to the commencement of welding. Replacement of material or application of remedial procedures shall be approved by CONTRACTOR on a case-by-case basis. Edges prepared for welding shall have smooth and uniform surface. In case gas cutting kerfs are left, they will be ground smooth. 8.3 Welding sequence and correction of distortion The sequence of assembling, joining and welding the various parts of the structures shall be planned in order to minimise distortion, shrinkage and accumulations of residual joint stresses in each part of the structure. VENDOR shall provide and exert all necessary supervision to ensure that the planned welding sequences are observed. Heat straightening shall only be used with the prior approval of CONTRACTOR/COMPANY. VENDOR shall submit for review and approval a procedure for correction of distortion if the use of such a procedure is envisaged during fabrication. No correction of distortion will be undertaken before the procedure is approved. Weld in special area requiring special weld dressing and/or fatigue grinding are specified on the Contractor drawings. 8.4 Weather & Conditions for Welding All welding operations and any uncompleted weld joints shall be adequately protected from adverse weather conditions, which may impair the quality of the completed weld. Such conditions include, but are not limited to airborne moisture, blowing sands or high winds. 8.5 Arc Strikes Arcs shall only be struck on fusion faces. Where stray arcs have accidentally occurred on the parent material surface they shall be repaired by grinding followed by 100% visual examination and magnetic

Project n° - Unit

XXXXX


SP

5103

001

Rev.

Page

1

16 / 34


particle inspection to ensure freedom from surface cracking. Repairs of stray arc strikes by welding are not permitted. 8.6 Tack Welding Tack welding shall be performed by qualified tack welders in accordance with the approved welding procedures (See AWS D1.1 Section 5.8.12). 8.7 Preheat / PWHT Preheating shall be performed when specified in the WPS or when ambient temperatures are less than 10°C. When the weld joint area is wet it shall be dried by applying preheat at a minimum temperature of 40°C. Preheating shall be carried out by electrical resistance or induction equipment or with gas burners specifically made and shaped for this type of operation. Torches for flame cutting shall not be used for preheating purposes. Monitoring of preheat temperature may be performed by thermal pencil, contact pyrometer or infrared pyrometer. In joints involving combination of base metals, preheat shall be based on the component part with the highest minimum preheat requirements. The points of temperature measurement shall be in accordance with AWS D.1.1 except that for all thickness ranges the distance for measurement shall be at least 75 mm from the weld centre line. The heat treatment shall take into account the initial state of the base material , i.e. Quenched, tempered, solution annealed , etc) in order to avoid any deterioration of mechanical properties. PWHT may be performed by electrical heating method with thermocouple monitoring or in furnace as per WPS requirements. 8.8 Weld Profiles In general, as welded profiles shall be in accordance with AWS D.1.1 with the following additional requirements: • Undercut in butt welds shall be limited to 0.5mm maximum. Linear imperfections shall not be allowed. • Maximum reinforcement on butt welds shall be 3 mm. 9. WELD INSPECTION 9.1 General requirements VENDOR shall prepare a plan for all NDT consisting of, but not limited to, the following: -A formal system that is capable of tracking and identifying welder quality and welder defect rates. -NDT procedures. -Qualifications of NDT personnel. -NDT shop drawings indicating the location, type and extent of NDT VENDOR shall furnish the services of a qualified, experienced NDT company to provide testing and written, signed reports of all findings. In each case, the designation of welds to the appropriate inspection category shall be identified on drawings or tabulated. In addition, reference should be made to any guidance on weld categorisation that may be included in CONTRACTOR supplied drawings. Where elements of two different structural categories shall be welded together, the lowest inspection category applicable to the joint shall be applied. Non-destructive testing shall be performed after a period of 24 hours has elapsed since the completion of welding but prior to subsequent shot blasting, painting or coating treatments.

Project n° - Unit

XXXXX


SP

5103

001

Rev.

Page

1

17 / 34


9.2 Extent of Inspection Non destructive examination extent in addition to AWS D1.1 requirements: Structural steel weld type Categories CJP longitudinal and butt welds CJP girth welds CJP-T joint Fillet welds and PJP welds

VT

MPI / DPI

UT

All 100%

Cat I 100%

Cat II,III 50%

Cat IV,V 20%

Cat I 100%

Cat II,III 50%

Cat IV,V 20%

100% 100% 100%

100% 100% 100%

50% 50% 50%

20% 20% 20%

100% 100% -

50% 50% -

20% 20% 20%

Legend: RT = Radiographic examination UT = Ultrasonic examination MPI = Magnetic particle examination DPI = Dye penetrant examination Notes: a) Manual UT may be substituted by RT when agreed by CONTRACTOR. b) % examination is defined as examination of the length of each kind of weld. c) Repair welds shall be examined 100% by visual, 100% by MPI, and 100% by the NDT technique specified for the original weld. Ultrasonic inspection shall be used in areas inaccessible or otherwise unsuitable for radiographic inspection. d) In addition, all ground areas shall be subject to visual examination and wall thickness checks following grinding, and dye penetrant (DPI) or magnetic particle (MPI) inspection where access permits. No surface breaking defects shall be revealed. e) Should visual inspection show that the thickness, surface contour or apparent continuity of any weld is not in accordance with this specification, or should radiographic, ultrasonic, or magnetic particle inspection reveal cracks or defects of an unacceptable nature, the defective weld shall be repaired and re-examined. f) Highest inspection category shall be used when structural category is not specified. g) Additional examination shall be performed when rejected flaws (defects) are found in welds designated for partial inspection where the original inspection coverage was less than 100%. In such cases, the requirements for additional testing shall be as follows: -Additional NDT shall be conducted with the same methods as the original inspection that detected the rejected flaw (UT, RT and/or MPI). -The additional NDT shall be conducted on the same weld, either side of the rejected flaw and in a location that was not previously inspected by UT, RT or MPI/DPI. -The additional NDT shall extend a length at least equal to 20 times the plate thickness. If a rejected flaw is found, then the additional examination requirements of this section including Note (c) above shall again be implemented until no rejected flaw is detected. The reasons for high levels of rejection shall be determined and reported to CONTRACTOR. Remedial action shall be subject to agreement by CONTRACTOR. h) Extent of inspection could be reduced based on reported defects history by SUPPLIER Concession Request. 9.3 NDT after Load Testing of Lift Points After load testing of lifting points (lifting eyes, lugs, trunions etc), the following examination shall be carried out: -UT examination on loaded welds. -MPI or DPI as appropriate.

Project n° - Unit

XXXXX


SP

5103

001

Rev.

Page

1

18 / 34


9.4 Acceptance Criteria Acceptance criteria shall be in accordance with AWS D1.1 Chapter6 or other recognised standard approved by CONTRACTOR. 9.5 Methods of Inspection 9.5.1 Visual Inspection (VI) All completed welds shall be subjected to 100% visual inspection with acceptance criteria as per AWD 1.1 Table 6.1.. In addition, visual inspection of welded joints by CONTRATOR shall be required at the following stages: 1. Inspection at fit-up. 2. Inspection following deposit of root pass or back gouging. Other techniques shall be required to explore the extent of visually observed flaws and when visual inspection cannot reveal the required information adequately. MPI shall always supplement visual inspection after back gouging. 3. Visual inspection shall be performed at the completion of all welds for weld size, profile and weld soundness, as specified below. Reports shall include reference to the method of inspection, extent of weld coverage and acceptance criteria. 9.5.2 Magnetic Particle Inspection (MPI) Magnetic particle inspection (MPI) shall be performed in accordance with a written procedure conforming to ASME Section V, Article 7 or other recognised standard. COMPANY shall approve the procedure prior to the start of fabrication. Magnetic particle inspection shall be by the AC yoke technique, wet method, unless otherwise agreed with COMPANY. The prod method shall not be used. The selection of contrast paints and particles shall be stated in the procedure. A report shall be produced for each magnetic inspection carried out, which shall provide the following information as a minimum: • Joint identification (weld number, unique pipe numbers). • Type of equipment and consumables used. • Status of welds (Original or Repair). • Date and time of test. • Name, signature and qualification of operator. • Conclusions (Accept or Reject). Reports shall include reference to the method of inspection, extent of weld coverage and acceptance criteria (same as visual inspection).. 9.5.3 Dye Penetrant Inspection (DPI) DPI is only to be used with the prior acceptance of CONTRACTOR when MPI is not practicable. DPI shall be performed in accordance with a written procedure conforming to ASME Section V or other recognised standard. COMPANY shall approve the procedure prior to the start of fabrication. In addition to weld and adjacent base metal examination, DPI shall be performed on repair weld bevels. A report shall be produced for each inspection carried out, which shall provide the following information as a minimum: • Joint identification (weld number, unique pipe numbers). • Type of consumables used. • Status of welds (Original or Repair). • Date and time of test. • Name, signature and qualification of operator. • Conclusions (Accept or Reject). 9.5.4 Radiographic Examination (RT) RT shall be performed in accordance with a written procedure conforming to ASME Section V, Article 2, or AWS D1.1 or other recognised standard and approved by CONTRACTOR prior to the start of fabrication.

Project n° - Unit

XXXXX


SP

5103

001

Rev.

Page

1

19 / 34


The source type (X-ray or Gamma) shall be subject to approval by CONTRACTOR. Fine-grained film and lead intensification screens are required. A report shall be produced for each inspection carried out, which shall provide the following information as a minimum: • Joint identification (weld number, unique pipe numbers). • Type of consumables used. • Status of welds (Original or Repair). • Date and time of test. • Name, signature and qualification of operator. • Conclusions (Accept or Reject) Reports shall include reference to the method of inspection, extent of weld coverage and acceptance criteria. Film Radiography Fluorometallic intensifying screens may be used (in lieu of lead screen) to produce radiographs for pipe joint welds. Screens shall be clean and free of cracks. Each film shall register the follow information: • Weld identification including unique pipe numbers. • Radiograph location with respect to weld datum. • Radiograph number of NDT report to which the radiograph relates. • Project identification. • Radiograph status (Original weld or Repair weld). • IQI placement (Film or Source side). • Welder(s) identification. Image Quality Indicators Image Quality Indicators (IQI) shall be of the wire type according ASME V-Article 2 T277.1 and shall be positioned across the weld at the edge of the diagnostic field length. A minimum of two IQI’s shall be used per film. The IQI shall be selected in order to achieve a sensitivity of radiography of 1.8% or better. Film-side penetrameters shall not be used except for double wall exposure of pipe and in this case shall be qualified by use of source side IQI’s. The penetrameter shall be of a similar material than the material to be tested. Image Processing All unexposed film shall be stored in a clean, dry place where the conditions will not detrimentally affect the emulsion. The image processing area and all accessories shall be kept clean at all times. All exposed radiographic film shall be processed suitable for storage for a minimum of 10 years under controlled conditions. 9.5.5 Ultrasonic Examination (UT) UT shall be performed in accordance with a written procedure conforming to AWS D1.1 chapter 6 or other recognised standard and approved by CONTRACTOR prior to the start of fabrication. Each ultrasonic examination performed shall be reported on an approved format, which shall contain the following minimum information: • Weld identification including unique pipe numbers. • Ultrasonic inspection procedure reference • Status of welds (Original or Repair). • UT Calibration block type. • Probe angles and frequencies. • Sensitivity level. • Equipment makes and models. • Surface correction factor. • Conclusion (Accept or Reject). • Sketch of locations for unacceptable defects. • Operator’s name, signature and qualification. • Date and time of test. • Welder(s) identification. 9.6 NDT Personnel qualification All NDE shall be performed by personnel certified in accordance with ASNT Recommended Practice SNT-TC-1A or equivalent such as the European norm EN 473 (according to construction code).

Project n° - Unit

XXXXX


SP

5103

001

Rev.

Page

1

20 / 34


Schemes such as PCN (Personnel Certification in Non-Destructive Testing), CSWIP (Certification Scheme for Welding Inspection Personnel) or ACCP (ASNT Central Certification Program) are considered acceptable for all NDE techniques. Qualification and Certification by the employer is not permitted unless specifically approved by CONTRACTOR / COMPANY. Interpretation of results shall be performed by personnel certified level II as a minimum. 10. WELD REPAIRS Weld repairs shall be carried out in accordance with qualified repair welding procedure specifications approved by CONTRACTOR. The removal of weld metal or portions of base metal to carry out a repair may be accomplished by machining, grinding or arc-air gouging. Oxy-fuel gouging shall not be permitted. The defective area shall be completely removed and the resulting cavity prepared to the dimensions specified on the repair procedure. The cavity shall be ground as required to remove arc-air gouging residue. In the case of planar defects, the repair cavity shall be inspected using magnetic particle testing to verify complete removal of the defect. If a second attempt at repair is required at the same location this shall be subject to CONTRACTOR approval.

Project n° - Unit

XXXXX


SP

5103


APPENDIX B: SUBSEA STRUCTURE WELDS SPECIFICATION, EN/ISO Standards

001

Rev.

Page

1

21 / 34

Project n° - Unit

XXXXX


SP

5103

001

Rev.

Page

01

22 / 34


TABLE OF CONTENTS

1. CODES AND STANDARDS

Page 23


Page 23

3. WELDING PROCEDURE QUALIFICATIONS

Page 24

4. ESSENTIAL VARIABLES

Page 26

5. WELDING PROCESSES

Page 26

6. WELDING CONSUMABLES

Page 27

7. QUALIFICATION OF WELDERS & WELDING OPERATORS

Page 28

8. PRODUCTION WELDING

Page 28

9. WELD INSPECTION

Page 30

10. WELD REPAIRS

Page 34

Project n° - Unit

XXXXX


SP

5103

001

Rev.

Page

01

23 / 34


1. Codes and Standards European Standards EN 473 EN 719 EN 15614-1 EN 287 - 1 EN 10204 EN 29000 EN 29001 Other documents: ASNT SNT TC 1A ISO 9001

Non Destructive testing – Qualification and Certification of NDT personnel – General Principles Welding Co-ordination: Tasks and Responsibilities Specification and qualification of welding procedures for metallic materials, Welding procedure test –Part1 Approval testing of welders for fusion welding EN 10204 Certificate of Metallic Products Quality systems – Guide to selection and use Quality systems – Model for quality assurance in design development, production, installation and servicing. Recommended practice – Guideline to Personnel Qualification and Certification in NDT Quality management and systems – Requirements


2.1 General All structural welding shall be in accordance with ISO 15614-1, amended and supplemented by this specification. CONTRACTOR shall develop and qualify welding procedure specifications, including repair welding and tack welding procedure specifications, for all structural welding. This shall be done prior to commencement of the work according to the ISO 15614-1 standard, and the requirements of this specification. 2.2 Welding Book The VENDOR shall submit a detailed Welding Data Book to the CONTRACTOR at the time of WPS/PQR submittal. Fabrication shall not start until the Welding Data Book is returned with agreement to proceed. The Welding Data Book shall include the following documents: ♦

A cover sheet with title block dedicated to the Project.

♦

A Weld map / Weld Key Form.

♦

Welding Procedure Specifications (WPS).

♦

Procedure Qualification Records (PQR).

♦

A NDE map with extensions of each NDE examination

2.2.1 Weld map The Weld map / Weld Key form shall contain as a minimum the following information: ♦

Sketch of the structural part.

♦

Material type(s) and grade(s) for each type of structural component.

♦

WPS to be used for each type of joint of same design and similar thickness.

♦

Actual thickness where each WPS is to be used.

♦

P.W.H.T. requirements (project specification or code as applicable).

Project n° - Unit

XXXXX


SP

5103

001

Rev.

Page

01

24 / 34


2.2.2 Welding procedure specification (WPS) Welding Procedure Specifications (WPS) and their supporting Procedure Qualification Records (PQR) shall conform to the requirements of ISO 15614-1 and to the requirements of this specification Welding Procedure Specifications together with Procedure Qualification Records shall be submitted to the CONTRACTOR prior to the start of fabrication. Welding shall not proceed until these documents are returned by the CONTRACTOR with agreement to proceed. All Welding Procedure Specifications and Procedure Qualification Records for purchased items subcontracted by the VENDOR shall be reviewed by the VENDOR for content and contract compliance prior to submittal to the CONTRACTOR. Each WPS shall be identified by a unique number and shall be identified on the welding map.

3. WELDING PROCEDURE QUALIFICATIONS 3.1 General Welding procedure qualifications tests shall be carried in accordance with ISO 15614-1: -Each applicable WPS shall be qualified by tests prior to commencement of the work as directed by the ISO 15614-1 standard, and the requirements of this specification. -Qualified welding procedures from previous orders approved by an international and CONTRACTOR recognized inspection agency may be accepted without further tests provided that acceptable documentation is supplied as regard to the requirements of present specification and subject to prior approval of the CONTRACTOR/COMPANY. - T, K, Y welds. Testing shall be as per the relevant original qualification scheme, unless otherwise specified by CONTRACTOR. -Shop welding procedure qualification for site application may be acceptable provided site machine and associated equipment are identical to those used for qualification and will require CONTRACTOR / COMPANY written approval. 3.2 Mechanical testing requirements Mechanical tests for procedure qualification shall be in accordance with ISO 15614-1 and the additional requirements as specified in the following Sections. 3.2.1 Hardness Hardness survey is only applicable for structural category I,II and III and shall be performed on weld macro cross section according to the Vickers hardness test method defined in the European norm EN 1043-1, under 10 kg load or other standards approved by CONTRACTOR / COMPANY . The series of readings shall include unaffected base material, Heat affected Zone, weld deposit at 1 to 2 mm from the surface as per below sketch. In the HAZ the first indentation shall be located as close as possible of the fusion line. A minimum of three impressions shall be made in each area (weld metal, HAZ, and base metal on each side). Hardness values requirements are: - TMCP and Q/T steels: 325 HV10 max. -Normalized and forged steels: 350 HV10 max.

Project n° - Unit

XXXXX


SP

5103

001

Rev.

Page

01

25 / 34


Examples of hardness survey locations are shown on below sketches: 2mm max

2mm max

0.5 to 1mm

2mm max 2mm max

3.2.2 Charpy V-notch impact testing Charpy impact toughness testing of the weld metal and heat affected zone (HAZ) shall be performed for welding of CJP joints. Locations for CVN test specimens shall be weld metal, Fusion Line, Fusion Line + 2mm and Fusion Line + 5mm. Test to be performed as per ISO 15614-1 §7.4.5 at LAST-20°C for for structural category I and at LAST for Structural Cat II. Test is not required for structural categories III,IV and V.

Project n° - Unit

XXXXX


SP

5103

001

Rev.

Page

01

26 / 34


Acceptance criteria are as a minimum 30J average and 27J individual. Location of samples shall be in compliance with EN 15614-1 and EN 875 requirements. Full size specimens shall be used where possible in the case of sub-size specimens the reduction factors shall be as follows: Specimen Size 10 mm 7.5 mm 5.0 mm

Energy Reduction Factor None 5/6 2/3

3.2.3 Retest: Should a qualification test weld fail any of the required tests or permitted re-tests, the cause of the failure shall be established and reported to CONTRACTOR. A revised WPS shall be submitted for CONTRACTOR approval prior to re-testing. 3.2.4 NDT: Results of non-destructive testing shall be completed and confirmed to be in compliance with the specified requirements before mechanical testing is carried-out. Failure to meet the acceptance criteria for non-destructive testing shall result in failure of the qualification test.

4. ESSENTIAL VARIABLES In addition to the requirements of ISO 15614-1 the following limits for essential variables shall apply: Variables Base Material Carbon Equivalent Base Material

PWHT

Limitations Carbon equivalent of base material used in production shall not exceed the carbon equivalent of the base material of the welding qualification + 0.03%. The following limits shall apply for welding procedure when Charpy Vee Notch testing is required (a change in an essential variable beyond the specified limits requires a new qualification): - A change in the process of manufacture for the base material, outside the following groups: 1. Quenched and Tempered steels 2. TMCP or Controlled-rolled steels 3. Normalized or as-rolled steels - An increase of more than 10°C over the maximum interpass temperature attained on the procedure qualification. Welds qualified with PWHT shall be PWHT in production.

• When weld-through primers are used during fabrication, they shall be included in the weld procedure qualifications. The specific primer shall be an essential variable. Weld through primers containing Deoxaluminite are preferred, 5. WELDING PROCESSES Acceptable methods of welding are SMAW, SAW, GMAW, FCAW, and GTAW processes as per NF EN ISO 4063. Combinations of processes may be qualified and used providing the following conditions are met: • The welding process has been explicitly stated for each pass (e.g. optional passes are not permitted); • The combination of processes has been fully tested with supporting PQR documentation; • Single welding processes qualified individually cannot be combined with another welding process unless tested in that combination.

Project n° - Unit

XXXXX


SP

5103

001

Rev.

Page

01

27 / 34


• Self-shielded flux cored arc welds shall not be followed by any other process, including weld repairs, unless specifically qualified. 6. WELDING CONSUMABLES 6.1 General Low hydrogen welding consumables shall be used for all welds. Low hydrogen consumables are those capable of producing weld metal with less than 10 ml of diffusible hydrogen per 100 g of deposited metal using the mercury or gas chromatography methods when stored and baked according to the manufacturer's recommendation. The COMPANY may request additional testing of consumables during construction, at COMPANY’s expense. Welding consumables shall be selected such as: -The tensile strength of deposited weld metal is at least equal to the specified minimum mechanical properties of the materials being welded in production. -The principal elements in the deposited weld metal are similar to the nominal composition of the base metal. Solid wires for automatic welding processes shall contain the principal elements required for the deposited weld metal. Welds deposited by the submerged arc process shall not derive any principal elements from the flux. Manufacturer’s storage and baking requirements must be adhered to. Fluxes that the flux Manufacturer recommends for single pass welds shall not be used for multiple pass welds. Active fluxes are not permitted. 6.2 Welding consumable classification and certification Filler metal shall be as specified in ASME Section II Part C or equivalent AWS Specification. Welding consumables shall be purchased from Manufacturer’s operating a quality system based on ISO 9001 or EN 12074. All FCAW consumables (either for FCAW-SS or FCAW-GS) shall be low hydrogen type, as tested and certified by the consumable manufacturer and shall conform to AWS A5.20 and AWS A5.29 Alloy fluxes as defined by ASME section II, Part C SFA 5.17 or 5.23 or equivalent shall not be used. Welding consumables shall be delivered with certificates EN 10204: -type 2.2 for structural categories III, IV and V otherwise more stringent requirement from project specifications if any. -type 3.1 for chemical analysis and mechanical tests for structural categories I and II otherwise more stringent requirement from project specifications if any. 6.3 Consumable storage Welding consumables shall be stored with care, under dry conditions in their original unopened packing. After opening shipping containers of electrodes, fluxes and other welding materials, storage and handling shall be as specified in the Manufacturer's recommendations. Electrodes, filler wires or fluxes that are damaged, damp, greasy or oxidized shall not be used. All electrodes, which have been in direct contact with water, shall be definitely rejected. VENDOR’s facilities shall include a temperature and humidity controlled welding consumable and flux store, including holding and drying ovens. Low hydrogen electrodes and fluxes shall be dried at 250°C/300°C for two hours prior to use, unless otherwise recommended by the electrodes manufacturer. Welding electrodes shall then be stored in ovens at a minimum temperature of 80 °C. When used for production they shall be placed in heated quivers capable of maintaining a minimum temperature of 75 °C. Above drying conditions do not apply to electrodes supplied in vacuum conditioning boxes unless unproperly stored and handled after opening.

Project n° - Unit

XXXXX


SP

5103

001

Rev.

Page

01

28 / 34


When using vacuum packed electrodes, each box shall be ink stamped with date and hour at opening. Electrodes shall be used within 4 hours after box opening unless otherwise recommended by the electrodes manufacturer. Submerged arc flux shall be clearly identified in moisture-proof containers and shall be stored in a dry location at a temperature recommended by manufacturer. Submerged arc, gas metal arc and flux-cored wire shall be clearly identified and shall be stored in a dry location at a temperature recommended by manufacturer. The identification shall state manufacturer, grade and batch number. Unidentifiable wire shall not be used. 6.4 Shielding Gases Shielding gases and gas mixtures shall be in accordance with AWS A5.32 / EN 439 unless otherwise specified in project specification. 7. QUALIFICATION OF WELDERS & WELDING OPERATORS VENDOR shall use only properly trained and qualified welders and welding operators. The ability of welder and operators shall be determined by qualification in accordance with EN 287-1 or EN 1418. VENDOR shall maintain records of the results of all welder qualification tests and make them available to CONTRACTOR upon request. Where feasible, existing current welder qualifications which comply with the requirements of the code and this specification may be proposed by the VENDOR and in this case, it is preferable (although not mandatory) that the certificates have been endorsed by an independent 3rd party. Welders and welding operators shall be qualified for each process used. However within the range for characteristics of GMAW and FCAW process, the significant characteristics ( i.e. GMAW spray arc vs. short circuiting or FCAW inner-shielded vs. outer shielded ) shall be considered essential variable for performance qualification. 8. PRODUCTION WELDING 8.1 General All structural welding shall be performed in accordance with qualified WPS’s. WPS’s that are approved for construction shall be posted at each applicable work location and shall be readily available to each welder and welding operator. All structural welding shall be performed by qualified welders and with welding equipment that has been calibrated prior to the commencement of production welding. All welding shall be continuous whenever possible. If welding is interrupted, the weld shall be covered by lagging and allowed to cool naturally. Preheat, when specified in the approved WPS, shall be reinstated before further welding is allowed. All butt joints shall be full penetration welds with welding from both sides wherever possible. Partial penetration welds shall not be acceptable. Fillet welds shall be made with a minimum of two passes. Special attention shall be given to any items that may be adversely affected by being in close proximity to welding activities e.g. valves, ROV connection points and instrumentation panels. The proposed methodology for installation, fit-up and welding of such items shall be subject to review by CONTRACTOR All welds shall exhibit good workmanship and shall be free of cracks, overlap, excessive undercut and other injurious defects. All production welding shall be executed as per the applicable qualified welding procedures. Prior to commencement of work VENDOR shall develop a weld sequence procedure for control of fabrication tolerances within the acceptable limits. VENDOR shall ensure through adequate supervision that the suggested sequence is followed throughout the fabrication.

Project n° - Unit

XXXXX


SP

5103

001

Rev.

Page

01

29 / 34


T joints: fillet welds shall be always continuous in order to avoid crevices. Except for fillet welds used to reinforce groove welds, the minimum fillet weld size (leg length) shall be equal to the thinner member thickness if not specified on the drawings. The maximum inter-pass temperature during welding shall not exceed 250 deg. C. Weld dressing shall be performed only by grinding without reduction of the material thickness. 8.2 Preparation & Fit-Up The weld joint and adjacent base metal shall be free of moisture, grease, loose mill scale, rust and paint prior to and during welding. Machining, oxygen cutting, air carbon arc gouging, chipping or grinding can be used for joint preparation, back gouging or removal of unacceptable work or metal, except that oxygen gouging shall not be used on Q&T steels. Surfaces showing carbon deposits or slag due to arc-air gouging, oxy-fuel cutting or heating shall be dressed by sandblasting, grinding or brushing as required to remove carbon residue. All members shall be well fitted and firmly tacked into place before welding. Tack welding shall be performed according to a qualified and approved welding procedure and shall only be performed by qualified tack welders or qualified welders. All other welding, including welding of temporary attachments, such as scaffolding supports and tie downs, shall be performed by qualified welders. All tack welds which will form part of the permanent weld shall be cleaned, ground down to a feather edge at both ends. Permanent backup bars shall not be used except as specifically approved by CONTRACTOR. Any deviation from welding procedure specifications (e.g. fit-up, weld preparations, inadequate preheat, etc) shall be rectified prior to welding. Where the fit-up of a groove weld joint results in root openings that exceed those specified in the WPS, the fit-up shall be corrected to bring the opening to within the dimensions allowed by the WPS prior to the commencement of welding. Replacement of material or application of remedial procedures shall be approved by CONTRACTOR on a case-by-case basis. Edges prepared for welding shall have smooth and uniform surface. In case gas cutting kerfs are left, they will be ground smooth. 8.3 Welding sequence and correction of distortion The sequence of assembling, joining and welding the various parts of the structures shall be planned in order to minimise distortion, shrinkage and accumulations of residual joint stresses in each part of the structure. VENDOR shall provide and exert all necessary supervision to ensure that the planned welding sequences are observed. Heat straightening shall only be used with the prior approval of CONTRACTOR/COMPANY. VENDOR shall submit for review and approval a procedure for correction of distortion if the use of such a procedure is envisaged during fabrication. No correction of distortion will be undertaken before the procedure is approved. 8.4 Weather & Conditions for Welding The welding operation and any uncompleted weld joints shall be adequately protected from adverse weather conditions, which may impair the quality of the completed weld. Such conditions include, but are not limited to airborne moisture, blowing sands or high winds.

Project n° - Unit

XXXXX


SP

5103

001

Rev.

Page

01

30 / 34


8.5 Arc Strikes Arcs shall only be struck on fusion faces. Where stray arcs have accidentally occurred on the parent material surface they shall be repaired by grinding followed by magnetic particle inspection to ensure freedom from surface cracking. Repairs of stray arc strikes by welding are not permitted. 8.6 Tack Welding Tack welding shall be performed by qualified tack welders in accordance with the approved welding procedures. 8.7 Preheat / PWHT Preheating shall be performed when specified in the WPS or when ambient temperatures are less than 10°C. When the weld joint area is wet it shall be dried by applying preheat at a minimum temperature of 40°C. Preheating shall be carried out by electrical resistance or induction equipment or with gas burners specifically made and shaped for this type of operation. Torches for flame cutting shall not be used for preheating purposes. Monitoring of preheat temperature may be performed by thermal pencil, contact pyrometer or infrared pyrometer. In joints involving combination of base metals, preheat shall be based on the component part with the highest minimum preheat requirements. Also for guidance on preheat and interpass temperatures for low temperature steels reference shall be made to EN 1011-2. The points of temperature measurement shall be in accordance with ISO 13916 except that for all thickness ranges the distance for measurement shall be at least 75 mm from the weld centre line. The heat treatment shall take into account the initial state of the base material , i.e. Quenched, tempered, solution annealed , etc) in order to avoid any deterioration of mechanical properties. PWHT shall be performed by electrical heating method with thermocouple monitoring or in furnace as per WPS requirements. 8.8 Weld Profiles In general, as welded profiles shall be in accordance with EN ISO 15613 with the following additional requirements: • Undercut in butt welds shall be limited to 0.5mm maximum. Linear imperfections shall not be allowed. • Maximum reinforcement on butt welds shall be 3 mm. 9. WELD INSPECTION 9.1 General requirements VENDOR shall prepare a plan for all NDT consisting of, but not limited to, the following: -A formal system that is capable of tracking and identifying welder quality and welder defect rates. -NDT procedures. -Qualifications of NDT personnel. -NDT shop drawings indicating the location, type and extent of NDT VENDOR shall furnish the services of a qualified, experienced NDT company to provide testing and written, signed reports of all findings. In each case, the designation of welds to the appropriate inspection category shall be identified on drawings or tabulated. In addition, reference should be made to any guidance on weld categorisation that may be included in CONTRACTOR supplied drawings. Where elements of two different structural categories shall be welded together, the lowest inspection category applicable to the joint shall be applied. Non-destructive testing shall be performed after a period of 24 hours has elapsed since the completion of welding but prior to subsequent shot blasting, painting or coating treatments...

Project n° - Unit

XXXXX


SP

5103

001

Rev.

Page

01

31 / 34


9.2 Extent of Inspection The extent and level of NDT shall be as per the following table. Structural steel weld type Categories CJP longitudinal and butt welds CJP girth welds CJP-T joint Fillet welds and PJP welds

VT

MPI / DPI

UT

All 100%

Cat I 100%

Cat II,III 50%

Cat IV,V 20%

Cat I 100%

Cat II,III 50%

Cat IV,V 20%

100% 100% 100%

100% 100% 100%

50% 50% 50%

20% 20% 20%

100% 100% -

50% 50% -

20% 20% 20%

Legend: RT = Radiographic examination UT = Ultrasonic examination MPI = Magnetic particle examination DPI = Dye penetrant examination Notes: a) Manual UT may be substituted by RT when agreed by CONTRACTOR. b) % examination is defined as examination of the length of each kind of weld. c) Repair welds shall be examined 100% by visual, 100% by MPI, and 100% by the NDT technique specified for the original weld. Ultrasonic inspection shall be used in areas inaccessible or otherwise unsuitable for radiographic inspection. d) In addition, all ground areas shall be subject to visual examination and wall thickness checks following grinding, and dye penetrant (DPI) or magnetic particle (MPI) inspection where access permits. No surface breaking defects shall be revealed. e) Should visual inspection show that the thickness, surface contour or apparent continuity of any weld is not in accordance with this specification, or should radiographic, ultrasonic, or magnetic particle inspection reveal cracks or defects of an unacceptable nature, the defective weld shall be repaired and re-examined. f) Highest inspection category shall be used when structural joint category is not specified. g) Additional examination shall be performed when rejected flaws (defects) are found in welds designated for partial inspection where the original inspection coverage was less than 100%. In such cases, the requirements for additional testing shall be as follows: -Additional NDT shall be conducted with the same methods as the original inspection that detected the rejected flaw (UT, RT and/or MPI). -The additional NDT shall be conducted on the same weld, either side of the rejected flaw and in a location that was not previously inspected by UT, RT or MPI/DPI. -The additional NDT shall extend a length at least equal to 20 times the plate thickness. If a rejected flaw is found, then the additional examination requirements of this section including Note (c) above shall again be implemented until no rejected flaw is detected. The reasons for high levels of rejection shall be determined and reported to CONTRACTOR. Remedial action shall be subject to agreement by CONTRACTOR. h) Extent of inspection could be reduced based on reported defects history by SUPPLIER Concession Request.

Project n° - Unit

XXXXX


SP

5103

001

Rev.

Page

01

32 / 34


9.3 NDT after Load Testing of Lift Points After load testing of lifting points (lifting eyes, lugs, trunions etc), the following examination shall be carried out: -UT examination on loaded welds. -MPI or DPI as appropriate. 9.4 Acceptance Criteria Acceptance criteria shall be in accordance with NORSOK M101 or other recognised standard approved by CONTRACTOR. 9.5 Methods of Inspection 9.5.1 Visual Inspection (VI) All completed welds shall be subjected to 100% visual inspection as per EN 970. In addition, visual inspection of welded joints by CONTRATOR shall be required at the following stages: 1. Inspection at fit-up. 2. Inspection following deposit of root pass or back gouging. Other techniques shall be required to explore the extent of visually observed flaws and when visual inspection cannot reveal the required information adequately. MPI shall always supplement visual inspection after back gouging. 3. Visual inspection shall be performed at the completion of all welds for weld size, profile and weld soundness, as specified below. Reports shall include reference to the method of inspection, extent of weld coverage and acceptance criteria. 9.5.2 Magnetic Particle Inspection (MPI) Magnetic particle inspection (MPI) shall be performed in accordance with a written procedure conforming to EN 1290 or other recognised standard. COMPANY shall approve the procedure prior to the start of fabrication. Magnetic particle inspection shall be by the AC yoke technique, wet method, unless otherwise agreed with COMPANY. The prod method shall not be used. The selection of contrast paints and particles shall be stated in the procedure. A report shall be produced for each magnetic inspection carried out, which shall provide the following information as a minimum: • Joint identification (weld number, unique pipe numbers). • Type of equipment and consumables used. • Status of welds (Original or Repair). • Date and time of test. • Name, signature and qualification of operator. • Conclusions (Accept or Reject). Reports shall include reference to the method of inspection, extent of weld coverage. Acceptance criteria shall be in accordance with the requirements of NORSOK M101 or/and ISO 23278 with criteria level 1 for inspection category I and criteria level 2 for inspection category II & III. 9.5.3 Dye Penetrant Inspection (DPI) DPI is only to be used with the prior acceptance of CONTRACTOR when MPI is not practicable. DPI shall be performed in accordance with a written procedure conforming to ISO 23277 or other recognised standard. COMPANY shall approve the procedure prior to the start of fabrication. In addition to weld and adjacent base metal examination, DPI shall be performed on repair weld bevels. A report shall be produced for each inspection carried out, which shall provide the following information as a minimum: • Joint identification (weld number, unique pipe numbers). • Type of consumables used. • Status of welds (Original or Repair). • Date and time of test. • Name, signature and qualification of operator.

Project n° - Unit

XXXXX


SP

5103

001

Rev.

Page

01

33 / 34


• Conclusions (Accept or Reject). Reports shall include reference to the method of inspection, extent of weld coverage and acceptance criteria (NORSOK M101). 9.5.4 Radiographic Examination (RT) RT shall be performed in accordance with a written procedure conforming to EN 1435 or other recognised standard and approved by CONTRACTOR prior to the start of fabrication. The source type (X-ray or Gamma) shall be subject to approval by CONTRACTOR. Fine-grained film and lead intensification screens are required. A report shall be produced for each inspection carried out, which shall provide the following information as a minimum: • Joint identification (weld number, unique pipe numbers). • Type of consumables used. • Status of welds (Original or Repair). • Date and time of test. • Name, signature and qualification of operator. • Conclusions (Accept or Reject) Reports shall include reference to the method of inspection, extent of weld coverage and acceptance criteria (NORSOK M101). Film Radiography Fluorometallic intensifying screens may be used (in lieu of lead screen) to produce radiographs for pipe joint welds. Screens shall be clean and free of cracks. Each film shall register the follow information: • Weld identification including unique pipe numbers. • Radiograph location with respect to weld datum. • Radiograph number of NDT report to which the radiograph relates. • Project identification. • Radiograph status (Original weld or Repair weld). • IQI placement (Film or Source side). • Welder(s) identification. Image Quality Indicators Image Quality Indicators (IQI) shall be of the wire type according EN 462-1 and shall be positioned across the weld at the edge of the diagnostic field length. A minimum of two IQI’s shall be used per film. The IQI shall be selected in order to achieve a sensitivity of radiography of 1.8% or better. Film-side penetrameters shall not be used except for double wall exposure of pipe and in this case shall be qualified by use of source side IQI’s. The penetrameter shall be of a similar material than the material to be tested. Image Processing All unexposed film shall be stored in a clean, dry place where the conditions will not detrimentally affect the emulsion. The image processing area and all accessories shall be kept clean at all times. All exposed radiographic film shall be processed suitable for storage for a minimum of 10 years under controlled conditions. 9.5.5 Ultrasonic Examination (UT) UT shall be performed in accordance with a written procedure conforming to EN 533 or EN 1714 or other recognised standard and approved by CONTRACTOR prior to the start of fabrication. Each ultrasonic examination performed shall be reported on an approved format, which shall contain the following minimum information: • Weld identification including unique pipe numbers. • Ultrasonic inspection procedure reference • Status of welds (Original or Repair). • UT Calibration block type. • Probe angles and frequencies. • Sensitivity level. • Equipment makes and models. • Surface correction factor.

Project n° - Unit

XXXXX


SP

5103

001

Rev.

Page

01

34 / 34


• Conclusion (Accept or Reject). • Sketch of locations for unacceptable defects. • Operator’s name, signature and qualification. • Date and time of test. • Welder(s) identification. Acceptance criteria shall be in accordance with EN 1714 and 1712 according to the category of welds defined by the supplier. 9.6 NDT personnel qualification All NDE shall be performed by personnel certified in accordance with ASNT Recommended Practice SNT-TC-1A or equivalent such as the European norm EN 473 (according to construction code). Schemes such as PCN (Personnel Certification in Non-Destructive Testing), CSWIP (Certification Scheme for Welding Inspection Personnel) or ACCP (ASNT Central Certification Program) are considered acceptable for all NDE techniques. Qualification and Certification by the employer is not permitted unless specifically approved by CONTRACTOR / COMPANY. Interpretation of results shall be performed by personnel certified level II as a minimum. 10. WELD REPAIRS Weld repairs shall be carried out in accordance with qualified repair welding procedure specifications approved by CONTRACTOR. The removal of weld metal or portions of base metal to carry out a repair may be accomplished by machining, grinding or arc-air gouging. Oxy-fuel gouging shall not be permitted. The defective area shall be completely removed and the resulting cavity prepared to the dimensions specified on the repair procedure. The cavity shall be ground as required to remove arc-air gouging residue. In the case of planar defects, the repair cavity shall be inspected using magnetic particle testing to verify complete removal of the defect. If a second attempt at repair is required at the same location this shall be subject to CONTRACTOR approval.



APPENDIX C PAINTING SPECIFICATIONS


5890-000-SP-5103-001_A.docx



APPENDIX D SURF STRUCTURES FASTENERS MATERIAL DATA SHEETS CARBON STEEL


5890-000-SP-5103-001_A.docx

Project n° - Unit

XXXX


SP

5107

0001

Rev.

Page

0

1 / 18

JOB SPECIFICATION SURF STRUCTURES FASTENERS MATERIAL DATA SHEETS CARBON STEEL

Pages modified under this revision: N/A

0

31/03/11

ISSUE FOR EXECUTION

O.MELIANI

S.ROUTEAU

S.ROUTEAU

Rev

Date DD/MM/YY

STATUS






Project n° - Unit

XXXX


SP

5107

0001

Rev.

Page

0

2 / 18

SUMMARY 1.

SCOPE

3

2.

REFERENCE

4

3.

MDS MATRIX

5

4.


6

4.1

MDS F10

6

4.2

MDS F11

7

4.3

MDS F12

8

4.4

MDS F20

9

4.5

MDS F21

10

4.6

MDS F40

11

4.7

MDS F41

12

4.8

MDS F42

13

4.9

MDS F43

14

5.

DESIGNATION

15

5.1

EXAMPLE FOR FASTENER DESIGNATIONS

15

5.2

CATEGORIE I

15

5.3

CATEGORIE II &III

15

5.4

CATEGORIE IV

15

Project n° - Unit

XXXX

1.


SP

5107

Rev.

Page

0

3 / 18

0001

SCOPE This specification gives the minimum requirements for bolting material and corrosion protection for structural applications. The different usage categories of fasteners are defined in Table 1:

Fastener Usage Category

Storage area Atmospheric zone Atmospheric zone Atmospheric zone

I II (1) III (2) IV

Classification of environments (5)

Atmospheric zone

(3)

Cathodic Protection

Service area

Design life (year) Storage

Service

Service condition T (°C)

Submerged Zone

Yes

1

25

-20 to 200

Submerged Zone

No

1

25

-20 to 200

Atmospheric zone

No

1

25

-20 to 200

Atmospheric zone, and/or Submerged zone

No (4)

1

2

-20 to 200

Table 1 – Definition of fasteners usage categories • • • • •

(1)

Shall be used only when required. Cathodic Protection shall be implemented as a base case except for some specific applications. In that case, fasteners must be checked with Corrosion allowance. (2) Fasteners category III shall be protected either by painting after installation or by plastic caps filled with inhibited grease. (3) Fasteners category IV are for temporary structures and installation aids. (4) If CP used refer to cat (5) The DNV-OS-C101 defines three different Environmental Zones: o Atmospheric zone: This zone is defined as the areas of a structure above the Splash Zone being exposed to sea spray, atmospheric precipitation and/or condensation. o Splash zone: For floating units with constant draught, the extent of the splash zone shall extend 5 m above and 4 m below this draught. For bottom fixed structures, such as jackets, the splash zone definitions in given in DNV-OS-C101 section F200, 205 to

207. o •

Submerged zone: This zone is defined as the zone below the splash zone.

Note: Fasteners in splash zone are not covered in this specification.

Project n° - Unit

XXXX

2.


SP

5107

0001

Rev.

Page

0

4 / 18

REFERENCE The following standards are used in the present document:

NF EN ISO 898-1

Mechanical properties of fasteners made of carbon steel and alloy steel – Part 1: Bolts, screws and studs with specified property classes – Coarse thread and fine pitch thread.

NF EN ISO 898-2

Mechanical properties of fasteners – Part 2: Nuts with specified proof load values – Coarse thread

NF EN ISO 898-6

Mechanical properties of fasteners – Part 6: Nuts with specified proof load values – Fine pitch thread

NF EN ISO 7089

Plain washers – Normal series – product grade A

SEI DNV-OS-C101 ASTM A193 / A193M ASTM A320 / A320M

Industrial Packaging Specifications Design of offshore steel structures, general (LRFD Method). April 2004. Standard specification for Alloy Steel and Stainless Steel Bolting Materials for High temperature service Standard specification for Alloy Steel and Stainless Steel Bolting Materials for Low temperature service

ASTM A194 / A194M

Standard specification for carbon and alloy nuts for bolts for high pressure or high temperature service, or both

ASTM F436M

Standard Specification for Hardened Steel Washers (metric)

OED-TP-249

Offshore engineering division – Technical bulletin “Guideline for the Selection of fasteners for subsea use”

NF EN 10204

Metallic products – Types of inspection documents

Project n° - Unit

XXXX


SP

5107

Rev.

Page

0

5 / 18

0001

MDS MATRIX

3.

Fastener Usage category

Minimum Yield Strength (MPa)

Minimum Tensile Strength (MPa)

Base case

550

690

N/A

F10

860

- Yield to tensile strength ratio ≤ 0.9 - Yield Strength ≤ 900 MPa - Hardness(3) : ≤ 30 HRC if the fasteners are batch tested ≤ 32 HRC if the fasteners are individually tested

F11

F12

With higher mechanical properties

720

II and III

I

(1)

With higher mechanical properties and improved fatigue (1) life

720

860

- Yield to tensile strength ratio ≤ 0.9 - Yield Strength ≤ 900 MPa - Hardness(3) : ≤ 30 HRC if the fasteners are batch tested ≤ 32 HRC if the fasteners are individually tested - Cold rolled thread after heat treatment

Base case

720

860

N/A

F20

With improved fatigue life

720

860

- Cold rolled thread after heat treatment

F21

Base case

720

860

N/A

F40

720

860

- Urgent procurement

F41

with higher mechanical properties

1100

1220

N/A

F42

with higher mechanical (2) properties

1100

1220

- Urgent procurement

F43

Base case

IV

Additional requirement

MDS number

category

Material data sheet (MDS) shall be chosen according to the usage category of the component. There are 4 usage categories I, II, III, IV depending on the application area defined here under.

(2)

(1): Shall be used only when required. Otherwise MDS F10 shall be preferred. (2): These bolts are hot dip galvanized. In comparison with bolts PTFE or Lamellar zinc coated, lead time is improved but corrosion protection is less efficient. Shall be used only when are required. Otherwise MDS F40 or F42 shall be preferred. (3) as per OED-TP-249 “Guideline for the Selection of fasteners for subsea use” It is the responsibility of the draughtsman or structure engineer to determine the usage category and the MDS number of each component. MDS number shall be reported on the drawings as presented in the MDS.

Project n° - Unit

XXXX

4.


4.1

MDS F10

MATERIAL DATA SHEET


SP

MDS F10

5107

0001

Rev.

Page

0

6 / 18

Rev. 0

PRODUCT

DESIGNATION

GRADE

Stud bolt and Standard screw Alternative

ASTM A193

B7M

DESIGNATION TO BE REPORTED ON THE DRAWINGS ASTM A193 B7M as per MDS F10

ASTM A320

L7M

ASTM A320 L7M as per MDS F10

Nut

ASTM A194

2HM

Washer

ASTM F436M or NF EN ISO 7089

SURFACE PROTECTION N/A

ASTM A194 2HM as per MDS F10 ASTM F436M Type 1 as per MDS Type 1 F10 or or A – 300 HV NF EN ISO 7089 A-300 HV as per MDS F10 PTFE or Lamellar Zinc as per spec N/A XXXX-SP-5101-0003-0. XXXX-SP5101-0003-0.

SCOPE

This MDS specifies the selected options in the referred standard and modified requirements which shall supersede the corresponding requirements in the referred standard.

STEEL GRADE

The steel grades defined here above are the minimum requirements

QUALIFICATION; STEEL As specified in relevant standard MAKING PROCESS As specified in relevant standard HEAT TREATMENT/ DELIVERY CONDITION As specified in relevant standard CHEMICAL COMPOSITION As specified in relevant standard TENSILE TESTING

SURFACE CONDITION

100% of supplied goods must be visually inspected Bearing area for nuts with a size ≥ M24 (1”) shall be dressed perpendicular to thread axis. See sketch attached in appendix D. The stud bolts / screws shall be checked by screwing freely after corrosion coating application. If tensioner option is indicated on drawings, nut shall be drilled as indicated in appendix A. As specified in relevant standard

NDT

As specified in relevant standard

MARKING CERTIFICATE PACKING

As specified in relevant standard EN 10 204 Type 3.1 As loose parts, each bolt shall be individually fit up with nuts before packing. Sketch for packing is attached in appendix B.

ADDITIONAL REQUIREMENTS

Project n° - Unit

XXXX

4.2


SP

5107

0001

Rev.

Page

0

7 / 18

MDS F11

MATERIAL DATA SHEET

MDS F11

Rev. 0

PRODUCT

DESIGNATION

GRADE

DESIGNATION TO BE REPORTED ON THE DRAWINGS


ASTM A193

B7

ASTM A193 B7 as per MDS F11

ASTM A320 ASTM A194 ASTM F436M or NF EN ISO 7089

L7 2H Type 1 or A – 300 HV

ASTM A320 L7 as per MDS F11 ASTM A194 2H as per MDS F11 ASTM F436M Type 1 as per MDS F11 or NF EN ISO 7089 A-300 HV as per MDS F11 PTFE or Lamellar Zinc as per spec XXXX-SP-5101-0003-0. XXXX-SP5101-0003-0.

Nut Washer


N/A

SCOPE and USAGE


STEEL GRADE


QUALIFICATION; STEEL MAKING PROCESS HEAT TREATMENT/ DELIVERY CONDITION CHEMICAL COMPOSITION TENSILE TESTING



As specified in relevant standard As specified in relevant standard As specified in relevant standard Yield to tensile strength ratio ≤ 0.9 Yield Stress shall be ≤ 900 MPa Hardness ≤ 30 HRC if the fasteners are batch tested Hardness ≤ 32 HRC if the fasteners are individually tested 100% of supplied goods must be visually inspected Bearing area for nuts with a size ≥ M24 (1”) shall be dressed perpendicular to thread axis. See sketch attached in appendix D. The stud bolts / screws shall be checked by screwing freely after corrosion coating application. If tensioner option is indicated on drawings, nut shall be drilled as indicated in appendix A.

SURFACE CONDITION


NDT MARKING CERTIFICATE

As specified in relevant standard As specified in relevant standard EN 10 204 Type 3.1 As loose parts, each bolt shall be individually fit up with nuts before packing. Sketch for packing is attached in appendix B.

PACKING

Project n° - Unit

XXXX

4.3


SP

5107

0001

Rev.

Page

0

8 / 18

MDS F12

MATERIAL DATA SHEET

MDS F12

Rev. 0

PRODUCT

DESIGNATION

GRADE


ASTM A193

B7

DESIGNATION TO BE REPORTED ON THE DRAWINGS ASTM A193 B7 as per MDS F12

ASTM A320

L7

ASTM A320 L7 as per MDS F12

Nut Washer

ASTM A194 ASTM F436M or NF EN ISO 7089

2H Type 1 or A – 300 HV

ASTM A194 2H as per MDS F12 ASTM F436M Type 1 as per MDS F12 or NF EN ISO 7089 A-300 HV as per MDS F12 PTFE or Lamellar Zinc as per spec XXXX-SP-5101-0003-0. XXXX-SP5101-0003-0.


N/A

SCOPE and USAGE


STEEL GRADE QUALIFICATION; STEEL MAKING PROCESS HEAT TREATMENT/ DELIVERY CONDITION CHEMICAL COMPOSITION


TENSILE TESTING



Yield to tensile strength ratio ≤ 0.9 Yield Stress shall be ≤ 900 MPa Hardness ≤ 30 HRC if the fasteners are batch tested Hardness ≤ 32 HRC if the fasteners are individually tested The threads shall be cold rolled after heat treatment 100% of supplied goods must be visually inspected Bearing area for nuts with a size ≥ M24 (1”) shall be dressed perpendicular to thread axis. See sketch attached in appendix D. The stud bolts / screws shall be checked by screwing freely after corrosion coating application. If tensioner option is indicated on drawings, nut shall be drilled as indicated in appendix A.

SURFACE CONDITION


NDT


MARKING CERTIFICATE


PACKING

As specified in relevant standard As specified in relevant standard As specified in relevant standard

Project n° - Unit

XXXX

4.4


SP

5107

0001

Rev.

Page

0

9 / 18

MDS F20

MATERIAL DATA SHEET

MDS F20

Rev. 0

PRODUCT

DESIGNATION

GRADE


Standard Stud bolt and screw Alternative

ASTM A193

B7


ASTM A320

L7


Nut

ASTM A194

2H

ASTM A194 2H as per MDS F20

Washer


Type 1 or A – 300 HV


N/A

ASTM F436M Type 1 as per MDS F20 or EN ISO 7089 A-300 HV as per MDS F20 PTFE or Lamellar Zinc as per spec XXXX-SP-5101-0003-0. XXXX-SP5101-0003-0.

SCOPE


STEEL GRADE


QUALIFICATION; STEEL As specified in relevant standard MAKING PROCESS HEAT TREATMENT/ As specified in relevant standard DELIVERY CONDITION CHEMICAL As specified in relevant standard COMPOSITION TENSILE TESTING



Bearing area for nuts with a size ≥ M24 (1”) shall be dressed perpendicular to thread axis. See sketch attached in appendix D. The stud bolts / screws shall be checked by screwing freely after corrosion coating application. If tensioner option is indicated on drawings, nut shall be drilled as indicated in appendix A.

SURFACE CONDITION


NDT


MARKING CERTIFICATE


PACKING

Project n° - Unit

XXXX

4.5


SP

5107

0001

Rev.

Page

0

10 / 18

MDS F21

MATERIAL DATA SHEET

MDS F21

Rev. 0

PRODUCT

DESIGNATION

GRADE



ASTM A193

B7


ASTM A320

L7


Nut

ASTM A194

2H


Washer


Type 1 ASTM F436M Type 1 as per MDS F21 or or A – 300 HV EN ISO 7089 A-300 HV as per MDS F21 PTFE or Lamellar Zinc as per spec N/A XXXX-SP-5101-0003-0. XXXX-SP-51010003-0.

SURFACE PROTECTION N/A SCOPE


STEEL GRADE





The threads shall be cold rolled after heat treatment Bearing area for nuts with a size ≥ M24 (1”) shall be dressed perpendicular to thread axis. See sketch attached in appendix D. The stud bolts / screws shall be checked by screwing freely after corrosion coating application. If tensioner option is indicated on drawings, nut shall be drilled as indicated in appendix A.

SURFACE CONDITION


NDT


MARKING CERTIFICATE


PACKING

Project n° - Unit

XXXX

4.6


SP

5107

0001

Rev.

Page

0

11 / 18

MDS F40

MATERIAL DATA SHEET PRODUCT

DESIGNATION

MDS F40

Rev. 0

GRADE


B7


L7


Nut

ASTM A194/A194M 2H


Washer


Stud bolt and Standard ASTM A193 screw Alternative ASTM A320


ASTM F436M Type 1 as per MDS Type 1 F40 or or A – 300 HV EN ISO 7089 A-300 HV as per MDS F40 PTFE or Lamellar Zinc as per spec N/A XXXX-SP-5101-0003-0. XXXX-SP5101-0003-0.

SCOPE


STEEL GRADE






SURFACE CONDITION


NDT


MARKING CERTIFICATE


PACKING

Project n° - Unit

XXXX

4.7


SP

5107

0001

Rev.

Page

0

12 / 18

MDS F41

MATERIAL DATA SHEET

MDS F41

Rev. 0

PRODUCT

DESIGNATION

GRADE



ASTM A193

B7


ASTM A320

L7


Nut

ASTM A194

2H


Washer



ASTM F436M Type 1 as per MDS F41 Type 1 or or EN ISO 7089 A-300 HV as per MDS A – 300 HV F41 Hot dip galvanized as per ASTM A153 N/A

SCOPE

with a thickness > 50μm This MDS specifies the selected options in the referred standard and modified requirements which shall supersede the corresponding requirements in the referred standard.

STEEL GRADE






SURFACE CONDITION


NDT


MARKING CERTIFICATE


PACKING

Project n° - Unit

XXXX

4.8


SP

5107

Rev.

Page

0

13 / 18

0001

MDS F42

MATERIAL DATA SHEET

MDS F42

Rev. 0

PRODUCT

DESIGNATION

GRADE


Stud bolt and screw

NF EN ISO 898

12.9

Grade 12.9 as per MDS F42

Nut

NF EN ISO 898

12

Grade 12 as per MDS F42

ASTM F436M Type 1 as per MDS ASTM F436M Type 1 F42 Washer or or or NF EN ISO 7089 A – 300 HV EN ISO 7089 A-300 HV as per MDS F42 PTFE or Lamellar Zinc as per spec SURFACE PROTECTION N/A N/A XXXX-SP-5101-0003-0. XXXX-SP5101-0003-0. SCOPE


STEEL GRADE






SURFACE CONDITION


NDT


MARKING CERTIFICATE


PACKING

Project n° - Unit

XXXX

4.9


SP

5107

Rev.

Page

0

14 / 18

0001

MDS F43

MATERIAL DATA SHEET

MDS F43

Rev. 0

PRODUCT

DESIGNATION

GRADE


Stud bolt and screw

NF EN ISO 898

12.9

Grade 12.9 as per MDS F43

Nut

NF EN ISO 898

12

Grade 12 as per MDS F43


Type 1 or A – 300 HV

Washer


N/A

ASTM F436M Type 1 as per MDS F43 or EN ISO 7089 A-300 HV as per MDS F43 Hot dip galvanized as per ASTM A153

SCOPE and USAGE

with a thickness > 50μm This MDS specifies the selected options in the referred standard and modified requirements which shall supersede the corresponding requirements in the referred standard.

STEEL GRADE


QUALIFICATION; STEEL As specified in relevant standard MAKING PROCESS As specified in relevant standard HEAT TREATMENT/ DELIVERY CONDITION As specified in relevant standard CHEMICAL COMPOSITION As specified in relevant standard TENSILE TESTING

SURFACE CONDITION

Bearing area for nuts with a size ≥ M24 (1”) shall be dressed perpendicular to thread axis. See sketch attached in appendix D. The stud bolts / screws shall be checked by screwing freely after corrosion coating application. If tensioner option is indicated on drawings, nut shall be drilled as indicated in appendix A. As specified in relevant standard

NDT


MARKING


CERTIFICATE PACKING

EN 10 204 Type 3.1 As loose parts, each bolt shall be individually fit up with nuts before packing. Sketch for packing is attached in appendix B.


Project n° - Unit

XXXX

5.


SP

5107

DESIGNATION Fasteners in accordance with standards shall be designated as the following: Description / Material / Observation

5.1

EXAMPLE FOR FASTENER DESIGNATIONS

5.2

CATEGORIE I [HOLD]

5.3

CATEGORIE II &III [HOLD]

5.4

CATEGORIE IV [HOLD]

0001

Rev.

Page

0

15 / 18

Project n° - Unit

XXXX

Appendix A:


SP

5107

0001

Rev.

Page

0

16 / 18

: Tensioner HEXAGONAL NUT DRILLING DETAILS nuts

In order to allow the rotation of the standard hexagonal nut, tommy bar holes are required to be drilled into the flat of each nut. Drilling details are shown below. HEXAGON NUT DRILLING - METRIC HEAVY SERIES BOLT Ø'A' B' C' NUT A/F DIA. mm mm mm M20 5.2 7 4* 30 M22 5.2 7 4* 32 M24 6.2 9 5* 36 M27 6.2 9 5* 41 M30 8.2 12 6* 46 M33 8.2 12 7* 50 M36 10.2 15 8* 55 M39 10.2 15 8 60 M42 10.2 15 9 65 M45 10.2 15 9 70 M48 12.4 18 11 75 M52 12.4 18 12 80 M56 14.4 21 12 85 M60 14.4 21 12 90 M64 16.4 24 14 95 M68 16.4 24 14 100 M72 16.4 24 14 105 M76 16.4 24 15 110 M80 16.4 30 15 115 M85 16.4 30 15 120 M90 16.4 30 18 130

HEXAGON NUT DRILLING - IMPERIAL HEAVY SERIES BOLT Ø'A' B' C' NUT A/F DIA. mm mm mm 3/4" 6.2 9 5.5 1.1/4" 7/8" 6.2 9 6.0 1.7/16" 1" 6.2 9 6.5 1.5/8" 1.1/8" 6.2 9 7.0 1.13/16" 1.1/4" 8.2 12 8.0 2" 1.3/8" 8.2 12 8.5 2.3/16" 1.1/2" 10.2 15 9.0 2.3/8" 1.5/8" 10.2 15 9.5 2.9/16" 1.3/4" 10.2 15 10.5 2.3/4" 1.7/8" 10.2 15 11 2.15/16" 2" 12.4 18 12 3.1/8" 2.1/4" 12.4 18 13 3.1/2" 2.1/2" 14.4 21 15 3.7/8" 2.3/4" 14.4 21 16 4.1/4" 3" 16.4 24 17 4.5/8" 3.1/4" 16.4 24 18 5" 3.1/2" 16.4 24 19 5.3/8"

Note: - The above tables are for use with heavy series nut only. - Dimension 'C' denotes maximum hole depth to drill point. Unless otherwise specified. * Indicates the use of a Flat Bottom Drill

Project n° - Unit

XXXX

Appendix B:

APPENDIX B: BOLT PACKING


SP

5107

0001

Rev.

Page

0

17 / 18

Project n° - Unit

XXXX

Appendix C:

Nut Bearing area machining.


SP

5107

0001

Rev.

Page

0

18 / 18

Project n° - Unit

XXXX

End of document


SP

5107

0001

Rev.

Page

0

19 / 18



APPENDIX E DELTA PROTEKT & XYLAN 1424 COATING SPECIFICATION FOR BOLTS


5890-000-SP-5103-001_A.docx

Project n° - Unit

XXXX


SP

5101

0003

Rev.

Page

0

1 / 28

Delta Protekt & Xylan 1424 Coating Specification for Bolts

JOB SPECIFICATION DELTA PROTEKT & XYLAN 1424 COATING SPECIFICATION FOR BOLTS

Pages modified under this revision:

0

25/08/11

ISSUE FOR EXECUTION

O.MELIANI

S.ROUTEAU

S.ROUTEAU

Rev

Date DD/MM/YY

STATUS






Project n° - Unit

XXXX


SP

5101

Rev.

Page

0

2 / 28

0003


SUMMARY

1.

SCOPE AND PURPOSE OF THE DOCUMENT

3

2.

REFERENCE

4

2.1

STANDARDS

4

2.2

TECHNICAL DATA SHEET

5

3.

SAFETY REGULATION

5

4.

DEFINITIONS

5

5.

COATING SYSTEM APPLICATION

6

5.1

PNEUMATIC (OR ELECTROSTATIC) SPRAYING EQUIPMENT

6

5.2

SPRAYING – NUMBER OF COATS

6

6.

CHECKS

6

6.1

NUMBER OF CHECKS

6

6.2

REPAIRS OF COATINGS

7

6.3

FINAL ACCEPTANCE

8

7.

OBLIGATIONS OF THE COATED FASTENERS SUPPLIER

9

7.1

OBLIGATIONS OF THE APPLICATORS

9

7.2

DOCUMENTATION

9

8.

APPENDICES

10

QUALITY PLAN

19

FASTENERS CATEGORY I

19

SYSTEM: SANDBLASTING + ZINC PHOSPHATE CONVERSION + XYLAN 1424

19

Project n° - Unit

XXXX


SP

5101

0003

Rev.

Page

0

3 / 28


SCOPE AND PURPOSE OF THE DOCUMENT

1.

This document covers the protection of fasteners for offshore used conditions. This document deals with multi-layers coatings.

Some coatings products, defined in this document, can be applied by spraying, dip-spin (or dip-drain) process. However a dip-spin process could give mechanical damages on the threaded surfaces with the biggest fasteners, and subsequent troubles when screwing or corrosion protection failure. In order to define a general specification whatever the fastener size, this document is only based on spraying process (pneumatic or electrostatic).

Below M12, dip-spin process maybe accepted, however any damage to thread area will result in rejection of the products.

The coatings systems deal with specific products and process. Some application steps shall meet specific guidance from the coatings products manufacturers and not general standards. The corrosion protection performances depend on the know-how of the Applicators carrying out the coatings. This document aims at defining the various application steps and the intermediate and final checks: •

surface preparation

•

application of the various coats and layers

•

intermediates checks or controls

•

final checks or controls

•

final quality certificate

As a result this document is written as quality plans (appendices) defining the various steps of the process. The main-top Applicator (and the possible subcontractor Applicators) of the coatings systems defined in this document shall be responsible for elaborating and writing its internal application instructions in accordance with the quality plans (appendices).

The coatings systems provide corrosion protection and reproducible friction coefficient properties.

Project n° - Unit

XXXX


SP

5101

0003

Rev.

Page

0

4 / 28


2.

REFERENCE

2.1

Standards The following standards are used in the present document: Document number

Document title

NF EN ISO 12944-2

Paints and varnishes Corrosion Protection of Steel Structures by protective paint systems Part 2 : Classifications of environments Phosphate conversion coatings for metals - Method of specifying requirements Conversion coatings on metallic materials - Determination of coating mass per unit area - Gravimetric methods Paints and varnishes. Determination of film thickness Corrosion tests in artificial atmospheres. Salt spray tests Metallic and oxide coatings. Measurement of coating thickness. Microscopical method Paints and varnishes. Cross-cut test Paints, varnishes and plastics -- Determination of non-volatile-matter content Preparation of steel substrates before application of paints and related products Surface Roughness Characteristics of Blast-Cleaned Steel Substrates Part 4: Method for the Calibration of ISO Surface Profile Comparators and for the Determination of Surface Profile - Stylus Instrument Procedure Preparation of steel substrates before application of paints and related products. Visual assessment of surface cleanliness. Rust grades and preparation grades of uncoated steel substrates and of steel substrates after overall removal of previous coatings

ISO 9717 ISO 3892 ISO 2808 ISO 9227 ISO 1463 ISO 2409 ISO 3251 ISO 8503-4

ISO 8501-1

NF EN ISO 12085 Whitford 115 A Whitford 132 C ISO 2081 NF EN 12329 ISO 2178 NF EN ISO 965-1

Surface texture : Profile method Cure test Crosshatch adhesion test Metallic and other inorganic coatings. Electroplated coatings of zinc with supplementary treatments on iron or steel Corrosion protection of metals - Electrodeposited coatings of zinc with supplementary treatment on iron or steel Non-magnetic coatings on magnetic substrates - Measurement of coating thickness - Magnetic method ISO General purpose metric screw threads – Tolerances – Part 1 : Principles and basic data

Project n° - Unit

XXXX


SP

5101

0003

Rev.

Page

0

5 / 28


2.2

Technical Data Sheet

Document number Delta Protekt KL100 Delta Protekt VH3xx Xylan 1424

3.

Document title Technical data sheet - Manufacturer DÖRKEN Technical data sheet - Manufacturer DÖRKEN Technical data sheet - Manufacturer WHITFORD

SAFETY REGULATION The application of the coatings (method and materials) shall meet the applicable health and safety regulations. In particular the relevant health and safety data sheets for the used coating shall be adhered to and shall be available for reference at all times. The application of the coatings shall meet the international and local regulations for environment protection.

4.

DEFINITIONS TECHNIP Main-top Applicator Applicator Coated fasteners Supplier Coating Product Manufacturer Operator Batch of pieces Sample

TECHNIP or any subsidiary of TECHNIP, or its Representative Main-top supplier for the application of the coatings systems Supplier for the application of one or several layers of the complete coatings systems. Subcontractor of the main-top supplier. The main supplier of the coated fasteners to TECHNIP or Technip subcontractors. Manufacturer of the coatings products to be applied Person in charge to carry out one or several steps of the application process Fasteners coated in the same cycle of treatment (treatment bath, cure in oven) Extra fasteners to carry out destructive checks : adhesion test, cure test or salt spray test

Project n° - Unit

XXXX


SP

5101

0003

Rev.

Page

0

6 / 28


5.

COATING SYSTEM APPLICATION The coatings shall be applied according to the quality plan (see appendices). Humidity, ambient temperature and steel temperature shall meet the requirements of the coatings products manufacturers, and the standard rules. The coatings systems shall be applied in several coats and layers with various equipments. The various steps shall be conducted to avoid any contaminants or signs of re-rusting between coats. The air supply (sandblasting, air cleaning and pneumatic spraying) shall be free from water or oil and shall have separators and filters installed.

5.1

Pneumatic (or electrostatic) spraying equipment The manufacturers of the coatings products recommend the use of equipments (brand name, type, tip) in order to get a required spraying. The Applicator is responsible to use equipment providing equivalent performances.

5.2

Spraying – Number of coats The fasteners are sprayed piece per piece typically after positioning on table, on rotary device or with clip. The contact area prevents the possibility to get a complete coating covering after one coat. This is the reason why the Xylan or Delta Protekt KL100 (sacrificial layer) products shall be applied in two coats to meet the required thickness all over the surface without any weak points. The Delta Protekt VH3xx shall be applied in one coat to avoid any over-thickness. Any overthickness could turn to friable or powdery film after cure and subsequent dust.

6.

CHECKS Each step of the process – application and checks – shall be carried out according to the appropriate quality plans (see appendices). Each step shall be registered with signature of the Operator on the workshop document following the fasteners: technical application instructions or application procedure in accordance with the quality plans.

6.1

Number of checks The number of checks shall be carried out according to the quality plans (see appendices).

Project n° - Unit

XXXX


SP

5101

0003

Rev.

Page

0

7 / 28


6.2

Repairs of coatings Any defect shall be registered. -Screwing defect before coating In case of defect for screwing test before coating, or screw/nut gap not taking into account the coating thickness the coated fasteners supplier shall be informed to get new fasteners. -Thickness defect: All the batch of fasteners shall be checked piece per piece. The coatings system shall be removed completely and re-applied for defective pieces. -Adhesion defect: All the batch of fasteners shall be checked piece per piece. The coatings system shall be removed completely and re-applied for defective pieces. -Cure defect: All the batch of fasteners shall be re-cured. A new cure test shall be carried out. In case of new test failure, the coatings system shall be removed completely and re-applied for the entire defective batch. -Screwing test defect All the batch of fasteners shall be checked piece per piece. The coatings system shall be removed completely and re-applied for defective pieces. -Salt spray test defect: TECHNIP shall be informed to determine any decision.

Project n° - Unit

XXXX


SP

5101

0003

Rev.

Page

0

8 / 28


6.3

Final acceptance A final acceptance report shall be released for each fasteners batch. The final quality certificate shall inform that the checks, tests and process steps have been carried out according to the quality plans with signature of the Operator at each step. This report shall inform about: •

fasteners type I, Xylan system, sandblasting, phosphate conversion :

Check of phosphate conversion baths:

no failure

Check of the phosphate conversion mass per unit area:

values

Cure test:

no failure

Adhesion test:

no failure

Screwing tests:

no failure

Final thickness measurements:

values

Number of checks and tests and sampling

•

fasteners type II & III & IV, Xylan system, electroplated coating of zinc, phosphate conversion :

Electrolytic coating of zinc baths :

no failure

Thickness measurements after electrolytic coating of zinc :

values


no failure


values

Cure test :

no failure

Adhesion test :

no failure

Screwing tests :

no failure

Final thickness measurements :

values


•

fasteners type I & II & III & IV, Delta Protekt, phosphate conversion :


no failure


values

Thickness control after Delta Protekt KL100:

values

Cure test:

no failure

Adhesion test:

no failure

Screwing tests:

no failure


values


Project n° - Unit

XXXX


SP

5101

0003

Rev.

Page

0

9 / 28


•

fasteners type I & II & III & IV, Delta Protekt, gritblasting :

Surface preparation:

no failure

Thickness control after Delta Protekt KL100:

values

Cure test:

no failure

Adhesion test:

no failure

Screwing tests:

no failure


values


Quality certificates (see templates in the appendices) shall be filled, stamped and returned with fasteners certificates. A specific quality certificate shall be released for the salt spray test (1000 hours without red rust).

7.

OBLIGATIONS OF THE COATED FASTENERS SUPPLIER The coated fasteners Supplier shall ensure the Applicator adheres to this specification. The coated fasteners Supplier shall register the acceptance reports and quality certificates. The coated fasteners Supplier shall communicate to TECHNIP the quality certificates for each fasteners batch. The coated fasteners Supplier shall provide extra fasteners (samples) to enable the destructive tests for each batch. Depending on the coatings system, the coated fasteners Supplier shall provide fasteners with dimensions (tolerance class) in accordance with the required coatings thickness in order to enable the screwing. In case of dispute, the thickness shall be measured by microscopic method.

7.1

Obligations of the applicators The Applicators shall be agreed by the coatings products manufacturers. The Operator shall be certified according to internal requirements of the Applicator. The Applicator shall apply the coatings according to the quality plans with signature of the Operators step by step. The Applicators shall release one final acceptance report and final quality certificate for each batch of fasteners. The Applicator in charge of the salt spray test shall register, release a new quality certificate and inform the coated fastener supplier.

7.2

Documentation The coated fasteners Supplier shall inform about: • choice of coatings system • tolerance class of the fasteners • steel grade of the fasteners • technical data sheets of the coatings products • agreed Applicators certificates (by the coatings products Manufacturers) • acceptance reports • quality certificate • quality certificate for salt spray test (after 1000 hours)

Project n° - Unit

XXXX


SP

5101


8.

APPENDICES

0003

Rev.

Page

0

10 / 28

Project n° - Unit

XXXX


SP

5101

0003

Rev.

Page

0

11 / 28


QUALITY PLAN Fasteners categories I, II, III & IV System: ZINC PHOSPHATE CONVERSION (or CLEANER/PHOSPHATE CONVERSION) + DELTA PROTEKT KL100 + DELTA PROTEKT VH3xx N°

Process step

Description

Comment

1

Visual check at receipt Screwing check at receipt Degreasing / cleaning (alkaline or solvent) Zinc phosphate conversion Or Cleaner/phosphate conversion Zinc phosphate check

- Visual inspection to check no mechanical damages (threaded surfaces). - Screwing checking screw/bolt.

- 100% check.

- Removal of contaminants, grease and oil.

- The degreasing shall enable adhesion of the coating.

- Zinc phosphate conversion with thin crystallin structure. The phosphate conversion shall be compatible with Dörken products and shall be agreed by Dörken.

- Before any sign of re-rusting. - Thickness < 3 µm (< 6g/m²). - Process requirement to avoid hydrogen embrittlement.

ISO 9717

- < 6 g/m².

ISO 3892

2 3

4

5

6 7

Zinc phosphate check Delta Protekt KL100 product preparation

- Checking of the treatment baths: products manufacturers requirements (temperature, concentration…). - Checking of the phosphate conversion mass per unit area - Temperature storage : 5 to 25°C. - Product < expiry date. - Product with quality certificate. - Product should be well mixed before use without creating air bubbles.

- At 20°C +/-5°C: - Viscosity shall be adjusted with Delta Protekt KL-T to meet viscosity < 40 seconds, viscosity cup 3 mm (depending on pneumatic or electrostatic spraying). - Registration of the product batch number.

Standard

Signature Operator / Who / When

Project n° - Unit

XXXX


SP

5101

0003

Rev.

Page

0

12 / 28

Delta Protekt & Xylan 1424 Coating Specification for Bolts 8

Delta Protekt KL100 product preparation

- Checking of the product temperature and registration. - Measurement of the viscosity and registration.

9

Visual inspection

10

Delta Protekt KL100 application: 1st coat (1/2)

- Checking that there is no re-rusting. - Checking that the pieces are dried and that there is no rusting in the retention areas. - Pneumatic or electrostatic spraying of the pieces on substrate at room temperature.

11

Desolvation

- Flash-off.

12

Desolvation

- Flash-off.

13

Cure

- In oven: > 40 minutes at 200-210°C metal temperature.

14 15

Cooling down Delta Protekt KL100 application: 2nd coat (2/2)

- To meet < 35°C metal temperature. - Pneumatic or electrostatic spraying of the pieces on substrate at room temperature.

16

Desolvation

- Flash-off.

17

Desolvation

- Flash-off.

18

Cure

- In oven: > 40 minutes at 200-210°C metal

- Product temperature: 15 to 28°C when applying. - The viscosity shall meet the optimal defined viscosity around +/-1 second when compared to 20°C (in agreement with the Dörken temperature/viscosity abacus). - Before the Delta Protekt spraying.

- Before 36 hours after phosphate conversion. - Ambient conditions: humidity 35 to 55%, temperature 15°C to 30°C. - Positioning of the pieces: typically on table, on rotary device, or with clip. - Thickness / coat : 5 to 10 µm. - Take care of the threaded surfaces. - Ambient conditions: 3 to 5 minutes at ambient temperature and humidity < 50%. - 5 minutes at 100°C in oven. - In order to avoid bubbling after curing. - Put the pieces in the oven at temperature. - In order to get a touch dry film. - Do not cure above 210°C to avoid any degradation of the phosphate conversion. - Ambient conditions: humidity 35 to 55%, temperature 15°C to 30°C. - Positioning of the pieces: typically on table, on rotary device, or with clip. - Thickness / coat: 5 to 10 µm. - Take care of the threaded surfaces. - Ambient conditions: 3 to 5 minutes at ambient temperature and humidity < 50%. - 5 minutes at 100°C in oven. - In order to avoid bubbling after curing. - Put the pieces in the oven at temperature. - Touch dry film. - Do not cure above 210°C to avoid any degradation of the

Project n° - Unit

XXXX


SP

5101

0003

Rev.

Page

0

13 / 28


temperature. 19 20

Cooling down Thickness check

- To meet < 35°C metal temperature. - Thickness measurements: magnetic method.

21 22

Cohesion control Delta Protekt VH3xx product preparation

23

Delta Protekt VH3xx product preparation Delta Protekt VH3xx application (only 1 coat)

- Checking with tape (ISO 2409) but without scratch. - Temperature storage: 5 to 25°C. - Product < expiry date. - Product with quality certificate. - Product should be well mixed before use without creating foam. - Checking of the non-volatile-matter content.

24

- Pneumatic spraying of the pieces on substrate at room temperature.

25 26

Desolvation Desolvation

- Flash-off. - Flash-off.

27

Cure

28 29 30

Cooling down Visual check Thickness check

- In oven : 20 minutes (+/-10) at 170°C (+/-20) metal temperature. - To room temperature. - Homogeneous and uniform. - Thickness measurements: magnetic method.

31

Screwing check

- Screwing checking screw/bolt.

32

Adhesion

test

- Crosshatch test on sample / batch.

phosphate conversion. - On flat surfaces. - Depending on the quantity and the TECHNIP order requirement, sampling 20% minimum. - Requirement thickness : 7 to 12 µm - No significant particles disbanding (< grade 2-3). - At 20°C : - Viscosity (raw product) shall be adjusted with 25% demineralised water. - Registration of the product batch number.

ISO 2808

- Non-volatile-matter content: 18 to 25%.

ISO 3251

ISO 2409

- Ambient conditions: temperature 15°C to 30°C. - Positioning of the pieces: typically on table, on rotary device, or with clip. - VH3xx thickness: 2 à 4 µm . - Take care of the threaded surfaces. - 3 to 5 minutes at 25 to 50°C. - 5 minutes at 100°C in oven. - In order to avoid bubbling after curing. - Put the pieces in the oven at temperature.

- On flat surfaces. - Depending on the quantity and the TECHNIP order requirement, sampling 20% minimum. - Requirement thickness: 9 to 16 average. - 100% check. Each bolt shall be individually fit up with nuts before packing. - Requirement : no adhesion failure

ISO 2808

ISO 2409

Project n° - Unit

XXXX


SP

5101

0003

Rev.

Page

0

14 / 28


33

34

(destructive) Final acceptance report and quality certificate Salt spray test

- Report : checks, tests and measurements - Quality certificate: process steps and checks in good agreement with the quality plan. - On samples: at least 2 samples / batch.

- 1 report and 1 quality certificate / batch. - Storage of the samples and registration for 1 year. - Requirement: 1000 hours without red rust. - Storage of the samples and registration for 1 year and 3 months. - 1 quality certificate for salt spray test / batch. - In case of salt spray test failure, TECHNIP shall be informed. - Less than one (1) year old successful salt spray test evidence, based on the same process and similar product may be accepted. (Similar product ranges are M10 to M36 and M39 and above)

ISO 9227

Project n° - Unit

XXXX


SP

5101

0003

Rev.

Page

0

15 / 28


QUALITY PLAN Fasteners categories I, II, III & IV System: GRITBLASTING + DELTA PROTEKT KL100 + DELTA PROTEKT VH3xx N°

Process step

Description

Comment

1

- Visual inspection to check no mechanical damages (threaded surfaces). - Screwing checking screw/bolt.

- 100% check.

- Removal of contaminants, grease and oil.


4

Visual check at receipt Screwing check at receipt Degreasing / cleaning (alkali or solvent) Gritblasting

- The gritblasting shall enable adhesion of the coating.

5

Gritblasting check

6 7

Air cleaning Delta Protekt KL100 product preparation

8

Delta Protekt KL100 product preparation

- Gritblasting with stainless steel beads or ceramic beads such as Zirblast Z60. - Gritblasting piece per piece to avoid any damage of the threaded surfaces. - Control of the beads with phenolphtaleine test to check any alkaline pollution. - Air cleaning to remove dust. - Temperature storage: 5 to 25°C. - Product < expiry date. - Product with quality certificate. - Product should be well mixed before use without creating air bubbles. - Checking of the product temperature and registration. - Measurement of the viscosity and registration.

9

Visual inspection

- Checking that there is no re-rusting.

- Before the Delta Protekt spraying.

2 3

- Air cleaning piece per piece. Take care of the threaded surfaces. - At 20°C +/-5°C: - Viscosity shall be adjusted with Delta Protekt KL-T to meet viscosity < 40 seconds, viscosity cup 3 mm (depending on pneumatic or electrostatic spraying). - Registration of the product batch number. - Product temperature: 15 to 28°C when applying. - The viscosity shall meet the optimal defined viscosity around +/-1 second when compared to 20°C (in agreement with the Dörken temperature/viscosity abacus).

Standard


Project n° - Unit

XXXX


SP

5101

0003

Rev.

Page

0

16 / 28


10

11 12

13

14 15

16 17

18

19 20

Delta Protekt - Pneumatic or electrostatic spraying of the - Before 24 hours after gritblasting. pieces on substrate at room temperature. - Ambient conditions: humidity 35 to 55%, temperature KL100 15°C to 30°C. application: 1st - Positioning of the pieces: typically on table, on rotary coat (1/2) device, or with clip. - Thickness / coat : 5 to 10 µm. - Take care of the threaded surfaces. Desolvation - Flash-off. - Ambient conditions: 3 to 5 minutes at ambient temperature and humidity < 50%. Desolvation - Flash-off. - 5 minutes at 100°C in oven. - In order to avoid bubbling after curing. - Put the pieces in the oven at temperature. Cure - In oven: > 40 minutes at 200-210°C metal - Touch dry film. temperature. - Do not cure above 210°C to avoid any degradation of the phosphate conversion. Cooling down - To meet < 35°C metal temperature. Delta Protekt - Pneumatic or electrostatic spraying of the - Ambient conditions: humidity 35 to 55%, temperature pieces on substrate at room temperature. 15°C to 30°C. KL100 - Positioning of the pieces: typically on table, on rotary application: 2nd device, or with clip. coat (2/2) - Thickness / coat: 5 to 10 µm. - Take care of the threaded surfaces. Desolvation - Flash-off. - Ambient conditions: 3 to 5 minutes at ambient temperature and humidity < 50%. Desolvation - Flash-off. - 5 minutes at 100°C in oven. - In order to avoid bubbling after curing. - Put the pieces in the oven at temperature. Cure - In oven: > 40 minutes at 200-210°C metal - Touch dry film. temperature. - Do not cure above 210°C to avoid any degradation of the phosphate conversion. Cooling down - To meet < 35°C metal temperature. Thickness check - Thickness measurements: magnetic method. - On flat surfaces. ISO 2808

Project n° - Unit

XXXX


SP

5101

0003

Rev.

Page

0

17 / 28


- Depending on the quantity and the TECHNIP order requirement, sampling 20% minimum. 21 22

Cohesion control Delta Protekt VH3xx product preparation

23

Delta Protekt VH3xx product preparation Delta Protekt VH3xx application (only 1 coat)

24

- Checking with tape (ISO 2409) but without scratch. - Temperature storage: 5 to 25°C. - Product < expiry date. - Product with quality certificate. - Product should be well mixed before use without creating foam. - Checking of the non-volatile-matter content.

- Pneumatic spraying of the pieces on substrate at room temperature.

- Requirement thickness : 7 to 12 µm - No significant particles disbonding (< grade 2-3). - Viscosity (raw product) shall be adjusted with 25% demineralised water. - Registration of the product batch number.

- Non-volatile-matter content: 18 to 25%.

ISO 3251

- Ambient conditions: temperature 15°C to 30°C. - Positioning of the pieces: typically on table, on rotary device, or with clip. - VH3xx thickness: 2 à 4 µm. - Take care of the threaded surfaces. - 3 to 5 minutes at 25 to 50°C. - 5 minutes at 100°C in oven. - In order to avoid bubbling after curing. - Put the pieces in the oven at temperature.

25 26



27

Cure

28 29 30

Cooling down Visual check Thickness check

- In oven: 20 minutes (+/-10) at 170°C (+/-20) metal temperature. - To room temperature. - Evenly. - Thickness measurements: magnetic method.

31

Screwing check


32

Adhesion test (destructive) Final acceptance report and quality


- On flat surfaces. - Depending on the quantity and the TECHNIP order requirement, sampling 20% minimum. - Requirement thickness: 9 to 16 µm average. - 100% check. Each bolt shall be individually fit up with nuts before packing. - Requirement: no adhesion failure

- Report : checks, tests and measurements - Quality certificate: process steps and checks in

- 1 report and 1 quality certificate / batch. - Storage of the samples and registration for 1 year.

33

ISO 2409

ISO 2808

ISO 2409

Project n° - Unit

XXXX


SP

5101

0003

Rev.

Page

0

18 / 28


34

certificate

good agreement with the quality plan.

Salt spray test

- On samples: at least 2 samples / batch.

- Requirement: 1000 hours without red rust. - Storage of the samples and registration for 1 year and 3 months. - 1 quality certificate for salt spray test / batch. - In case of salt spray test failure, TECHNIP shall be informed. - Less than one (1) year old successful salt spray test evidence, based on the same process and similar product may be accepted. (Similar product ranges are M10 to M36 and M39 and above)

ISO 9227

Project n° - Unit

XXXX


SP

5101

0003

Rev.

Page

0

19 / 28


QUALITY PLAN Fasteners category I System: SANDBLASTING + ZINC PHOSPHATE CONVERSION + XYLAN 1424 N°

Process step

1

Visual receipt

2

Screwing check at receipt

- Screwing checking by pairing screw/bolt.

-100% check.

3

- Removal of contaminants, grease and oil with solvent. - Sandblasting with aluminium oxide mesh 80 to 100.


4

Degreasing cleaning Sandblasting

5 6

Air cleaning Visual inspection

7

Roughness check

- Air cleaning to remove aluminium oxide dust. - To check that all the surfaces are sandblasted: clean, homogeneous and uniform. - Measurement of the roughness.

8

Zinc phosphate conversion

- Zinc phosphate conversion with thin crystallin structure.

9

Zinc

- Checking of the treatment baths : products

check

Description

at

/

phosphate

Comment

Standard

- Visual inspection to check no mechanical damages (threaded surfaces)

- With abrasive dry, clean and free from contaminants. - Ambient conditions: humidity < 85°C and steel temperature > 5°C above the dew-point. - Take care of the threaded surfaces. - Requirement: roughness Ra = 2,5 (+/-1) µm. The sandblasting shall provide a surface free from any rust point. - Air cleaning piece per piece. Take care of the threaded surfaces. - Requirement : Sa3 - Using of a stylus instrument. - Requirement : roughness Ra = 2,5 (+/-1) µm. - Just after sandblasting and before any sign of re-rusting. - 15 grammes/m² minimum to be applied. - Process requirement to avoid hydrogen embrittlement.

ISO 8503-4

ISO 8501-1 ISO 8503-4 ISO 9717


Project n° - Unit

XXXX


SP

5101

0003

Rev.

Page

0

20 / 28

Delta Protekt & Xylan 1424 Coating Specification for Bolts check

manufacturers requirements (temperature, concentration…). - Temperature storage: 5 to 30°C. - Product < expiry date. - Product with quality certificate. - Product should be well mixed before use.

10

Xylan 1424 product preparation

11 12 13

Xylan 1424 product preparation Visual inspection Xylan 1424 application: 1st coat (1/2)

14 15



16 17 18 19

Drying Cooling down Thickness check Xylan 1424 application: 2nd coat (2/2)

- In oven: typically 30 minutes at 180°C. - To room temperature. - Optional. - Pneumatic spraying of the pieces on substrate at room temperature.

- Checking of the product temperature. - Checking that there is no re-rusting. - Pneumatic spraying of the pieces on substrate at room temperature.

- The product should be filter with mesh 75-150. - At 23°C : typically depending on the colour: 40-45 seconds, viscosity cup BS4 27-31 seconds, viscosity cup DIN4 30-40 seconds, viscosity cup FORD4 - Viscosity shall comply with the value given in the batch quality certificate from Whitford. - Viscosity can be adjusted with clean water or Whitford 54 thinner. - Registration of the product batch number. - Product temperature : 15 to 30°C when applying. - Before the Xylan spraying. - Before 2 hours after phosphate conversion. - Before 24 hours after phosphate conversion + passivation. - Ambient conditions: humidity 35 to 55%, temperature 15°C to30°C. - Positioning of the pieces: typically on table, on rotary device, or with clip. - Thickness : 15 to 20 µm / coat. - Take care of the threaded surfaces. - Ambient conditions : 3 to 5 minutes at 25 to 50°C. - 5 minutes at 100°C in oven. - In order to avoid bubbling after curing. - Put the pieces in the oven at temperature. - In order to get a touch dry film. - Depending on the Operator know-how. - Ambient conditions: humidity 35 to 55%, temperature 15°C to 30°C. - Positioning of the pieces: typically on table, on rotary device, or with clip. - Thickness: 15 to 20 µm / coat. - Take care of the threaded surfaces.

Project n° - Unit

XXXX


SP

5101

0003

Rev.

Page

0

21 / 28

Delta Protekt & Xylan 1424 Coating Specification for Bolts 20 21



22

Xylan 1424 cure

- In oven: typically 20 minutes at 205°C metal substrate temperature.

23 24 25

- To room temperature. - Homogeneous and uniform. - With Methyl Ethyl Cetone (MEK) soaked cloth.

26

Cooling down Visual check Cure test (destructive) Thickness check

27

Screwing check


28


29

Adhesion test (destructive) Final acceptance report and quality certificate

- Report : checks, tests and measurements - Quality certificate : process steps and checks in good agreement with the quality plan.


30

Salt spray test

- On samples : at least 2 samples / batch.

- Requirement: 1000 hours, 15% maximum red rust. - Storage of the samples and registration for 1 year after salt spray test. - 1 quality certificate for salt spray test / batch. - In case of salt spray test failure, TECHNIP shall be informed. - Less than one (1) year old successful salt spray test evidence, based on the same process and similar product may be accepted (Similar product ranges are M10 to M36 and M39 and above)

- Thickness measurements : magnetic method.

- Ambient conditions : 3 to 5 minutes at 25 to 50°C. - 5 minutes at 100°C in oven. - In order to avoid bubbling after curing. - Put the pieces in the oven at temperature. - Depending on the thermal mass of the pieces, the temperature cycle shall be adjusted. - Do not cure above 205°C to avoid any degradation of the phosphate conversion.

- Requirement: no substrate exposure after 50 rubs. Slight discoloration is acceptable after 50 firm rubs. - On flat surfaces. - Depending on the quantity and the TECHNIP order requirement, sampling 20% minimum. - Requirement thickness : 30 to 40 µm - - 100% check. Each bolt shall be individually fit up with nuts before packing. - Requirement: no failure. - Requirement : no adhesion failure

Whitford 115A ISO 2808

Whitford 132C

ISO 9227

Project n° - Unit

XXXX


SP

5101

0003

Rev.

Page

0

22 / 28


QUALITY PLAN Fasteners categories II, III & IV System: ELECTROPLATED COATING OF ZINC + PHOSPHATE ZINC CONVERSION + XYLAN 1424 N°

Process step

Description

Comment

1

Degreasing / cleaning Visual check at receipt « Screwing » check at receipt Electroplated coating of zinc Check of the electroplated coating of zinc Thickness check

- Removal of contaminants, grease and oil with solvent. - Visual inspection to check no mechanical damages (threaded surfaces) - Screwing checking screw/bolt.


- Electroplated coating of zinc.

Process requirement to avoid hydrogen embrittlement. - Zinc coating purity : > 99%. - Requirement thickness : 18 to 25 µm.

ISO 2081

- On flat surfaces. - Depending on the quantity and the TECHNIP order requirement, 100% check or sampling. - Requirement thickness: 18 to 25 µm. - In case of dispute, the thickness shall be measured by microscopical method. - 5 to 7 grammes/m² to be applied. - Process requirement to avoid hydrogen embrittlement.

ISO 2178 ISO 1463

2 3 4 5

6

7 8

9

Zinc phosphate conversion Zinc phosphate check Xylan 1424 product preparation

Checking of the treatment baths : products manufacturers requirements (temperature, concentration…). - Thickness measurements: magnetic method.

- Zinc phosphate conversion with thin crystallin structure. - Checking of the treatment baths: products manufacturers’ requirements (temperature, concentration…). - Temperature storage: 5 to 30°C. - Product < expiry date. - Product with quality certificate.

Standard

- 100% check.

- The product should be filter with mesh 75-150. - At 23°C : typically depending on the colour: 40-45 seconds, viscosity cup BS4

ISO 9717


Project n° - Unit

XXXX


SP

5101

0003

Rev.

Page

0

23 / 28

Delta Protekt & Xylan 1424 Coating Specification for Bolts - Product should be well mixed before use.

10 11 12

Xylan 1424 product preparation Visual inspection Xylan 1424 application: 1st coat (1/2)

- Checking of the product temperature.

13 14



15 16 17 18

Drying Cooling down Thickness check Xylan 1424 application: 2nd coat (2/2)

- In oven: typically 30 minutes at 180°C. - To room temperature. - Optional. - Pneumatic spraying of the pieces on substrate at room temperature.

19 20



21

Xylan 1424 cure

- In oven: typically 20 minutes at 205°C metal substrate temperature.

- Checking that there is no re-rusting. - Pneumatic spraying of the pieces on substrate at room temperature.

27-31 seconds, viscosity cup DIN4 30-40 seconds, viscosity cup FORD4 - Viscosity shall comply with the value given in the batch quality certificate from Whitford. - Viscosity can be adjusted with clean water or Whitford 54 thinner. - Registration of the product batch number. - Product temperature : 15 to 30°C when applying. - Before the Xylan spraying. - Before 2 hours after phosphate conversion. - Before 24 hours after phosphate conversion + passivation. - Ambient conditions: humidity 35 to 55%, temperature 15°C to 30°C. - Positioning of the pieces: typically on table, on rotary device, or with clip. - Thickness: 15 to 20 µm / coat. - Take care of the threaded surfaces. - Ambient conditions: 3 to 5 minutes at 25 to 50°C. - 5 minutes at 100°C in oven. - In order to avoid bubbling after curing. - Put the pieces in the oven at temperature. - In order to get a touch dry film. - Depending on the Operator know-how. - Ambient conditions: humidity 35 to 55%, temperature 15°C to30°C. - Positioning of the pieces: typically on table, on rotary device, or with clip. - Thickness: 15 to 20 µm / coat. - Take care of the threaded surfaces. - Ambient conditions: 3 to 5 minutes at 25 to 50°C. - 5 minutes at 100°C in oven. - In order to avoid bubbling after curing. - Put the pieces in the oven at temperature. - Depending on the thermal mass of the pieces, the temperature cycle shall be adjusted.

Project n° - Unit

XXXX


SP

5101

0003

Rev.

Page

0

24 / 28

Delta Protekt & Xylan 1424 Coating Specification for Bolts - Do not cure above 205°C to avoid any degradation of the phosphate conversion. 22 23 24

- To room temperature. - Homogeneous and uniform. - With Methyl Ethyl Cetone (MEK) soaked cloth.

25

Cooling down Visual check Cure test (destructive) Thickness check

26

Screwing check


27


28

Adhesion test (destructive) Final acceptance report and quality certificate

- Report : checks, tests and measurements - Quality certificate: process steps and checks in good agreement with the quality plan.


29

Salt spray test

- On samples : at least 2 samples / batch.

- Requirement: 1000 hours, 15% maximum red rust. - Storage of the samples and registration for 1 year after salt spray test. - 1 quality certificate for salt spray test / batch. - In case of salt spray test failure, TECHNIP shall be informed. - Less than one (1) year old successful salt spray test evidence, based on the same process and similar product may be accepted. (Similar product ranges are M10 to M36 and M39 and above)

- Thickness measurements: magnetic method.

- Requirement: no substrate exposure after 50 rubs. Slight discoloration is acceptable after 50 firm rubs. - On flat surfaces. - Depending on the quantity and the TECHNIP order requirement, sampling 20% minimum. - Requirement thickness : 48 to 65 µm - - 100% check. Each bolt shall be individually fit up with nuts before packing. - Requirement: no failure. - Requirement : no adhesion failure

Whitford 115A ISO 2808

Whitford 132C

ISO 9227

Project n° - Unit

XXXX


SP

5101

0003

Rev.

Page

0

25 / 28


QUALITY CERTIFICATE Fasteners type I, Xylan system, sandblasting, phosphate conversion

Name

Date

Visa

Applicator

Name of the operator Check that phosphate conversion baths have no failure

Value (SI unit)

N/A

Indicate the phosphate conversion mass per unit area Check that the cure test has no failure :

N/A

Check that the adhesion test has no failure

N/A

Check that the screwing tests have no failure

N/A

Indicate the final thickness Number of checks and tests and sampling

VISA of the operator

Project n° - Unit

XXXX


SP

5101

0003

Rev.

Page

0

26 / 28


QUALITY CERTIFICATE Fasteners type II, III & IV, Xylan system, electroplated coating of zinc, phosphate conversion

Name

Date

Visa

Applicator

Name of the operator Check that electrolytic coating of zinc baths has no failure

Value (SI unit)

N/A

Indicate the thickness measurements after electrolytic coating of zinc Check that the phosphate conversion baths have no failure :

N/A

Indicate the phosphate conversion mass per unit area Check that the cure test has no failure

N/A


N/A


N/A

Indicate the final thickness Number of checks and tests and sampling


Project n° - Unit

XXXX


SP

5101

0003

Rev.

Page

0

27 / 28


QUALITY CERTIFICATE Fasteners type I, II, III & IV, Delta Protekt, phosphate conversion

Name

Date

Visa

Applicator

Name of the operator Check that phosphate conversion baths have no failure

Value (SI unit)

N/A

Indicate the phosphate conversion mass per unit area Indicate the thickness after Delta Protekt KL100 coating Check that the cure test has no failure :

N/A


N/A


N/A

Indicate the final thickness



Project n° - Unit

XXXX


SP

5101

0003

Rev.

Page

0

28 / 28


QUALITY CERTIFICATE Fasteners type I, II, III & IV, Delta Protekt, gritblasting

Name

Date

Visa

Applicator

Name of the operator

Check that the surface preparation has no failure

Value (SI unit)

N/A

Indicate the thickness after Delta Protekt KL100 coating Check that the cure test has no failure :

N/A


N/A


N/A

Indicate the final thickness


----End of document-----




APPENDIX F JOB SPECIFICATION FOR WELDABLE FORGED PIECES MATERIAL DATA SHEET


5890-000-SP-5103-001_A.docx

Project n° - Unit

XXXX


SP

5103

0003

Rev.

Page

1

1/9

JOB SPECIFICATION WELDABLE FORGED PIECES MATERIAL DATA SHEET

Pages modified under this revision: All pages

1 0 Rev

04/05/12

Issue For Implementation

Y.JESTIN

R.KARNAFEL

S.ROUTEAU

J. EMERY

B.SANCHEZ

S.ROUTEAU

STATUS




02/06/09 Date DD/MM/YY



Project n° - Unit

XXXX


SP

5103

0003

Rev.

Page

1

2/9

SUMMARY

1.

SCOPE

3

2.

REFERENCES

3

3.

ABREVIATIONS

3

4.

MATERIAL DATA SHEET

4

4.1

MDS W6 SS

4

4.2

MDS W6 NS

6

4.3

MDS W5 NS

8

Project n° - Unit

XXXX

1.


SP

5103

0003

Rev.

Page

1

3/9

SCOPE This document defines the technical requirements for the fabrication of weldable forged pieces. Forged material shall comply with ASTM A694 and the requirements specified in the present document. Two material data sheets are included in the present document according to the material grade F65 and F52. The forgings manufactured according to this specification are suitable for :  Pressure containment items for Sour or Non-sour Service, and Structural items  Minimum design temperature ≥-20°C  CTOD testing not required MDS applies for all types of weldable wrought, forged piece, including hubs, flanges, tees, bulkheads, axles, etc. Material description shall be reported on the drawing material lists. Note that the only difference between MDS W6 SS and MDS W6 NS is the maximum allowable hardness on surface, which is more stringent for Sour Service.

2.

REFERENCES ASTM A370 ASTM A388 ASTM A694 ASTM A751 ASTM A961 ASTM E8 ASTM E10 ASTM E23 ASTM E 709 ASTM E1417

Standard Test Methods and Definitions for Mechanical Testing of Steel Products Standard Practice for Ultrasonic Examination of Heavy Steel Forgings Standard Specification for Carbon and Alloy Steel Forgings for Pipe Flanges, Fittings, Valves, and Parts for High-Pressure Transmission Service Standard Test Methods, Practices, and Terminology for Chemical Analysis of Steel Products Standard Specification for Common Requirements for Steel Flanges, Forged Fittings, Valves, and Parts for Piping Applications Standard Test Method for Tension Testing of Metallic Materials Standard Test Method for Brinell Hardness of Metallic Materials Test Methods for Notched Bar Impact Testing of Metallic Materials Standard Guide for Magnetic Particle Testing Standard Practice for Liquid Penetrant Testing

“latest revision” for all references

3.

ABREVIATIONS FBH MDS NDT WT CTOD

Flat Bottom Hole Material Data Sheet Non Destructive Test Wall Thickness Crack Tip Opening Displacement

Project n° - Unit

XXXX

4.


SP

5103

0003

Rev.

Page

1

4/9

MATERIAL DATA SHEET 4.1

MDS W6 SS

MATERIAL DATA SHEET

MDS W6 SS Sheet 1/2

TYPE OF MATERIAL: ASTM A694 F65 SCOPE and USAGE STEEL GRADE DESCRIPTION TO BE REPORTED ON THE DRAWINGS

APPLICABLE STANDARDS

STEEL MAKING PROCESS

CHEMICAL COMPOSITION

MECHANICAL PROPERTIES

This MDS specifies the requirements for the fabrication of forged pieces for pressure containing applications: - Sour Service - Minimum design temperature above or equal to -20°C. ASTM A694 F65 F65 as per MDS W6 SS

ASTM A694 : Standard Specification for Carbon and Alloy Steel Forgings for Pipe Flanges, Fittings, Valves, and Parts for High-Pressure Transmission Service ASTM A370 : Standard Test Methods and Definitions for Mechanical Testing of Steel Products ASTM A388 : Standard Practice for Ultrasonic Examination of Heavy Steel Forgings ASTM A751 : Standard Test Methods, Practices, and Terminology for Chemical Analysis of Steel Products ASTM E8 : Standard Test Method for Tension Testing of Metallic Materials ASTM E10 : Standard Test Method for Brinell Hardness of Metallic Materials ASTM E23 : Test Methods for Notched Bar Impact Testing of Metallic Materials ASTM E709 : Standard Guide for Magnetic Particle Testing All steel supplied shall be made by the basic oxygen steelmaking process or the electric arc furnace method. All steel shall be fully killed and made to fine grain practice. After forging, forged pieces shall be quenched and tempered Forging ratio 1:4 minimum On C Mn Si Cr Al Mo P S Ni Va Cu CEV casting 0.16 1.5 0.4 0.25 0.06 0.3 0.025 0.025 0.8 0.06 0.30 0.42 (max) The sum of Cr + Mo + Cu < 0.5% ASTM A 694 F65 Ambient Mechanical characteristics -20°C Remarks temp. YS MPa Yield stress at 0.2% 450 min. / UTS MPa Ultimate tensile stress 530 min. / YS/ / Ratio UTS / YS 0.89 max. / UTS A % Elongation 20 min. /

KV

Average

/

50J

Individual

/

40J

J

Nota : only one value can be inferior to the average. Temperature -20°C unless otherwise specified in the other Purchase Order documents

175 min. / Sour service 235 max. Quenching and tempering heat treatment shall be performed on items after forging and premachining. H

HB

Hardness on surface

HEAT TREATMENT Item shall be pre-machined to near the final dimension prior Q+T heat treatment. Tempering temperature shall be above 590°C

Project n° - Unit

XXXX

MATERIAL DATA SHEET TYPE OF MATERIAL: ASTM A694 F65

PRODUCTION TESTING

NDT

DIMENSIONAL INSPECTION

PACKING

MARKING

CERTIFICATE


SP

5103

0003

Rev.

Page

1

5/9

MDS W6 SS Sheet 2/2

Test Number Requirement Standard / Spec Criteria Chemical 1 per cast Certificate review / Cast ASTM A 751 See above analysis analysis Following tests to be performed per heat treatment batch, cast number and forging size. They shall be taken on a prolongation or on a sacrificial piece Tensile test 2 - Transversal and longitudinal ASTM A 370 See above - Taken at 1/3 of max. WT Impact tests 2 sets - Transversal and longitudinal ASTM A370 / See above - Notch perpendicular to the ASTM E23 surface - Taken at 1/3 of max WT Macrography / 1 Hardness: 2 x 3 survey at mid ASTM A 370 / See above Hardness HB thickness and 1.5mm below the ASTM E10 surface (inner and outer) Re-Tests In accordance to ASTM A694 ASTM A 370 Examination Number Requirement Standard / Spec Criteria Visual Each item 100% after final machining / ASTM A961 MagneticEach item 100% + bevel after final ASTM E 709 / - No crackparticle or dye machining E1417 like penetrant indications examination - No linear indication - Rounded indication <3mm Ultrasonic Each item 100% after heat treatment ASTM A 388 Straight examination beam : FBH 3mm Angle beam: 60° V notch 5%WT Hardness Each item 4 measurements per item ASTM E10 See above minimum (after final machining) Defect / By grinding then magneticASTM A961 removal particle inspection or dye penetrant testing All NDT must be realized by qualified technician, at least level II ASNT TC 1A or equivalent. Control Type Number Requirement Standard / Spec Criteria Dimensional Each Item Dimensions on drawing / Drawings and standards Unless otherwise specified in the Purchase Order documents, the following minimum requirements shall apply: Weld bevel to be protected by caps Flange contact faces to be protected against corrosion and mechanical damages Unless otherwise specified in the Purchase Order documents, the following minimum requirements shall apply: Heat / item number Steel grade Mill name/mark Use of low stress stamp EN 10 204 Type 3.1

Project n° - Unit

XXXX

4.2


SP

5103

0003

Rev.

Page

1

6/9

MDS W6 NS

MATERIAL DATA SHEET

MDS W6 NS Sheet 1/2






This MDS specifies the requirements for the fabrication of forged pieces for pressure containing and structural applications : - Non-sour Service or structural - Minimum design temperature above or equal to -20°C. ASTM A694 F65 F65 as per MDS W6 NS

ASTM A694 : Standard Specification for Carbon and Alloy Steel Forgings for Pipe Flanges, Fittings, Valves, and Parts for High-Pressure Transmission Service ASTM A370 : Standard Test Methods and Definitions for Mechanical Testing of Steel Products ASTM A388 : Standard Practice for Ultrasonic Examination of Heavy Steel Forgings ASTM A751 : Standard Test Methods, Practices, and Terminology for Chemical Analysis of Steel Products ASTM E8 : Standard Test Method for Tension Testing of Metallic Materials ASTM E10 : Standard Test Method for Brinell Hardness of Metallic Materials ASTM E23 : Test Methods for Notched Bar Impact Testing of Metallic Materials ASTM E709 : Standard Guide for Magnetic Particle Testing All steel supplied shall be made by the basic oxygen steelmaking process or the electric arc furnace method. All steel shall be fully killed and made to fine grain practice. After forging, forged pieces shall be quenched and tempered Forging ratio 1:4 minimum On C Mn Si Cr Al Mo P S Ni Va Cu CEV casting 0.16 1.5 0.4 0.25 0.06 0.3 0.025 0.025 0.8 0.06 0.30 0.42 (max) The sum of Cr + Mo + Cu < 0.5% ASTM A 694 F65 Ambient Mechanical characteristics -20°C Remarks temp. YS MPa Yield stress at 0.2% 450 min. / UTS MPa Ultimate tensile stress 530 min. / YS/ / Ratio UTS / YS 0.89 max. / UTS A % Elongation 20 min. /

KV

Average

/

50J

Individual

/

40J

J

Nota : only one value can be inferior to the average. Temperature -20°C unless otherwise specified in the other Purchase Order documents

175 min. / Non-sour Service 270 max. Quenching and tempering heat treatment shall be performed on items after forging and premachining. H

HB

Hardness on surface


Project n° - Unit

XXXX


PRODUCTION TESTING

NDT


PACKING

MARKING

CERTIFICATE


SP

5103

0003

Rev.

Page

1

7/9

MDS W6 NS Sheet 2/2


Project n° - Unit

XXXX

4.3


SP

5103

0003

Rev.

Page

1

8/9

MDS W5 NS

MATERIAL DATA SHEET

MDS W5 NS Sheet 1/2






This MDS specifies the requirements for the fabrication of forged pieces for pressure containing and structural applications : - Non-sour Service or structural - Minimum design temperature above or equal to -20°C. ASTM A694 F52 F52 as per MDS W5 NS

ASTM A694 : Standard Specification for Carbon and Alloy Steel Forgings for Pipe Flanges, Fittings, Valves, and Parts for High-Pressure Transmission Service ASTM A370 : Standard Test Methods and Definitions for Mechanical Testing of Steel Products ASTM A388 : Standard Practice for Ultrasonic Examination of Heavy Steel Forgings ASTM A751 : Standard Test Methods, Practices, and Terminology for Chemical Analysis of Steel Products ASTM E8 : Standard Test Method for Tension Testing of Metallic Materials ASTM E10 : Standard Test Method for Brinell Hardness of Metallic Materials ASTM E23 : Test Methods for Notched Bar Impact Testing of Metallic Materials ASTM E709 : Standard Guide for Magnetic Particle Testing All steel supplied shall be made by the basic oxygen steelmaking process or the electric arc furnace method. All steel shall be fully killed and made to fine grain practice. After forging, forged pieces shall be quenched and tempered Forging ratio 1:4 minimum On C Mn Si Cr Al Mo P S Ni Va Cu CEV casting 0.16 1.5 0.4 0.25 0.06 0.3 0.025 0.025 0.8 0.06 0.30 0.42 (max) The sum of Cr + Mo + Cu < 0.5% ASTM A 694 F52 Ambient Mechanical characteristics -20°C Remarks temp. YS MPa Yield stress at 0.2% 360 min. / UTS MPa Ultimate tensile stress 455 min. / YS/ / Ratio UTS / YS 0.85 max. / UTS A % Elongation 22 min. / KV

Average

/

50J

Individual

/

40J

J

Nota : only one value can be inferior to the average. Temperature -20°C unless otherwise specified in the Purchase Order documents

140 min. / Non-sour Service 270 max. Quenching and tempering heat treatment shall be performed on items after forging and premachining. H

HB

Hardness on surface


Project n° - Unit

XXXX


PRODUCTION TESTING

NDT


PACKING

MARKING

CERTIFICATE


SP

5103

0003

Rev.

Page

1

9/9

MDS W5 NS Sheet 2/2




APPENDIX G JOB SPECIFICATION FOR PAINTING OF INSTALLATION AIDS


5890-000-SP-5103-001_A.docx

Project n° - Unit

XXXX


SP

5101

0002

Rev.

Page

0

1 / 11

JOB SPECIFICATION PAINTING OF INSTALLATION AIDS


0

10/09/2010

For application

A.BOUARIB

O.LE GUENNEC

S.ROUTEAU

Rev

Date DD/MM/YY

STATUS






Project n° - Unit

XXXX


SP

5101

0002

Rev.

Page

0

2 / 11

CONTENTS

1.

SCOPE

3

1.1

DEFINITIONS AND ABBREVIATIONS

3

2.

REFERENCE

4

2.1.1 CODES AND STANDARDS

4

3.

GENERAL REQUIREMENTS

4

3.1

Health and Safety Requirements

5

3.2

Coating System Requirements

6

3.2.1 COATING SYSTEM SELECTION

6

3.3

Coating procedure

7

4.

SURFACE PREPARATION

7

4.1

Degreasing / Cleaning

7

4.2

Ambient Conditions

8

4.3

Abrasives

8

4.4

Blasting Equipment

8

4.5

Blast Cleaning

8

5.

COATING APPLICATION

8

5.1

Storage of Coating Materials

8

5.2

Application of the Coating

9

6.

INSPECTION & TESTING

9

6.1

Requirements

10

6.2

Production & Inspection Testing

10

6.2.1 SHELF LIFE OF PRODUCT

10

6.2.2 CLIMATIC CONDITIONS

10

6.2.3 SURFACE PREPARATION

10

6.2.4 SOLUBLE SALT CONTAMINATION

10

6.2.5 DRY FILM THICKNESS

11

6.3

Access & Facilities

11

7.

DOCUMENTATION

11


Project n° - Unit

XXXX

1.


SP

5101

0002

Rev.

Page

0

3 / 11

SCOPE This specification defines the requirements governing the protective painting. It determines the surface preparation, application conditions, coating system, paint product selection and inspection requirement. This specification is applicable to external surfaces steel of installations aids. Equipment such as installation aids have a life period up to 2 years approximately.

1.1

DEFINITIONS AND ABBREVIATIONS CS

Carbon Steel

DC

Direct Current

DFT

Dry Film Thickness

HSE

Hygiene Security and Environment

NDFT

Nominal Dry Film Thickness

QA/QC

Quality Activities / Quality Control

SSPC

Steel Structures Painting Council (US)

SUBCONTRACTOR

Supplier responsible of the painting of the equipment

TDFT

Total Dry Film Thickness

VOC

Volatil Organic Compound

WFT

Wet Film Thickness

The following definitions are used in the present document: Can

Verbal form used for statements of possibility and capability, whether material, physical or casual

Degreasing

Application of an alkali detergent

Fresh water

Industrial fresh water

Fresh water washing

High pressure fresh water washing

May

Verbal form used to indicate a course of action permissible within the limits of the standards.

Shall

Verbal form used to indicate requirements strictly to be followed in order to conform to the standard and form which no deviation is permitted, unless accepted by all approved parties (COMPANY, CONTRACTOR and SUBCONTRACTOR)

Should

Verbal form used to indicate that among several possibilities, one is recommended as particularly suitable, without mentioning or excluding others, or that a certain course of action is preferred but not necessary required.

Soluble salt contamination


Pollution of the surface to be painted by soluble salts of any origin

Project n° - Unit

XXXX

2.

REFERENCE

2.1.1

Codes and Standards


SP

5101

Rev.

Page

0

4 / 11

0002

The codes and standards listed below form an integral part of this Specification. Unless otherwise stipulated, the applicable version of these documents, including relevant appendices and supplements, is the latest revision published at the EFFECTIVE DATE of the CONTRACT. Document Title Paints and varnishes -- Corrosion protection of steel structures by protective paint systems -- Part 3: Design considerations Paints and varnishes -- Corrosion protection of steel structures by protective paint systems -- Measurement of, and acceptance criteria for, the thickness of dry films on rough surfaces Preparation of steel substrates before application of paints and related products -- Visual assessment of surface cleanliness -- Part 1: Rust grades and preparation grades of uncoated steel substrates and of steel substrates after overall removal of previous coatings Preparation of steel substrates before application of paints and related products -- Tests for the assessment of surface cleanliness -- Part 3: Assessment of dust on steel surfaces prepared for painting (pressuresensitive tape method) Preparation of steel substrates before application of paints and related products -- Tests for the assessment of surface cleanliness -- Part 6: Extraction of soluble contaminants for analysis -- The Bresle method Preparation of steel substrates before application of paints and related products -- Tests for the assessment of surface cleanliness -- Part 9: Field method for the conductometric determination of water-soluble salts Preparation of steel substrates before application of paints and related products -- Surface roughness characteristics of blast-cleaned steel substrates Solvent Cleaning 3.

Document No. ISO 12944-3 ISO 19840

ISO 8501-1

ISO 8502-3

ISO 8502-6

ISO 8502-9

ISO 8503 SSPC SP1

GENERAL REQUIREMENTS SUBCONTRACTOR shall furnish all labour, materials and equipment necessary for the cleaning, surface preparation, coating and inspection of the coated subsea equipments in accordance with this specification. All structure and equipment shall be manufactured according to ISO 12944-3 to avoid any problem during surface cleaning or coating application. It is the responsibility of SUBCONTRACTOR to meet the requirements of this specification, to use equipment capable of meeting the requirements and to perform all inspections necessary to ensure compliance. SUBCONTRACTOR shall ensure all surface preparation, paint application and control operations are supervised and inspected by qualified personnel.


Project n° - Unit

XXXX


SP

5101

0002

Rev.

Page

0

5 / 11

The following areas are not to be painted as a general rule, however some exceptions may be specified on painted structure drawing (in case of conflict, the information found in the drawing and/or the manufacturing specification of the equipment shall prevail over the listed below): •

Internal part of hollow beams,

•

Equipment, name or special instruction plates attached to or included as part of any unit,

•

Valve stems, movable linkages or any similar surfaces that are normally lubricated or have close working tolerances,

•

Threaded connections, flange faces and groove areas shall not be painted; they shall be covered with grease or with a protective film. Wooden covers shall be placed on each flange face to prevent them from damage,

•

The area under washers and nuts shall not be painted but protected with grease or with a protective film,

•

Clamp connectors mating faces, clamp interface with hub and at the bevel for the weld,

•

Sacrificial anodes (Anode support not to be painted),

•

Where weld bevels are left unpainted for future welding, a protective film shall be applied on the bare metal.

All items that have been previously shop coated shall not be blasted except for a welding area or large damaged parts. 3.1

Health and Safety Requirements The methods and materials used shall meet the applicable health and safety regulations. In particular the relevant health and safety data sheets for the used coating shall be adhered to and shall be available for reference at all times. SUBCONTRACTOR shall also ensure that the surface preparation and coating is carried out in a safe working environment, particularly when coating inside enclosed spaces. All blast cleaning and spray-coating equipment shall be continuously electrically bonded from the nozzle to the surface being painted and backwards from the nozzle to the compressor, which shall be earthed. In hazardous areas, SUBCONTRACTOR shall use non-spark tools for cleaning purposes and flameproof equipment shall be compulsory. All work performed under this specification shall be conducted in accordance with all health, safety an environmental regulation that is applicable to the work site and the following materials shall be prohibited: •

abrasive containing silica (e.g. sand)

•

coating containing heavy metals, such as arsenic, barium, cadmium, lead, mercury, silver, chromium and selenium.

•

coating containing substances recognized for being carcinogenic (e.g. chromate pigments, coal tar).

•

coating containing asbestos.

Additionally, Compliance of coating products with the VOC “Volatil Organic Compounds” regulation of the place of application is required.


Project n° - Unit

XXXX

3.2


SP

5101

0002

Rev.

Page

0

6 / 11

Coating System Requirements The applied coating systems shall conform to the following requirements:

3.2.1

•

Each coating system shall be selected in accordance with Table 1 of this specification for the appropriate scope of work;

•

SUBCONTRACTOR shall provide documentation verifying the suitability of the coating to meet the requirements of this specification.

•

Each coating deposit / layer shall be of a contrasting colour when feasible;

•

Marking colour and equipment top coat colour coding shall be yellow RAL 1003 (or approached shade) or in accordance with drawings,

•

SUBCONTRACTOR shall also ensure that the necessary health and safety procedures are rigorously applied when coating inside enclosed spaces.

•

Inspections and tests shall fulfil the requirement of the paragraph 6 of this specification.

•

When touch-up is necessary, coatings should be repaired with the same coating system.

Coating System selection Coating system for external surfaces of installation aids shall be selected as follows:

3.2.1.1

Coating System N° T01 (for exposure up to 12 months) Surface preparation:

Abrasive blasting Sa 2 ½ in accordance with ISO 8501-1 Surface profile: 50 to 75µm (Rz) or “Medium (G)” as per ISO 8503

Operating temperature:

Ambient FIRST COAT


CARBOLINE

CARBOGUARD 890

200µm

HEMPEL

HEMPADUR 4514 (1 or 3)

175µm

INTERNATIONAL

INTERSEAL 670HS

150µm

JOTUN

JOTAMASTIC 87

200µm

PPG

SIGMACOVER 630

200µm

Project n° - Unit

XXXX

3.2.1.2


SP

5101

Rev.

Page

0

7 / 11

0002

Coating System N° T02 (for exposure up to 2 years appreciatively) Surface preparation:

Abrasive blasting Sa 2 ½ in accordance with ISO 8501-1 Surface profile: 50 to 75µm (Rz) or “Medium (G)” as per ISO 8503

Operating temperature:

Ambient

FIRST COAT

3.3

SECOND COAT

CARBOLINE

CARBOGUARD 890

150µm

CARBOGUARD 890

150µm

HEMPEL

HEMPADUR 45540

200µm

HEMPADUR 4514 (1 or 3)

100µm

INTERNATIONAL

INTERSEAL 670HS

150µm

INTERSEAL 670HS

150µm

JOTUN

JOTACOTE UNIVERSAL

250µm

PENGUARD TOPCOAT

50µm

PPG

SIGMACOVER 630 ALU

150µm

SIGMACOVER 630

150µm

Coating procedure Prior to coating application, SUBCONTRACTOR shall submit for approval, a detailed coating procedure that he proposes to use for the application and repair of subsea coatings. This document shall describe the procedures to be followed before, during and after coating application.

4.

SURFACE PREPARATION Prior blast cleaning, the surface of the metal shall be inspected for any discontinuities or defects. Any major surface defects, particularly surface laminations or scabs detrimental to the protective coating system shall be removed by suitable hand tool grinding. Surface pores, cavities etc. shall be removed by suitable grinding or weld repair. Welds shall be free from porosity and shall have a smooth profile, without sharp edges or recesses. SUBCONTRACTOR shall suitably mask the equipment to ensure that no damage shall come to susceptible areas such as threads and seal surfaces, etc. All masked areas shall be done in accordance with CONTRACTOR general arrangement drawings. If there is any doubt as to which areas are to be masked then SUBCONTRACTOR shall contact CONTRACTOR / COMPANY for clarification.

4.1

Degreasing / Cleaning A suitable degreasing solvent or emulsion cleaner shall be used for removal of grease and oil in accordance with SSPC-SP 1. Slow evaporating solvents such as paraffin shall not be permitted.


Project n° - Unit

XXXX

4.2


SP

5101

0002

Rev.

Page

0

8 / 11

Ambient Conditions Blast cleaning shall only take place when air humidity is below 85%, when the steel temperature is at least 5°C and 3°C above the dew point. Following blasting, these conditions shall be maintained until coating application is completed. Any blasted surfaces, which are exposed to humidity levels above 85% or temperatures less than 3°C above the dew-point, shall be re-blasted. If necessary, to maintain surface temperature above the specified criterion, a non-contaminating heat source may be used.

4.3

Abrasives All abrasive grit shall be clean, dry and free from contaminants such as chlorides and shall not be re-used unless they are processed through proprietary recycling equipment before re-use.

4.4

Blasting Equipment SUBCONTRACTOR shall ensure that the blasting equipment is in good condition and is able to meet the requirements of this specification. The air compressor shall be capable of supplying a continuous flow of air volume at the nozzle of each blast gun.

4.5

Blast Cleaning The minimum acceptable surface preparation standard shall be as a minimum grade Sa 2 ½ in accordance with ISO 8501-1. The type and size of abrasive grit shall be selected such that the required surface profile shall be achieved. The particles type and size shall be selected to achieve an angular surface profile of 50µm to 85µm (Rz) or Medium “G” in accordance with ISO 8503 standard. All dust, grit, shot, etc. shall be removed before coating application. The dust level shall be thoroughly checked in accordance with ISO 8502-3 (level 2 is the maximum allowable). The contamination surface level, including chloride, shall be done in accordance with ISO 8502-6 & 9 and shall not exceed a maximum of 30 mg/m2. The maximum time between blasting and coating shall not exceed four (4) hours and shall be such that no signs of re-rusting or contamination occur. This requirement may be relaxed if the work is fully enclosed, the ambient temperature is above 10°C and the humidity is below 85%. If this time is elapsed and previous conditions cannot be justified, all equipment surfaces shall be re-blasted.

5.

COATING APPLICATION

5.1

Storage of Coating Materials The coating materials shall be stored according to the Painting Manufacturer’s recommendations. They shall be clearly marked with the Painting manufacturer name, batch number and shelf life. If any portion of the coating shows sign of degradation then it shall be discarded. In addition no coatings that have exceeded their shelf life shall be used. The contents of each container shall be thoroughly mixed by a mechanical method only according to the Painting Manufacturer’s recommendations. For a two-component system then only the amount that can be used shall be mixed by a mechanical method only. Air agitation of the pots is not permitted. Thinning is permitted only when specified by the Painting Manufacturer’s, and then in accordance with their instructions.


Project n° - Unit

XXXX

5.2


SP

5101

0002

Rev.

Page

0

9 / 11

Application of the Coating The coating shall be applied in accordance with the Painting Manufacturer’s recommendations and shall usually be by airless spraying. Each layer of coating shall be applied evenly and shall be free from defects such as runs, pin-holes or bubbles, etc. The environmental conditions during application shall be recorded. Coating application is not permitted if the relative humidity, or if the ambient temperature is outside of the range specified by the Painting Manufacturer’s recommendations. Unless otherwise stated by CONTRACTOR / COMPANY, coating shall not take place under the following conditions: •

If the weather is rainy or foggy, except under shelter, and subject to verification of the atmospheric conditions,

•

If the ambient temperature is below 10°C,

•

If the relative humidity is >85%,

•

Metal surface temperature < 3°C above the ambient dew point,

•

Outside daylight hours on field site locations.

Strip coat shall be applied by brush to all angles, corners, sharp edges, etc. with the same product than is to be applied on the surface to be painted. The cure time between coats shall be as per the Painting Manufacturer’s recommendations. The cure times specified prior to handling shall be adhered to. The wet film thickness WFT shall be spot checked by comb gauge in random areas as a means of indicating whether or not the required dry film thickness DFT is to be achieved. WFT shall be in accordance with the requirements of the Painting Manufacturer’s. DFT of each individual coat and of the total coating system shall be checked by magnetic thickness gauge. The gauge shall be calibrated, at least twice daily using (a) foils in the thickness range being measured and (b) over steel plate with a surface profile representative of that being achieved in practice. The wet film thickness (WFT) shall be controlled during painting application. Dry film thickness (DFT) of each coat shall be checked by SUBCONTRACTOR according to ISO 19840 and shall be recorded. 6.

INSPECTION & TESTING Prior to the commencement of any work, CONTRACTOR / COMPANY shall approve all coating and inspection procedures. SUBCONTRACTOR shall provide an inspection and test plan (ITP) for CONTRACTOR / COMPANY approval prior to the commencement of any coating. This ITP shall include the definition of the frequency of testing and all witness and survey requirements. ITP shall contains as a minimum the following test type with their frequency and acceptance criteria : environmental condition, abrasive testing, visual inspection of blasting cleanliness, soluble salts test, roughness, visual examination of coating and dry film thickness measurements for each coat.


Project n° - Unit

XXXX

6.1


SP

5101

0002

Rev.

Page

0

10 / 11

Requirements All test equipments shall be regularly and routinely recalibrated. All inspection and test results shall be recorded and shall be maintained by SUBCONTRACTOR. A copy of all calibration device certificates shall be attached in As-Build dossier. The original of quality certificate supplied with each batch of abrasive shall be retained by SUBCONTRACTOR and shall be included in the As-Build dossier. This certificate shall contain as a minimum the following information: batch number, type, origin, chemical composition, density, hardness, conductivity. It shall be verified that Incoming painting material batch certificates are in compliance with painting material manufacturer’s specification. Certificates shall contain as a minimum: Name of manufacturer, Brand, type and name, the batch number, production date, quantity, expiry date and storage temperature limits. Ambient temperature, humidity, and metal surface temperature shall be recorded for each separate equipment or sub-assembly, etc., or at least three (3) times per shift, whichever is the more frequent.

6.2

Production & Inspection Testing Before any test, all measuring equipments, etc., shall be calibrated. The following test shall be applied for each equipment coated in accordance with this specification. In case of suspicions on the applied test method, unscheduled tests could be carried out.

6.2.1

Shelf life of product Verify that shelf life of painting products is not exceeded. Painting products having exceeded their shelf life shall be discarded. Product certificates and batch numbers shall be recorded.

6.2.2

Climatic conditions Relative humidity and air temperature shall be permanently checked (as a minimum before start of each shift and twice per shift). Substrate temperature shall also be tested in order to confirm that it is more than 3°C above the dew point. Relative Humidity shall be less than 85%, ambient and substrate temperatures above 10°C.

6.2.3

Surface preparation - The degree of surface cleanliness shall be checked in accordance with ISO 8501-1 and shall not be less than Sa 2 ½. - The presence of dust before paint application shall be checked according to ISO 8502-3, in such a way that the particle quantity and particle size shall not exceed rating 2. - Surface profile shall be assessed with test e.g. Press-O-Film and a calibrated micrometer (according to ISO 8503) or by using an ISO-Comparator. Measured roughness shall be in range 50µm to 85µm (Rz) or equivalent to Medium “G” in accordance with ISO 8503-2.

6.2.4

Soluble salt contamination Testing for chloride and soluble salt concentrations shall be done after surface preparation using Bresle test according to ISO 8502-6. The maximum content of soluble impurities of the blasted surface shall not exceed a conductivity corresponding to a NaCl content of 30mg/m² (measured in accordance with ISO 8502-9). If the requirements is not achieved surface shall be cleaned with fresh water and re-prepared.


Project n° - Unit

XXXX

6.2.5


SP

5101

0002

Rev.

Page

0

11 / 11

Dry Film Thickness The dry film thickness of individual paint coatings and the total system shall be checked in accordance with ISO 19840 and shall comply with all following criteria: - No measurement shall be below 80% of specified nominal dry film thickness (NDFT), - Maximum 20% of the measurements shall be between 80% of NDFT and NDFT, - The average of all measurements shall be equal or above NDFT. - Maximum dry film thickness shall not exceed the tolerance of fabrication or the recommendations of the Coating Manufacturer. If the required DFT is not achieved, an additional coat of the same product and colour will be applied to meet the DFT requirement. If the overall thickness is higher than the maximum thickness allowed by the Coating Manufacturer, then the system shall be blasted off and re-applied.

6.3

Access & Facilities Access and facilities shall be provided for CONTRACTOR / COMPANY in order to be able to carry out intended monitoring/inspection duties and reasonable notice shall be given before commencement of any surface preparation and painting work.

7.

DOCUMENTATION Prior to commence the work, a procedure shall be submitted for approval. A daily log must be prepared by SUBCONTRACTOR, and shall record, as a minimum; • Temperature and humidity during blasting and coating, • Surface preparation quality and profile; • Dry film thickness measurements; • Time interval between blasting and coating and between coating layers; • Identification of equipment(s) being coated; • Receipt and correct storage of coating materials including batch numbers and product reference numbers; • Results of all inspections and tests; • Calibration of inspection instruments; • Repairs or other further work necessary.




APPENDIX H JOB SPECIFICATION FOR WELDING AND NDE REQUIREMENT FOR PRESSURE VESSELS ACCORDING TO ASME


5890-000-SP-5103-001_A.docx

Project n° - Unit


XXXXX-0000 SP

5254

001

Rev.

Page

0

1 / 21

JOB SPECIFICATION FOR SUPPLY OF PRESSURE VESSELS ACCORDING to ASME Code

WELDING AND NDE

OF

PRESSURE VESSELS

ACCORDING to ASME Code


0

20/07/2010

IFR

J.QUERE

B.SANCHEZ

S.ROUTEAU

Rev

Date DD/MM/YY

STATUS

Written By (name & visa)

Checked by (name & visa)

Approved By (name & visa)

Sections changed in last revision are identified by a vertical line in the left margin

Project n° - Unit

XXXXX-0000 SP


5254

001

Rev.

Page

0

2 / 21


CONTENTS

1.

SCOPE

3

2.

REFERENCE DOCUMENTS

3

3.

WELDING DATA BOOK

4

4.

WELDERS QUALIFICATION

7

5.

WELDING PROCESSES

7

6.

WELDING CONSUMABLES

8

7.

WELD JOINT PREPARATION

10

8.

FABRICATION

11

9.

TESTING

14

10.

QUALITY REQUIREMENTS FOR WELDING

19

ATTACHMENT 1: PRESSURE VESSELS WELDING KEY FORM

20

ATTACHMENT 2 : PRESSURE VESSELS TESTING KEY FORM

21

Project n° - Unit

XXXXX-0000 SP


5254

001

Rev.

Page

0

3 / 21


1.

SCOPE

1.1

INTRODUCTION The present Project Procedure is established for the implementation of the Carbon Steel Pressure Vessels for the Subsea projects such as Mid Water Arch, Buoyancy tanks…etc.

1.2

SCOPE This Specification defines the welding, heat treatment, non-destructive examination, and testing requirements for Carbon Steel Pressure Vessels, and tanks, including equipment within VENDOR package.

1.3

PURPOSE This Specification supplements the Codes listed in Section 2.0, the PROJECT Equipment Specifications, the PROJECT equipment data sheets/drawings and any applicable licensor specifications. This specification primarily refers to pressure containing equipment according ASME VIII Div 1 & 2 code.

1.4

DEFINITIONS For the purpose of this specification, the following definitions shall apply COMPANY: TECHNIP’s client. CONTRACTOR: TECHNIP. MANUFACTURER/VENDOR/SUPPLIER: The party(s) which manufactures and/or supplies equipment and services to perform the duties specified by the CONTRACTOR. The word "Shall" is to be understood as mandatory.

2.

REFERENCE DOCUMENTS

2.1

APPLICABLE CODES AND STANDARDS The following Codes and Standards, to the extent specified herein, form a part of this Specification. When an edition date is not indicated for a Code or Standard, the latest edition in force when the Purchase Order is awarded shall apply. (ASME) AMERICAN SOCIETY OF MECHANICAL ENGINEERS BOILER AND PRESSURE VESSEL CODE: Section II, Part A

Ferrous materials specification

Section II, Part C

Welding Rods, Electrodes, and Filler Metals

Section II, Part D

Material Properties

Section V

Non-destructive Examination

Section VIII, Div. 1

Pressure Vessels

Section VIII, Div. 2

Pressure Vessels

Section IX

Welding and Brazing Qualifications

SA20

Specification for General Requirements for Steel Plates for Pressure Vessels

Project n° - Unit


XXXXX-0000 SP

5254

001

Rev.

Page

0

4 / 21


(ASNT) AMERICAN SOCIETY OF NONDESTRUCTIVE TESTING: SNT-TC-1A

Recommended Practice for Non-destructive Testing Personnel Qualification and Certification

(ASTM) AMERICAN SOCIETY FOR TESTING AND MATERIALS: A240

Standard specification for heat-resisting chromium and chromiumnickel stainless steel plate, sheet and strip for pressure vessels

A370

Standard test methods and definitions for mechanical testing of steel products

A380

Practice for Cleaning and Descaling Stainless Steel Parts, Equipment and Systems.

E94

Guide for Radiographic Testing.

E142

Method for Controlling Quality of Radiographic Testing.

E165

Test Method for Liquid Penetrant Examination.

EUROPEAN COMMITTEE FOR STANDARDIZATION EN 10 204

Metallic Products - Types of Inspection Documents

EN 462-1

Image Quality Indicators (wire type)

EN 473

Qualification and Certification of NDT personnel.

EN 719

Welding coordination, Tasks and responsibilities

EN 729-2

Quality requirements for welding. Fusion welding of metallic materials. Comprehensive quality requirements

(AWS) AMERICAN WELDING SOCIETY: A3.0

Standard Welding Terms and Definitions

(API) AMERICAN PETROLEUM INSTITUTE API 582

Welding guidelines for the chemical and oil industries

(*) Last Edition for all Code Applicable 2.2

PROJECT SPECIFICATIONS The applicable PROJECT specifications are listed in the Material specification associated to the Purchase Order.

3.

WELDING DATA BOOK The VENDOR shall submit a detailed Welding Data Book to CONTRACTOR at the time of WPS/PQR submittal. Fabrication shall not start until the Welding Data Book is returned with agreement to proceed which in no way relieve the VENDOR of the responsibility of providing welds which are sound and suited for the services for which they are intended. The Welding Data Book shall include the following documents: ♦ A cover sheet with title block dedicated to the Project. ♦ A Weld map / Weld Key Form. ♦ Welding Procedure Specifications (WPS).

Project n° - Unit

XXXXX-0000 SP


5254

Rev.

Page

0

5 / 21

001


♦ Procedure Qualification Records (PQR). ♦ A NDE map with extensions of each NDE examination. 3.1

WELD MAP / WELD KEY FORM The Weld map / Weld Key form shall contain as a minimum the following information: ♦ Sketch of the equipment item. ♦ Design /Fabrication code with joint efficiency ♦ Material type(s) and grade(s) for each type of equipment component. ♦ WPS to be used for each type of joint of same design and similar thickness (i.e., longitudinal and circumferential seam, closing seam, typical large nozzle connection, typical small nozzle connection, fillet weld attachments and any back cladding, if applicable). ♦ Minimum Design Metal Temperature (MDMT) and whether impact-tested WPS is/are required according ASME ♦ Actual thickness where each WPS is to be used. ♦ P.W.H.T. requirements (process or code). Suggested weld map /Weld Key form is attached in Attachment 1.

3.2

WELDING PROCEDURE SPECIFICATION (WPS) Welding Procedure Specifications (WPS) and their supporting Procedure Qualification Records (PQR) shall conform to the requirements of ASME section IX and to the requirements of this specification Welding Procedure Specifications together with Procedure Qualification Records shall be submitted to CONTRACTOR prior to the start of fabrication. Welding shall not proceed until these documents are returned by CONTRACTOR with agreement to proceed. All Welding Procedure Specifications and Procedure Qualification Records for purchased items subcontracted by the VENDOR shall be reviewed by the VENDOR for content and contract compliance prior to submittal to CONTRACTOR. Each WPS shall be identified by a unique number and shall be identified on the welding map. Vendor can use its own WPS forms provided that complete welding data defines in ASME IX forms QW-482, and following information are included: a. Welding process or processes when more than one is used in making a complete joint. b. Parent metal specification and thickness. c. Joint preparation (sketch). d. Cleaning, degreasing, etc. e. Welding position (position of groove) and welding progression (upward, downward) f.

Weaving limitation

g. Brand name, AWS classification and size (diameter) of welding consumables. h. Pre-heating and interpass temperature, including method of heating and method of temperature measurement. i.

Travel speed

j.

Run Out Length for manual welding according ASME IX QW-409.1 (b) (2) below -46°C

Project n° - Unit

XXXXX-0000 SP


5254

001

Rev.

Page

0

6 / 21


k. Approximate number and arrangement of runs and weld dimensions (sketch). l.

Welding sequence.

m. Back gouging. n. Tack-welding requirements o. P.W.H.T. requirements including the detailed cycle of heat treatment, heating rate cooling rate, holding time and temperature. p. When welding quenched and tempered steels, low alloy steels or steel requiring impact testing the heat input in conjunction with the minimum/maximum interpass temperatures shall be restricted to the values shown in the supporting PQR. Heat input values shall be recorded on WPS and PQR.

Heat input in Joules/cm =

Amperage x Voltage x 60 Travel speed in cm/min

3.3

WELDING PROCEDURE QUALIFICATION TESTS

3.3.1

GENERAL

All welding procedures shall be qualified in accordance with the requirements of ASME IX, supplemented as follows: ♦ All welding procedure qualification tests shall be witnessed, or at least certified by an Independent Inspecting Authority approved by CONTRACTOR, unless the Vendor is holding a valid ASME code stamp. In that case VENDOR shall be authorised to qualify by himself the Welding Procedure Qualification and responsible to grant necessary PQR's qualification from ASME Authorised Inspector. ♦ For pressure vessels field closing seams, shop welding procedure qualification for field application may be acceptable provided field machine and associated equipment are identical to those used and ASME requirements followed for qualification and will require CONTRACTOR written approval.

Acceptable Independent Inspecting Authority are as follows: ♦ American Bureau of Shipping (ABS) ♦ Bureau Veritas (BV) ♦ Det Norske Veritas (DNV) ♦ Germanischer Lloyd ♦ Lloyds Register of Shipping ♦ Stoomwezen ♦ TÜV ♦ APAVE ♦ Institut de soudure / ASAP ♦ Hartford Steam Boiler

Any other agencies not listed above will require CONTRACTOR prior approval.

Project n° - Unit


XXXXX-0000 SP

5254

Rev.

Page

0

7 / 21

001


4.

WELDERS QUALIFICATION

Welders and welding operators shall be qualified in accordance with ASME Section IX. Welders and welding operators shall be qualified by a recognised Independent Inspection Authority, unless the Vendor is holding a valid ASME VIII code stamp. Welder's certificates shall be made available to the review of CONTRACTOR ’s Inspector. All welds shall be clearly marked with the welder's symbol. (unless otherwise agreed upon). Welder identification by die-stamping is not allowed on stress relieved welds and welds in stainless steel or non-ferrous materials. Welder identification on all other materials shall be by die-stamping. All other methods of welder identification requires prior CONTRACTOR approval. 4.1

WELDER PERFORMANCE REGISTRATION

In order to control and maintain the validation of performance qualification, a welder performance register shall be kept up to date by the VENDOR. This register should at least contain the following data: a. Welder’s name and stamp. b. Data of weld inspection and inspection results. c. Materials (base and consumable). d. Configuration data (diameter, wall thickness, position of welding, etc.). e. Reference to WPS used. f.

Qualification range, including welding position

5.

WELDING PROCESSES

5.1

ACCEPTABLE WELDING PROCESSES

For pressure retaining welds, following welding processes are acceptable: Welding processes

AWS Designation

Shielded Metal Arc Welding

SMAW

Gas Tungsten Arc Welding

GTAW

Automatic Submerged Arc Welding

SAW

Flux Cored Arc Welding

FCAW (See § 5.2.3)

Gas Metal Arc Welding

GMAW (See § 5.2.4)

5.2

WELDING PROCESS RESTRICTION

5.2.1

SHIELDED METAL ARC WELDING

Down hill progression shall not be allowed when using low hydrogen electrodes. The maximum width of weave shall not exceed three times the electrode core diameter. The heat input for SMAW shall be recorded and controlled by measuring the length of weld bead per unit length of electrode (run-out ratio) according ASME IX QW-409.1 (b) (2).

Project n° - Unit

XXXXX-0000 SP


5254

001

Rev.

Page

0

8 / 21


5.2.2

FLUX CORED ARC WELDING

Flux Cored Arc Welding (FCAW) is subject to the following provisions unless approved otherwise by CONTRACTOR: a. VENDOR must provide evidence of successful previous experience with this process. b. The flux-cored arc welding process is protected with external shielding gas. c. Application of FCAW process is limited to: ♦ Category A & B (as defined in ASME Code) for thickness below 12,5mm efficiency factor 0.85 and below. ♦ Category C & D (as defined in ASME Code) provided 100% UT examination is performed on shell thickness above 12,5mm. Applicable only for radial nozzle on category D joints.

d. For category D joints welded on shell thickness above 50 mm, first layers each side shall be welded with SMAW due to FCAW torch access limitations. Other application of FCAW process shall be subjected to CONTRACTOR prior approval and shall require, test coupon and additional NDE. Vendor shall inform on fabrication process of flux-cored wire (strip or tubular) and associated filler metal manufacturers recommendations for storage and handling with regards to moisture pick-up. FCAW is permitted on non-pressure retaining weld with external shielding gas. 5.2.3

GAS METAL ARC WELDING

For pressure retaining welds only machine (mechanized) GMAW shall be allowed subjected to CONTRACTOR prior approval. GMAW process application shall be limited to non-pressure parts in the spray transfer mode. However, GMAW process in the short-circuiting mode may be used for root passes, back welds, temporary attachments and other applications where the weld made by this process is completely removed or remelted. A proper parameter control is required to be demonstrated by VENDOR. 6.

WELDING CONSUMABLES

6.1

GENERAL

Filler metal shall be as specified in ASME Section II Part C or equivalent AWS Specification. Welding consumables shall be selected such as: ♦ The strength of deposited weld metal is at least equal to the specified minimum mechanical properties of the materials being welded in production. ♦ The principal elements in the deposited weld metal are similar to the nominal composition of the base metal.

When using the shielded metal arc welding process on ferritic material, only low hydrogen (< 10 ml / 100g) electrodes shall be used for all pressure retaining welds or attachments to pressure boundaries. Electrodes designated as "Rutile" or "cellulosic" shall not be acceptable for pressure retaining welds. All filler metals shall contain the principal elements in the wire, alloying via the electrode covering or the flux is not allowed. Carbon and low alloy steel electrodes/barewire that have a non-specific chemistry as indicated by a “G” classification suffix (i.e. EXXXX-G, ERXXX-G, EG, or EXXXTX-G) shall not be used unless welding procedure qualifications are carried out by referenced trade name as identified within the welding consumable supplier catalogue, and subjected to CONTRACTOR prior approval.

Project n° - Unit


XXXXX-0000 SP

5254

Rev.

Page

0

9 / 21

001


Solid wires for automatic welding processes shall contain the principal elements required for the deposited weld metal. Welds deposited by the submerged arc process shall not derive any principal elements from the flux. Alloy fluxes shall not be used as defined by ASME section II, Part C SFA 5.17 or 5.23. Manufacturer’s storage and baking requirements must be adhered to. Fluxes that the flux Manufacturer recommends for single pass welds shall not be used for multiple pass welds. Active fluxes are not permitted. Except for P No 1 steel without impact testing, the brand name of welding consumables (electrodes, rods, wire, flux cored, flux) shall be the same as used in the PQR. 6.2

WELDING CONSUMABLE CLASSIFICATION AND CERTIFICATION

Welding consumables used for pressure retaining parts shall be supported by Inspection Document, classification and schedule as specified in Table 2, unless otherwise specified in project specifications. Table 2 ASME IX

ASME II A SFA 5.01

Inspection document according EN 10204

P-No

P No 1

Classification

Schedule

C1, S1,T1,F1

F

Chemical Analysis

Mechanical Properties

3.1

6.3

WELDING CONSUMABLES SELECTIONS

6.3.1

PROVISIONS FOR THE USE OF WELDING CONSUMABLES TO WELD P NO 1 STEELS

2.2

Welding consumable shall be selected on the basis of the mechanical properties of the parent metal. Welding consumables shall conform to: ♦ ASME II C SFA-5.1 E7018 or E7016 classification for SMAW process ♦ ASME II C SFA-5.23 or SFA-5.17 for wire and flux combination ♦ ASME II C SFA 5.18 classification for bare wires for GTAW process

unless agreed by CONTRACTOR for: - Welds which will be subsequently normalized. - P No 1 with specified Yield Strength > 355 MPa. Gas tungsten arc welding rod shall conform to SFA 5.18 6.4

CONSUMABLE STORAGE

Welding consumables shall be stored with care, under dry conditions in their original unopened packing. After opening shipping containers of electrodes, fluxes and other welding materials, storage and handling shall be as specified in the Manufacturer's recommendations. Electrodes, filler wires or fluxes that are damaged, damp, greasy or oxidized shall not be used. All electrodes, which have been in direct contact with water, shall be definitely rejected. VENDOR’s facilities shall include a temperature and humidity controlled welding consumable and flux store, including holding and drying ovens.

Project n° - Unit

XXXXX-0000 SP


5254

001

Rev.

Page

0

10 / 21


Low hydrogen electrodes and fluxes shall be dried at 250°C/300°C for two hours prior to use, unless otherwise recommended by the electrodes manufacturer. Welding electrodes shall then be stored in ovens at a minimum temperature of 80 °C. When used for production they shall be placed in heated quivers capable of maintaining a minimum temperature of 75 °C. Above drying conditions do not apply to electrodes supplied in vacuum conditioning boxes unless un-properly stored and handled after opening. When using vacuum packed electrodes, each box shall be ink stamped with date and hour at opening. Electrodes shall be used within 4 hours after box opening. Carbon steel low hydrogen electrodes shall be used within 8 hours when stored in quivers. Electrodes stored in quivers, but not used within the specified time, shall be redried/rebaked in ovens. No electrodes shall be left lying about the site or in the shop. Electrodes so left shall be scrapped. Redried / rebaked electrodes shall be identified with paint color code. Electrodes can be rebaked maximum twice. Submerged arc flux shall be clearly identified in moisture-proof containers and shall be stored in a dry location at a temperature recommended by manufacturer. Submerged arc, gas metal arc and flux-cored wire shall be clearly identified and shall be stored in a dry location at a temperature recommended by manufacturer. The identification shall state manufacturer, grade and batch number. Unidentifiable wire shall not be used. Submerged arc, gas metal arc and flux-cored arc consumables shall be withdrawn from storage only when required for immediate use. Unused consumables shall be returned to storage on completion of the welding operation. The backing, issuance and return of welding consumables shall be formally recorded. Submerged arc flux may be recycled one time up but shall be free from fused flux, millscale, dirt or other foreign matter. Before reuse, the flux shall be re-baked in accordance with the manufacturer's instructions. 7.

WELD JOINT PREPARATION

All shell, head and nozzle joints shall be double welded butt joints with full penetration. Double welded groove joints shall have their root passes back gouged to sound metal on the reverse side before welding on that side. In case where double welding is impractical, the root pass shall be made by the Gas Tungsten Arc Welding (GTAW) process. When air arc gouging is used, the carburised and hardened surfaces shall be removed by grinding. Permanent backing rings and consumable inserts shall not be used. Temporary fabrication attachment welds on pressure shells shall be removed. The surface under such welds and under backing rings that have been removed shall be properly conditioned to eliminate surface stress risers. Such surfaces shall be inspected by the magnetic particle or liquid penetrant method in accordance with § 9.1 of this specification. Temporary attachments, backing rings or bars intended to be removed after weld completion shall match the analysis of the base metal. Filler metal used shall be the same as one used for permanent welds. Weld joint preparation shall be made by machining, grinding, or thermal cutting. When thermal cutting is performed, the edges shall be mechanically cleaned to sound metal prior to welding. Weld bevel preparation for carbon steel over 100 mm (4 in.) in thickness, quenched and tempered carbon steels, steels containing more than ½ percent chromium shall be machined, or ground back to clean and sound metal if they are flame or arc cut.

Project n° - Unit

XXXXX-0000 SP


5254

001

Rev.

Page

0

11 / 21


Surfaces for welding shall be clean and free from paint, oil, dirt, scale, oxides, and other foreign material detrimental to the integrity of the weld. Grinding wheels and wire brushes shall be used only for a single type of material. 8.

FABRICATION

8.1

GENERAL

Compliance with this Specification and authorization of WPS, PQR and weld map shall in no way relieve the VENDOR of the responsibility of providing welds suitable to the services for which they are intended. All tack welds shall be made in accordance with a previously approved welding procedure and shall be performed by qualified welders. Tack-welds shall be made in the weld groove, shall be performed with the same welding process and filler metal that is used for the root pass, and shall be specified in the welding procedure. Tack welds shall be of sufficient cross-section and length in order to avoid cracks, especially on high strength steel materials. Temporary welds for temporary handling attachments, lugs, etc..., shall be minimized. When temporary welding is deemed necessary, welding shall be performed with the same care, materials, electrodes, minimum preheat and procedures as for the main fabrication welding. The temporary welds shall subsequently be removed and ground flush with the base material, and then inspected by non-destructive methods (magnetic particle or dye penetrant). Any defect found during this inspection shall be removed and repaired by a qualified welder using welding procedures approved by the CONTRACTOR. The method of removing attachments shall not injure the metal surface (i.e. they shall not be removed by hammering off). Attachments such as lugs, clips, support rings and similar items shall not be located on or adjacent to a weld seam. Removable starting and stopping tabs shall be used for longitudinal welding where automatic welding processes are used. In case of circular weld preparation already bevelled before longitudinal welding, tabs shall be fit-up so as to ensure arc continuity between tabs and shell on the whole thickness. Weld techniques shall be selected to assure that specified tolerances for straightness and out-ofroundness are not exceeded. If such tolerances are not stated in the drawings, standards or specifications, the applicable section of the relevant code shall govern. Alignment tolerances of edges of butt joints shall be in accordance with ASME VIII Div. 1 UW 33. or ASME VIII Div. 2 §6.1.6. Cleaning of the surfaces to be welded shall be done in a manner that will not lead to contamination of the weld or base metal. Only stainless steel brushes and tools dedicated to stainless steel shall be used on stainless steels and nickel-alloyed materials. Peening is not permitted. Pneumatic cleaning of slag is not considered as peening. Adequate precautions shall be taken and suitable equipment shall be available on site or shop open areas in order to protect the welds (and welders) from adverse weather conditions (rain, wind...) at the time of welding. If weather conditions become too severe, welding operations shall be stopped. No welding shall be done on wet base materials. All pressure retaining welds shall be made in at least two passes Dimensional or straightening corrections after welding by means of local heating are not allowed.

Project n° - Unit

XXXXX-0000 SP


5254

001

Rev.

Page

0

12 / 21


8.2

WELD CONTOUR AND FINISH

8.2.1

WELD REINFORCEMENT

Weld reinforcement and finish shall be as required by ASME VIII Div. 1 UW 35 or ASME VIII Div. 2 § 6.2.4 and 6.6.5.5. Internal protrusion shall not exceed the reinforcement thickness specified by the applicable standard. Weld finish shall not impair the interpretation of NDT results. Code requirements regarding absence of coarse ripples, grooves, overlaps, abrupt ridges and valleys shall be strictly conformed to. For drain nozzles, internal weld reinforcement is not allowed. 8.2.2

ARC STRIKES

Arc strikes outside weld bevels shall be avoided. Should this occur, the deposit shall be carefully removed by mechanical means and the area shall be 100% examined by magnetic particle (on magnetic materials) or dye penetrant (on non magnetic materials). Repairs shall be in accordance with this Specification. 8.3

WELD REPAIRS

Prior to any repair work, the full size and location of each defect shall be identified by NDE and the cause established to prevent reoccurrence. Unacceptable discontinuities shall be completely removed by chipping, gouging, grinding, or other methods (for the type of material being repaired) to clean, sound metal, and the excavated area shall be examined by (MT) or (PT) to assure complete removal of defects. Repairs to correct weld defects shall be made using the same WPS used for the original weld or other previously authorized WPS. Depending on the repair configuration, a higher preheat may be necessary together with the use of a smaller diameter electrode. Two repair attempts will be allowed on any one defective area. No further attempts to repair shall be carried out without the authorization of the CONTRACTOR. For Duplex Stainless Steel only one repair attempt will be allowed on any one defective area. Repairs on Duplex are allowed only after CONTRACTOR permission. Weld repair procedures shall be submitted to the CONTRACTOR prior to equipment repair. The procedure shall state, as a minimum, the following information: ♦ Means of excavating defect from weld. ♦ NDE method used to verify complete defect removal. ♦ WPS used to fill excavated area (including preheating temperature to be used). ♦ NDE method used to verify repair weld is sound. ♦ Other required tests (PMI, Hydro Tests, etc.).

Welds containing cracks shall be subject to additional non-destructive testing (Ultrasonic or Magnetic Particle). Repair welding will only be permitted after consideration of the nature and cause of cracking. For partial repairs, the cut-out portion shall be sufficiently deep and long to remove the defect. At the ends and sides of the cut, there shall be a gradual taper from the base of the cut to the surface of the weld metal. The width and profile of the cut shall provide adequate access for re-welding. As a general rule and depending on size of weld repair, at least 50 mm of sound metal at either end shall be removed. Special care shall be taken to remove weld defects located at the root in order to obtain an acceptable root gap.

Project n° - Unit

XXXXX-0000 SP


5254

Rev.

Page

0

13 / 21

001


Preheating (where required) and interpass temperatures shall be maintained during all weld repairs. Following defects are classified as major and requires CONTRACTOR approval before proceeding:

8.4

-

Cracks in the first layer of a weld.

-

Any defect which is indicative of either a fundamental material problem or an out-of-control welding process.

-

A repair other than weld metal and plate edge lamination which require an excavation in excess of 10 % or 10 mm of the wall thickness whichever is less.

-

Any repair welding after PWHT

-

Any repair after hydrostatic pressure test

-

Plate edge lamination in excess of 25 mm.

PREHEAT/INTERPASS TEMPERATURE AND PWHT

Preheat temperatures shall be in accordance with ASME IX or ASME VIII Div 2 §6.4.1 Interpass temperature shall not exceed the one qualified for PQR. PWHT time and temperature shall be in accordance with ASME Section VIII Division 1 UCS 56 or Division 2 §6.4 (as applicable). The reduced temperature when permitted shall not be used without written authorization from the CONTRACTOR. PWHT shall be accomplished after all welds of the pressure boundary have been completed (including lugs or attachment welds). PWHT shall be performed in a furnace except for final closing welds, which may be Post weld Heat Treated locally. Internal Gas firing of equipment is not permitted unless otherwise agreed by CONTRACTOR. Thermocouples shall be flash welded or mechanically bonded to the equipment pressure boundary. The number and location of thermocouples shall be in accordance with the applicable ASME Code. A minimum of four thermocouples shall be used, attached to the thickest and thinnest weldments, at top and bottom of the pressure boundary and the test coupons if any. All thermocouple attachments shall be adequately insulated to avoid temperature misreading caused by the effect of radiation. When a production test coupon is to be heat-treated a thermocouple shall be attached to it. Temperature shall be continuously recorded. A chart of the heat up, soak and cool down while at temperature above 400°C (or 300 °C for vessels or components of 60 mm thickness or over or of complex shape) is required. Time intervals shall be recorded with temperature, and clearly indicated. Thread and gasket surfaces shall be suitably protected from excessive oxidation during heat treatment if applicable. PWHT procedures shall be submitted to the CONTRACTOR for review. PWHT procedures shall include as a minimum the following information: type of PWHT (furnace/local), place of PWHT (either shop or field), sequences of PWHT support types, number and locations, thermocouple types, number, method of attachment, locations and calibration method, full treatment cycle including heating and cooling methods, heating, cooling rates holding time and temperature.

Project n° - Unit

XXXXX-0000 SP


5254

001

Rev.

Page

0

14 / 21


9.

TESTING

NDE / Hardness / Production test coupons requirements, shall be as specified on CONTRACTOR’s equipment drawings, applicable code, PROJECT Specifications, Purchase Requisitions, or Purchase Orders and summarised in a “Testing key form”. Suggested “Testing Key form” is attached in Attachment 2. This “Testing Key form” shall be submitted for review together with VENDOR Quality Control plan to CONTRACTOR. 9.1

NON DESTRUCTIVE EXAMINATION (NDE)

9.1.1

EXTENT STAGE AND METHOD OF NDE

9.1.1.1

EXTENT According to ASME VIII Div 1:

Unless otherwise specified in data-sheet, process data sheet or guide drawing, extent of NDE shall be in accordance with ASME VIII Div 1 UW-12 supplemented by: -The Radiographic examination of welded seams shall be performed strictly in compliance with the contractual Codes and Standards and according to the requirements specified in CONTRACTOR's drawings. -In any case the Radiographic spot examination is required as minimum, unless otherwise specified. Spot examination shall not be less than 10% of each weld type. -When Radiographic spot examination is required, the points to be radiographied shall at least include all the T crosses between circumferential and longitudinal joints, as well as the welded seams in the torical section of the formed heads. -Magnetic particles spot examination (10% minimum) is required for each weld type i.e longitudinal, circumferential, branch connections. 100% MPI is required on permanent attachments to the shell. -For Thickness equal or greater than 50 mm, branch connection nozzles shall be examined by UT. For Thickness below 50 mm, only MT or PT shall be mandatory. -For thicknesses greater than 50 mm, the bevels prepared for welding shall be examined by MT. -After removing parts temporarily welded to the shell, the involved area shall be ground flush and checked by MT. - When PWHT is required the Radiographic examination (RT) shall be performed after PWHT. According to ASME VIII Div 2:

Unless otherwise specified in data-sheet, process data sheet or guide drawing, extent of NDE shall be in accordance with ASME VIII Div 2 Part 7. When PWHT is required the Radiographic examination (RT) shall be performed after PWHT. 9.1.2

NDE PERSONNEL QUALIFICATION

All NDE shall be performed by personnel certified in accordance with ASNT Recommended Practice SNT-TC-1A or equivalent such as the European norm EN 473 (according to construction code). All level III NDE personnel shall be experienced in pressure vessel inspection and hold independent certification by a scheme meeting the requirements of EN 473 or ISO 9712. Schemes such as PCN (Personnel Certification in Non-Destructive Testing), CSWIP (Certification Scheme

Project n° - Unit

XXXXX-0000 SP


5254

001

Rev.

Page

0

15 / 21


for Welding Inspection Personnel) or ACCP (ASNT Central Certification Program) are considered acceptable for all NDE techniques. Qualification and Certification by the employer is not permitted unless specifically approved by CONTRACTOR. Level I and Level II NDE personnel may be certified by the employer in accordance with the recommendations in SNT-TC-1A providing Level III NDE personnel responsible for the certification program meet the above noted requirements. Certification in accordance with SNTTC-1A shall cease once an NDE operator leaves the employer Interpretation of results shall be performed by personnel certified level II or III. 9.1.3

NDE PROCEDURES AND ACCEPTANCE CRITERIA

Non-destructive Examination (NDE) procedures and a NDE map shall be submitted to CONTRACTOR for review as required in Purchase Requisition. Examination shall not proceed until procedures are accepted by CONTRACTOR. All records pertaining to inspection and certification shall be available for review by CONTRACTOR’s Inspector. Acceptance criteria shall be as required in ASME Section VIII Division 1 UW 46 to 54 or ASME VIII Division 2 §7.5. 9.1.4

VISUAL EXAMINATION

Visual examination procedures shall be in accordance with ASME Section V, Article 9, and this Specification. All prepared surfaces shall be visually examined for fit-up and alignment as well as for soundness prior to welding. The surfaces examined shall be free from oil, grease, paint, rust, burrs, tears, or dirt. Visual examinations shall be performed on accessible surfaces of all completed welds and shall include a band of base metal at least 25 mm wide on each side of the weld. The surface under examination shall be viewed under white light of at least 1000 Lux intensity on the surface. Glare and reflections shall be avoided. 9.1.5

MAGNETIC PARTICLE EXAMINATION (MT)

Magnetic particle examination procedures shall be in accordance with the requirements and methods specified in ASME Section V, Article 7. The evaluation of indications and the acceptance criteria shall be in accordance with ASME Section VIII, Division 1 or 2. Magnetic particle examination of welds shall include a band of base metal at least 25 mm wide on each side of the weld. The surface shall be examined in at least two approximately perpendicular directions to detect defects lying in any orientation. For non-fluorescent particles, the surface under examination shall be viewed under white light of at least 1000 Lux intensity on the surface. Glare and reflections shall be avoided. Only magnetic yoke method with wet or fluorescent particles shall be used. Permanent magnetic probes shall not be permitted as well as magnetization accomplished by passing current through the part to be examined. For the wet particles method the surface to be inspected shall be coated with a white background paint of a fine consistency. Fluorescent particles shall be used to examine internal surfaces with black light. The surface under examination shall be viewed under UV-A (Black light) of at least 10W/m2 intensity on the surface. The background white light intensity shall not exceed 20 Lux. The black light intensity shall be measured with a black light meter.

Project n° - Unit

XXXXX-0000 SP


5254

001

Rev.

Page

0

16 / 21


Adequacy of magnetic field strength shall be verified by Magnetic particle field indicator. As a minimum the following shall be included in the MT procedure: scope, surface preparation, areas to be examined; stage(s) at which examined (i.e. after welding, after heat treatment, after hydrotest, etc.,); magnetizing technique (e.g. AC Yoke), equipment used, paint and magnetic ink trade name; frequency of calibration of equipment and test of bath strength; coverage and direction of magnetic field, measurement of field strength; application of examination media; acceptance level; reporting format; operator qualifications. 9.1.6

LIQUID PENETRANT EXAMINATION (PT)

Liquid penetrant examination procedures shall be in accordance with ASME Section V, Article 6. The evaluation of indications and the acceptance criteria shall be in accordance with ASME Section VIII, Division 1 or 2. Penetrant materials shall meet the requirements of ASME Section V, Article 6 for sulphur and halogen content regardless of the type of material to be examined. Liquid penetrant examination of welds shall include a band of base metal at least 25 mm wide on each side of the weld. The surface under examination shall be viewed under white light of at least 1000 Lux intensity on the surface. Glare and reflections shall be avoided. As a minimum the following shall be included in the PT procedure: scope, surface preparation; cleaning and drying; temperature limitations; cleaner, penetrant and developer trade name; penetrant application method and time; removal of excess penetrant; drying; application of developer; development time; acceptance level; reporting format; operator qualifications. 9.1.7

RADIOGRAPHIC EXAMINATION (RT)

9.1.7.1

GENERAL

Radiographic examination procedures shall be in accordance with the requirements and methods specified in ASME Section V, Article 2. Interpretation and acceptance criteria of radiographs shall be in accordance with Section VIII, Division 1 or 2. 9.1.7.2

RADIATION

For base metal thickness ≤ 10 mm radiographic examination shall be performed by X-Ray or Selenium 75 (However when accessibility does not permit the use of X-Ray, Gamma radiation with Ir-192 may be used further CONTRACTOR agreement). For base metal thickness > 10 mm radiographic examination shall be performed by X-Ray whenever possible and practicable however Gamma radiation may be used with Se 75, Ir192. Co60 may also be used for thickness above 50mm provided the required radiographic sensitivity is obtained. 9.1.7.3

EXAMINATION

The double films technique may be used to reduce shooting time with wall thicknesses exceeding 50mm. Film overlap shall be 50 mm minimum. Radiography of welds on nozzles and communicating chambers, etc… having a nominal diameter of 3” or less may be performed by the elliptical projection technique. At least two separate exposures are required at locations 90° apart. Where there is no internal access, radiographs of welds in pipe shall be double wall technique with a minimum of 3 shots up to 4” in diameter and 4 shots over 4” in diameter and only that portion of

Project n° - Unit


XXXXX-0000 SP

5254

001

Rev.

Page

0

17 / 21


the weld on the film side of the pipe (opposite to the radiation-source side) shall be interpreted. Because of the variation in pipe diameters, wall thickness and source-to-film distances, it may be necessary to take more than the minimum number of radiographs to properly examine the entire circumference of a weld. 9.1.7.4

FILM SELECTION

Unless otherwise agreed by CONTRACTOR the following table shall be used for the selection of film depending of materials and thickness involved: A minimum of 200mm film length should be used when access permit.

9.1.7.5

EN 584-1

ASTM E 1815

KODAK M

C2

I

FUJI IX50

C2

I

AGFA D3

C2

I

AGFA D4

C3

I

KODAK MX125

C3

I

FUJI IX80

C3

I

KODAK T200

C4

I

AGFA D5

C4

I

KODAK AA 400

C5

II

AGFA D7

C5

II

FUJI IX100

C5

II

Material and Thickness

P n° 1 above 50 mm

P n°1 from 20 to 50mm

P n°1 up to 20mm

GEOMETRICAL UNSHARPNESS LIMITATION

Geometrical unsharpness shall be in accordance with ASME V Article 2. 9.1.7.6

SENSITIVITY

Sensitivity of the films shall be verified by the use of wire-type Image Quality Indicator (IQI) as per ASTM E 142 or per European Norm EN 462-1. As a minimum sensitivity shall be as per table T-276 in ASME V, Article 2. IQI shall be located on the weld seam at source side. Whenever this is impractical the IQI shall be placed at film side together with a lead symbol “F” and the sensitivity shall be in accordance with ASME V article 2 Table T-276. 9.1.7.7

RADIOGRAPHIC DENSITY

Unless otherwise agreed with CONTRACTOR the following film density shall be obtained depending of

Note:

Technique

Range

Simple film X-Radiation

1,8 to 3.5

Simple film Gamma Ray

2 to 3.5

Double film Gamma Ray

2.7 to 3.5

Project n° - Unit

XXXXX-0000 SP


5254

Rev.

Page

0

18 / 21

001


For composite viewing of multiple film exposures, each film of the composite set shall have a minimum density of 1,3. Density may be up to 4 provided films are interpreted with appropriate film viewer. The density of the radiograph anywhere through the area of interest shall not vary by more than minus 15% or plus 30% from the density through the body of the hole IQI or adjacent to the designated wire of a wire IQI, within the minimum/maximum allowable density ranges specified in T-282.1. 9.1.7.8

FILM MARKING

Following information shall be marked on the films: ♦ Job number, ♦ Item number, ♦ Weld number Welder's symbol, ♦ Examination stage ♦ Date of examination

Markings shall clear the outer edges of the weld and shall not interact with IQI designation. 9.1.7.9

REPORT

In addition to code requirement, report shall include the following information as a minimum : ♦ Date of examination ♦ Job number / item number ♦ Source of radiation used together with power ♦ Codification of defects used for interpretation ♦ For each weld joint : shooting technique / geometrical unsharpness or calculating parameters ♦ For each film : density / film used / IQI seen versus IQI required ♦ Names and qualification reference of radiographer and radiographic interpreter. 9.1.7.10 RADIOGRAPHIC PROCEDURE As a minimum the following shall be included in the RT procedure: scope, source type (e.g. X-ray, IR912, etc.); material type; material thickness; pipe diameter for pipe components; maximum KV of Xray source, maximum focal spot size; minimum film to source distance; exposure time; sketch of component and source; film and penetrameter placement for components other than simple shape; intensifying screens type and thickness; image quality indicator type and pattern; technique (e.g. double wall single image, etc.); sensitivity; film density; viewing conditions for high density; back scatter checks/protection; marking and identification of radiographs; film overlap; film storage; acceptance criteria; reporting format; operator qualifications. 9.1.8

ULTRASONIC EXAMINATION (UT)

Ultrasonic examination procedures shall be in accordance with the requirements and methods specified in ASME Section V, Article 5. The acceptance criteria shall be in accordance with ASME Section VIII, Division 1 or 2. The frequency of the transducers shall be 2 or 4 Mhz and the angle shall be in the range of 45° to 70°. As a minimum at least two different probe angles shall be used. Inspection reports, shall include as a minimum all information specified in ASME V Article 5, paragraph T590.

Project n° - Unit

XXXXX-0000 SP


5254

001

Rev.

Page

0

19 / 21


As a minimum the following shall be included in the UT procedure: scope; equipment; probe type and details; surface preparation; cleaning and couplant; technique sheet for each technique specified (number of techniques to be sufficient to cover all type of joints to be covered by the procedures scope); material; weld material (if different); sketch showing joint configuration, beam coverage; extent of scan; scanning pattern; material thickness and curvature; calibrations and frequency; means of setting and scanning sensitivity levels and DAC curves, flaw location and size evaluation; acceptance criteria; reporting format; operator qualifications.

9.2

PRODUCTION HARDNESS TESTING Surface Brinell hardness tests shall apply to Post Weld Heat Treated vessels and shall be performed after Post Weld Heat Treatment. Production hardness testing shall be performed by the Brinell method and procedures in accordance with ASTM Method E10 and E110 as applicable or any other proposed method approved by CONTRACTOR that does not introduce a sharp indentation. Portable dynamic or rebound type hardness testing shall be performed in accordance with ASTM A 956 and the equipment manufacturer’s recommendations. The accuracy of portable equipment shall be verified by tests made on a master block of known hardness. The hardness of master blocks shall be determined by a calibrated laboratory hardness testing machine or alternatively standard hardness blocks may be purchased. Personnel performing hardness testing shall be familiar with all hardness testing procedures and test methods. Hardness test shall consist of at least one hardness measurement in weld metal, Heat affected Zone and Base metal which shall be taken on each longitudinal and circumferential weld seam and each diameter of branch connection nozzle. Each welding procedure used shall be tested. Each weld forming part of prefabricated head shall be as well hardness tested. Hardness results shall not exceed 200 HB for P-No. 1

Hardness testing results shall be expressed in Brinell numbers. The hardness report shall indicate actual hardness reading for the test method used, type of hardness tester, personnel conducting hardness tests, type of material, and calibration. Hardness test reports shall be part of the Manufacturer’s data book. 9.3

VESSELS PRODUCTION WELD TEST COUPONS

Weld test coupon shall comply with ASME VIII Div 1 (when impact tests are required) or ASME VIII Div 2 §3.11 requirements. Test coupons shall be of sufficient length to allow for all mechanical tests to be taken. Test coupons shall be welded attached to the part being welded where possible and shall reflect the actual welding and heat treatment conditions of the equipment. Mechanical tests and acceptance criteria shall be the same as required for welding procedure qualifications. 10.

QUALITY REQUIREMENTS FOR WELDING

Within the certified quality system of the manufacturer the welding activities need a special attention. Welding coordination shall be in accordance with EN 719. The quality assurance with respect to the welding in general shall meet the requirements of EN 729-2.

Project n° - Unit


XXXXX-0000 SP

5254

001

Rev.

Page

0

20 / 21


ATTACHMENT 1: PRESSURE VESSELS WELDING KEY FORM PROJECT: COMPANY:

WELDING KEY FORM

PROJ. No:

PRESSURE VESSELS

Rev.

Sh. of

SUPPLIER:

MR

ITEM

DESCRIPTION OF PART

SUPPLIER DOC. No SKETCH AND RELEVANT DATA

Service Requirements: Design / Fabrication code : Materials : Minimum Design Temperature (MDMT): Post Weld Heat Treatment : Yes / No

Hardness (Sour service) :

Yes / No

POS

WPS

Impact testing requirement on PQR : : Yes / No

APPLICABLE WPS-PQR JOINTS

Thickness

PQR (1)

1) REV.

A = approved as final DATE

POS

B = approved as noted DESCRIPTION

JOINTS

Thickness

WPS

(1)

PQR (1)

C = Rejected

APPROVAL BY SUPPLIER REVIEWED

PP 1 - ANG - rev. 0

REJECTED

AS NOTED

BY

DATE

(1)

Project n° - Unit


XXXXX-0000 SP

5254

Rev.

Page

0

21 / 21

001


ATTACHMENT 2 : PRESSURE VESSELS TESTING KEY FORM PROJECT: COMPANY: PROJ. No: SUPPLIER:

TESTING KEY FORM PRESSURE VESSELS

Rev.

Sh of

BASE MATERIAL TESTING MATERIAL TYPE

UT (%)

RT

Stand.

(%)

Stand.

PT

MT

HT

(%)

(%)

(1)

COUPONS Kv No

°C

Tens.

Hard.

Simulated

No

No

HT cycle

Plain Plate Clad Plate Forging Pipe Cast Notes : (1) Heat treatment shall be specified as: N = Normalizing ; QT = Quenched and tempered NT = Normalized and tempered , etc.

PRODUCTION WELDING JOINT TYPE

PWHT data °C - h

NDE (%)

Notes

Final / before PWHT RT

UT

PT

COUPONS

Kv

(No)

J - °C

After PWHT MT

RT

UT

PT

MT

Longitudinal Circumferential Tee joint Head / shell Nozzle to head/ shell Pipe to flange Lifting lug Ext. supports Notes:

WELD OVERLAY Test type

FORMING DATA

Longitudinal

Circumferential

joint

joint

POS

DESCRIPT.

THK. A

F

% (2)

TYPE HOT

COLD

HT (3)

COUP . (4)

RT / UT PT Chemical check Ferrite Check

Notes: (1) A= actual (THK before forming) F=final (THK after forming) (2) Fiber elongation (see ASME VIII Div 1 or 2) (3) Heat treatment after forming shall be specified and shown as:

Removal Notes:

PP 1 - ANG - rev. 0

N = normalizing;

QT = quenched and tempered

NT = normalized and tempered; etc. (4) Acc To ASME VIII Div 1 or 2 part 6 coupons shall be subjected To simulated heat treatment including any intermediate and/or final heat treatment.

5890-000-SP-5103-001_A.pdf

Recommend Documents