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Please note that whilst every effort has been made to ensure the accuracy of the NORSOK standards neither OLF nor TBL or any of their members will assume liability for any use thereof.
1 FOREWORD
NORSOK (The competitive standing of the Norwegian offshore sector) is the industry initiative to add value, reduce cost and lead time and remove unnecessary activities in offshore field developments and operations. The NORSOK standards are developed by the Norwegian petroleum industry as a part of the NORSOK initiative and are jointly issued by OLF (The Norwegian Oil Industry Association) and TBL (The Federation of Norwegian Engineering Industries). NORSOK standards are administered by NTS (Norwegian Technology Standards Institution). The purpose of this industry standard is to replace the individual oil company specifications for use in existing and future petroleum industry developments, subject to the individual company's review and application. The NORSOK standards make extensive references to international standards. Where relevant, the contents of this standard will be used to provide input to the international standardization process. Subject to implementation into international standards, this NORSOK standard will be withdrawn. Annex A is informative. Annexes B, C and D are normative.
2 SCOPE
This standard covers the requirements for fabrication and inspection of offshore steel structures with SMYS < 500MPa and with a minimum design temperature down to -10C. Note: For highly fatigue utilized structures, more severe requirements may apply, and these shall be shown on the design drawings.
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3 NORMATIVE REFERENCES
API 2B API RP 2X ASME, Section V BS 7448 Part 1, BSI PD6493 DnV DnV RP D404 EN 287 EN 288 Specification for fabricated structural steel pipe. Ultrasonic examination of offshore structural fabrications. Non-destructive testing. Fracture mechanics toughness tests. Guidance on some methods for the derivation of acceptance levels for defects in fusion welded joints. Rules for classification of fixed installations, structures. Part 3, chapter 2, Fabrication and construction. Unstable fracture.
Approval testing of welders - Fusion welding. Specification and qualification of welding procedures for metallic materials. EN 444 NDT - General principles for radiographic examination of metallic materials by X-rays and gamma rays. EN 462 NDT - Image quality of radiographs. EN 473 Qualification and certification of NDT personnel - General principles. EN 719 Welding coordination - Tasks and responsibilities. EN 729 Quality requirements for welding - Fusion welding of metallic materials. EN 875 Welding - Welded joints in metallic materials - Specimen location and notch orientation for impact tests. prEN 970 Welding - Visual examination of fusion welded joints. prEN 1011 Recommendation for arc welding of ferritic steels. prEN 1290 NDE of welds - Magnetic particle testing of welds - Method. prEN 1291 NDE of welds - Magnetic particle testing of welds - Acceptance levels and criteria. prEN 1418 Welding personnel - Approval testing for fully mechanised and automatic welding. prEN 1597-1 Welding consumables - testing for classification. prEN 10025 Hot rolled products of non-alloy structural steels: Technical delivery conditions. EN 10204 Metallic products - Types of inspection documents. prEN 10225 Weldable structural steels for fixed offshore structures. EN 26847 Covered electrodes for manual metal arc welding. Deposition of a weld pad for chemical analysis. ISO 3690 Welding determination of hydrogen weld metal arising from the use of covered electrodes for welding mild and low alloy steels. ISO 5817 (=EN 25817) Arc welded joints in steel - Guidance on quality levels for imperfections. NS 477 Welding. Rules for approval of welding inspectors. M-DP-001 Material selection. M-CR-120 Material data sheets for structural steel.
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N-CR-001
tructural design.
4.2 Abbreviations
AWS CE CTOD DAC DC DIN DnV EN FSH HDM IIW NDT MDS PWHT SMYS WPS WPAR American Welding Society Carbon Equivalent Crack Tip Opening Displacement Distance Amplitude Curve Design Class Deutsche Industrie Normen Det norske Veritas Euronorm Full Screen Height Hydrogen content, deposit metal International Institute of Welding Non Destructive Testing Material Data Sheet Post Weld Heat Treatment Specified Minimum Yield Strength Welding Procedure Specification Welding Procedure Approval Record
5 SELECTION OF STEELS
M-CR-101, Rev. 2, January 1996 page 3
1 2 3 4 5
6 QUALIFICATION OF WELDING PROCEDURES AND WELDERS 6.1 Welding procedure specification (WPS)
WPS shall be established in accordance with EN 288 part 2.
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Table 6.1 Type and number of tests Joint configuration Buttwelds (Tubulars and plates) T-joints (plates) 5) Tubular joints 5) Fillet welds Notes: 1. Bend tests shall consist of 1 face and 1 root bend specimen for t < 20mm and 2 side bend specimens for t >= 20mm 2. One set consists of three test specimens. 3. If the dimensions of the joint does not allow Charpy V-notch testing, the Charpy V-notch properties shall be documented on a butt weld joint made with the same consumable and same base material, and welding parameters and thickness within the range qualified for the joint. 4. It shall be documented on a butt weld test that the welding consumable used will have sufficient tensile strength. 5. T-joints on plates qualify for tubular joints, and vice versa. 6. For welds on submerged structures with cathodic protection, the hardness limits in NORSOK M-DP-001 (i.e. max 350 HV10) shall apply in addition to the requirements of EN 288. Joint thickness (mm) t < 50 t => 50 t < 50 t => 50 t < 50 t => 50 All 2 2 4) 4) 4) 4) Mechanical testing Tensile test Bend tests 1) 2 2 Charpy V- Hardness and notch tests 2) macro 6) 4 sets 6 sets 4 sets 3) 6 sets 4 sets 3) 6 sets 1 1 2 2 2 2 2 CTOD Ref. 6.4.4
6.4.2 Charpy V-notch testing Sampling of Charpy V-notch impact tests shall be carried out in accordance with prEN 875, with the notch in the positions listed below. (All specimens shall be machined with the notch through the thickness, 2 mm below the surface of the material.) (Designation in parenthesis refers to prEN 875).
Notch in centre of weld (VWT 0/2) Notch in fusion line (VHT 0/2) Notch in HAZ, 2mm from fusion line (VHT 2/2) Notch in HAZ, 5mm from fusion line (VHT 5/2)
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For welds with a joint thickness of 50mm or more, two additional sets of Charpy V-notch tests shall be taken from the root area, with the notch in the following positions:
Notch in centre of weld (VWT 0/b1)) Notch in fusion line (VHT 0/b1))
Note: For single sided welds, the face of the Charpy specimen shall be 2mm from the root face to the weld. For double-sided welds, the centre of the Charpy specimen shall be positioned in the centre of the root area. The test temperature and energy requirements shall comply with table 6.2. Table 6.2 Charpy impact test temperatures and energy requirements for welding procedure qualifications. Steel quality level Material thickness mm t 12 12 < t 25 25 < t 50 t > 50 Energy Requirement Note: 1. The minimum average value is given in the table. No individual value shall be less than 70% of the minimum average value.
1)
I SMYS <= 400 MPa 0C -20C -40C -40C 36J SMYS > 400 MPa -20C -40C -40C -40C 42J SMYS <= 400 MPa 0C 0C -20C -40C 27J
6.4.3 Transverse tensile testing Testing shall be carried out in accordance with EN 288. The fracture shall be located outside the weld metal (i.e. max. 20% of the fracture surface shall consist of weld metal). 6.4.4 CTOD testing CTOD testing shall be included in qualification of welding procedures for joints requiring steel quality level I and II, with a thickness above 50mm for steels with SMYS < 460MPa, and with a thickness above 30mm for steels with SMYS > 460MPa.
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It shall be executed on weld assemblies in the actual heat treating condition (PWHT/as-welded) covering the following combined conditions:
Full penetration buttweld with K-, single V- or X-groove as deemed most representative for the actual fabrication. A welding procedure representing the maximum heat input to be used in fabrication. Maximum joint thickness (within 10%).
One (1) such assembly shall be made and tested for each combination of steel grade, each welding process and each welding consumable (brand) used, except welding consumables used for root passes only. The CTOD-technique with the Bx2B, through-thickness notched type specimen according to BS 7448 should be used. Three (3) valid test specimens shall be obtained for each test position. Note: Test assemblies may be given a precompression and/or hydrogen diffusion treatment prior to testing. CTOD-testing of welds shall be carried out with the fatigue notch tip positioned in the coarse grained region of the heat affected zone and in the weld metal. For HAZ, positioning and determination of the actual location of the fatigue crack tip shall be performed after testing. HAZ testing can be omitted if relevant CTOD properties in HAZ have been documented previously for the base material (i.e. on the same grade of material from the same manufacturer). CTOD-testing of weld metal can be omitted if relevant CTOD properties in accordance with requirements above have been documented previously. Test temperature shall be:
The required CTOD value has to be decided in each case, based on a fracture mechanics evaluation for the particular structure. When the minimum single CTOD-value at the required temperature exceeds 0.25 mm (0.20 mm for welds with PWHT), the test series is normally acceptable without a detailed fracture mechanics evaluation. CTOD testing should also be performed when required for fitness for purpose evaluations according to 10.8.6.
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For welding of joints where steel quality level IV is required, a certificate for welding of plates in position PE is sufficient for welding all product forms.
7.2 Forming
Cold forming of steel (i.e. forming below 250C) shall be carried out within the deformation range recommended by the steel manufacturer. For steel quality level I and II, the deformation limit without documentation of mechanical properties is 5%. If the deformation is more than the above given limits, either heat treatment shall be performed, or strain ageing tests shall be carried out according to the following procedure:
The material shall be permanently strained locally to the actual deformation. The material shall be artificially aged at 250C for 1 hour. One set of 3 impact test specimens shall be tested from the base material in the strained plus artificially aged condition. The notch shall be located within the plastically strained portion of the material, in the part of the cross section which have received the highest strain. The impact testing temperature shall be as specified for the actual steel grade in question. The Charpy-V impact value shall comply with the minimum requirements for the steel grade and shall not be more than 25% lower than the impact value for the material before deformation and strain ageing.
If forming is performed at temperature above 250C, it shall be documented that the base material properties, weldability, weldmetal and HAZ properties satisfy the actual MDS and this standard. The percentage strain due to forming is defined as follows:
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Sequence of operation. Equipment to be used. Cold rolling method. Methods for avoiding "flats" along the longitudinal seam. Method for avoiding local thinning, steps or wavy edges. Welding procedure. Visual inspection and NDT. Mechanical testing. Splices. Dimensional inspection and acceptance criteria, both at tubular ends and intermediate sections.
7.4 Assembly
7.4.1 General In tubular joints, circumferential and longitudinal weld joints should not be placed in the shaded areas shown in fig. 7.1.
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W1 = 150mm or min. 2 times chord thickness W2 = 300mm or min. D/4 W3 = 600mm or min. D Fig. 7.1 Prohibited location of welds in tubular joints. Longitudinal or circumferential welds shall not be located in shaded area. 7.4.2 Splices Splices shall not be located in restricted areas, as shown on design drawings. 7.4.3 Tapering Tapering shall be in accordance with the requirements given in relevant standards or drawings. If no other requirements are specified, a tapering of 1:4 should be used.
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7.4.4 Bolting connection Bolting material shall comply with requirements in NORSOK standard M-DP-001, Material selection. Holes shall be made by machine drilling. 7.4.5 Seal/blind-compartments. Crevices and areas which become inaccessible after fabrication or assembly shall be sealed off from the outside atmosphere. Seal welds shall have a throat thickness of at least 3mm. Where steel items shall be hot dip galvanised, hollow sections shall be ventilated. 7.4.6 Temporary cut-outs Temporary cut-outs shall not be located in restricted areas as shown on design drawings. Temporary cut outs shall have a corner radius not less than 100mm. Temporary cut-outs shall be closed by refitting the same or an equivalent plate and employing the same welding, inspection and documentation procedures and requirements that govern the structural part in question. 7.4.7 Straightening of structural members Members distorted by welding shall be straightened according to a detailed work instruction. The base material properties shall satisfy the specified requirements after straightening. Maximum temperature for straightening shall not exceed the temperature limit recommended by the steel manufacturer, but it shall in no case be higher than 600 C. 7.4.8 Doubler plates All temporary attachments which shall be flame cut or welded under water shall be attached to the structure by using doubler plates. All attachments in the splash zone shall be attached to the structure by using doubler plates.
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Batch testing including chemical analysis and mechanical properties, see annex D. An established and reliable system of batch certification against accepted supplier data sheets, see annex C.
Except for solid wires such consumables shall be classified by the supplier as extra low hydrogen, i.e. HDM<= 5ml/100g weld metal. For self shielded flux cored wire HDM<= 8ml/100g may be accepted, provided preheating temperature and post weld holding temperature and time is assessed to avoid hydrogen cracking. Hydrogen testing shall be according to ISO 3690 or equivalent. Consumables for joints in steel quality level III and IV and for joining stainless to carbon steel shall be selected with due consideration of base material properties, thickness and weldability, to ensure sufficient weld strength, toughness and homogenity. Such consumables shall be delivered with EN 10 204 type 2.2 certificate, as a minimum. All welding consumables shall be individually marked. When certification according to annex C is used, welding consumables (except welding fluxes) shall be supplied with an inspection certificate (type 3.1B) in accordance with EN 10204, including a statement of compliance with the Welding Consumable Data Sheet and the chemical composition of the weld deposit (elements of the data sheet). Welding fluxes shall be supplied with a test report (EN 10 204 type 2.2), declaring conformity with the approved product type.
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Heating rate. Cooling rate. Soaking temperature and time. Heating facilities. Insulation. Control devices. Recording equipment. Configuration of structure to be PWHT or details if local PWHT shall be carried out. Number and location of thermocouples to be used during PWHT.
The holding temperature shall be as recommended by the steel manufacturer. The holding time shall be at least 2.5 min per mm thickness (of the thickest member).
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The temperature difference between different parts of the structure during soaking time shall not exceed 30 C within the heated area. Double sided heating shall be used as far as possible. The temperatures shall be continuously and automatically recorded on a chart.
7.12 Grinding
When grinding is specified on design drawings or is instructed as a corrective action, the grinding shall be performed according to a detailed procedure. Grinding tools, direction, surface roughness and final profile shall be specified. Reference samples for typical joints and sections may be prepared and used for acceptance of treated welds. Typical examples for requirements for grinding of joints are given in annex A.
8 PRODUCTION TESTS
Production testing should be conducted on weldments performed in critical regions to verify that the specified requirements have been meet. For welds where steel quality level I or II are required, minimum one test coupon is required from each applied welding process. Test coupons shall be welded in a manner which realistically simulates the actual production welding, normally as extension of the production weld, and meet the requirements for welding procedure approval tests. CTOD testing is not required for production testing. If a production test fails, the reason for the failure shall be determined and remedial action implemented.
9 FABRICATION TOLERANCES
Fabrication tolerances shall be in accordance with relevant standards and/or drawings issued for fabrication.
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Prior to fabrication start-up, contractor shall implement a system for recording of weld defect rates. If this system shall be used as basis for a reduction of NDT extent according to table 10.1, the system must ensure that a correct rate identification is prepared for each weld method, each NDT method and each production area. The defect rate is defined as:
Note 1: "Tested part of welds" means the part that is tested with the same NDT method. NDT after repair shall not be included when calculating the defect rate.
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Table 10.1 Minimum extent (in %) of non-destructive examination for structural welds.
Inspection category
Type of connection Buttw. T-conn. Fillet/partial Buttw. T-conn. Fillet/partial Buttw. T-conn. Fillet/partial All conn. All conn.
Visual examination 100 100 100 100 100 100 100 100 100 100 100
Extent of testing RT 10 Spot UT 100 100 50 1) 50 1) 20 1) 20 1) MT 100 100 100 100 1) 100 1) 100 1) 20 1) 20 1) 20 1) spot -
C D E
Legend RT = Radiographic testing UT = Ultrasonic testing MT = Magnetic particle testing Spot means approximately 5%.
Note: 1. The extent may be reduced to 50% of the specified extent, based on experience and documented records with similar joints, provided the defect rate (see clause 10.1 and 11.1) for UT/RT is <2.0% and for MT is <0.2% during the last 100m of weld. The last 100m shall be continuosly updated every week. If the defect rate exceeds the limits given above, the normal extent of NDT shall apply again. A possible reduction in the extent of NDT shall be considered separately for each welding method and each production area.
When partial testing is defined for welds in an area, the testing shall be spread such that the most essential members and nodes are included in the inspection, and such that areas of welds most susceptible to weld defects are covered. The specified percentage to be tested in table 10.1 refers to the total length of welds in each inspection category. All WPS's used and welding personnel involved in the fabrication shall be subject to NDT. During the initial fabrication the extent of UT and MT of inspection category B and C welds shall be intensified, normally to twice the level given in table 10.1. This extent shall be maintained for a weld and test length sufficient to conclude that the weld repair percentage is at a reasonable level.
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The increased initial testing may be accounted for in the overall extent provided the initial testing confirms consistent good workmanship. The extent of NDT shall be increased if repeated occurrence of cracks or other significant weld defects are revealed. Corrective actions shall be taken to ensure that all similar defects will be detected. In addition to what is listed in table 10.1, the following shall apply for inspection category A and B: a) One film at each end for longitudinal welds of tubulars (including tubulars for nodes and stubs). b) Where radiographic testing is required, intersection welds, and those locations where presence of defects is deemed to be most harmful, shall be tested. c) Ultrasonic and radiographic testing shall not overlap, except when 100% UT is specified. However, ambiguous imperfections revealed by UT shall in addition be tested by RT. d) Ultrasonic testing is normally not applicable for thicknesses less than 10mm. For such thicknesses, UT may be replaced with RT. In general, RT should be considered if UT is not possible. Radiographic testing is normally not applicable for thicknesses above 40mm. e) MT shall be performed on both external and internal surface as accessible.
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The effective test range of a DAC curve shall be determined by the point at which the curve has fallen to 25% FSH, when it will be necessary to raise the curve using reflectors at increased depth. The reference block shall be from a steel type that is representative for the steel to be inspected. Where ultrasonic testing is to be performed on steel produced by controlled rolling or thermomechanical treatment, blocks shall be produced both perpendicular to, and parallel to, the direction of rolling. The rolling direction shall be clearly identified. The actual refracted angle for each probe measured from the reference block or as measured on the actual object being examined, shall be used when plotting indications. A transfer correction between the reference block and the test surface shall be performed. Ultrasonic examination procedures shall be sufficiently detailed to ensure 100% of the weld body and heat affected zones are examined for longitudinal defects in accordance with ASME V, Article 5, T-542.7.2.3. All indications exceeding 20% DAC shall be investigated to the extent that they can be evaluated in terms of the acceptance criteria. All indications exceeding 50% DAC and having any dimension exceeding 5mm shall be reported, unless more stringent requirements are given in table 10.5. The examination record shall include the position, the echo height, length, depth and type of indication.
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10.8.4 Ultrasonic testing acceptance criteria The acceptance criteria for welds shall comply with table 10.5, except that the acceptance criteria for tubular joints shall comply with API RP 2X level C, unless more stringent requirements are specified by the designer. Table 10.2 Calibration reference block requirements Thickness of material to be examined (mm) 10 < t < 50 50 < t < 100 100 < t < 150 150 < t < 200 200 < t < 250 t > 250 Thickness of block 40 or t 75 or t 125 or t 175 or t 225 or t 275 or t 6mm +/0.2mm Diameter of hole 3mm +/0.2mm t/2 and t/4. Additional holes areallowed and recommended Distance of hole from one surface
Table 10.3 Visual acceptance criteria for structural steel welds Welding Type of defect Cracks Lack of penetration or lack of fusion Acceptance criteria Insp. cat. A, B Not acceptable Not acceptable Max depth 0.5mm Continuous undercut is not permitted Inspection category C, D, E Not acceptable Single - side weld: Length < t/2, max 10mm Defects shall be regarded as a continuous defect if the distance between them is <t. Maximum depth 0.75mm Continuous undercut is not permitted Not acceptable. However,the following defects may be acceptable if it does not conflict with surface treatment requirements: Accumulated pore diameters in any area of 10 x 150mm is not to exceed 15mm. Max. size of a single pore is t/4 or 4mm, whichever is the smaller.
Undercut
Not acceptable
"U" shall be less than 2.5mm. Weld surface shall be smooth, without Roughness of weld (fig. 1) sharp transitions. The bottom of roughness in butt welds shall not be below the base material surface. M-CR-101, Rev. 2, January 1996 page 20
Max. misalignment (M), 0.15 x t or max. 4mm, whichever is the smaller. "t" less or equal to 10 "t" greater than 10, up to 25 "t" greater than 25, up to 50 "t" greater than 50 "a" less or equal to 10 "a" greater than 10, up to 15 "a" greater than 15, up to 25 "a" greater than 25 "a" less or equal to 6 "a" greater than 6, up to 13 "a" greater than 13 Max reinforcement "C" 2mm Max reinforcement "C" 3mm Max reinforcement "C" 3mm Max reinforcement "C" 5mm Max reinforcement "C" 2mm Max reinforcement "C" 3mm Max reinforcement "C" 4mm Max reinforcement "C" 5mm Max difference, b - h: 3mm Max difference, b - h: 5mm Max difference, b - h: 8mm
Symmetry of fillet welds (fig. 5) Grinding arc strikes etc. Removal of temporary attachments 2) Sharp edges Notes:
Grinding of base material shall not exceed 7% of the wall thickness or max. 3mm. Repair welding and inspection shall be performed if removal of the base metal exceeds the specified requirements. Minimum 2 mm radius (Ref. 7.5)
1. Localised reinforcements exceeding the above requirements are acceptable. 2. Temporary attachments shall be flame cut min. 3mm from the base metal and ground smooth. The ground area shall be visually inspected and MT shall be performed in accordance with the inspection category in question. 3. When required (ref. 7.12), grinding of the surface shall be specified. Typical examples of grinding requirements are given in annex A.
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Figure 4b Reinforcement of partial pen weld Figure 5 Symmetri of fillet weld Table 10.4 Structural steel welds, Radiographic acceptance criteria Type of defect Internal porosity (Note 1) Isolated: Pore diameter Cluster: Pore diameter Piping porosity: Length of projected area Scattered: Accumulated pore diameters in any 10x150mm area of weld Slag inclusions (Note 2) Width max t/4,but max.6mm max.3mm max.25mm max.20mm t/4, max .6mm 2t, max 50mm max t/3, but max.6mm max .4mm max. 30mm max. 25mm t/3, max. 6mm 4t, max. 100mm Inspection category A, B C, D, E
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Length Lack of penetration Length (Note 2) Lack of fusion Length (Note 2) Cracks Notes: 1. If more than one pore is located inside a circle of diameter 3 times the pore diameter, the pores are to be considered as a cluster. 2. Defects in a line where the distance between the defect is shorter than the longest defect shall be regarded as one continuous defect. t, max. 25 mm Not acceptable Not acceptable 2t,max 50 mm 2t, max.50mm Not acceptable
Table 10.5 Ultrasonic acceptance criteria for weld defects Description General Inspection category A+B Inspection category C, D, E Notes 1 2 3 4 1 2 3 4 5
If the type of defect can not be ascertained with certainty the defect shall be repaired when the length exceeds 10mm and the echo height exceeds the reference curve. Unambiguous cracks are unacceptable regardless of size or amplitude. Internal defects : I: The echo height exceeds the reference curve: Max length t, max 25mm Max length 2t, max 50mm
II: The echo height is between 50 and 100% of the reference curve: Max length 2t, Max length 4t, max 50mm max 100mm Surface defects are not acceptable except: For root defects in single sided welds , the max length for which the echo height exceeds the reference curve shall be: Max length t, Max length 2t, max 25mm max 50mm
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Slag inclusions
When echo height exceeds the reference curve: Max length 2t, Max length 4t, max 50mm max 100mm Repair is required if porosity may mask for other defects.
1 2 1
Porosity Notes:
1. Type of defect shall be decided by: I: Supplementary non-destructive testing. II: The ultrasonic operator's assessment of the defect, using his knowledge of the welding process, signal geometry, defect position etc. 2. If elongated defects are situated on line and the distance between them is less than the length of the longest indication, the defects shall be evaluated as one continuous defect. 3. Defect length shall be determined by the 6dB drop method from the end of the defect (for defects larger than the beam) or by the maximum amplitude technique (for defects smaller than the beam). 4. With UT performed from only one side of the weld with only one surface accessible, the acceptable echo heights are reduced from 100% to 50% and from 50% to 20%, respectively. 5. With "internal defects" it is meant defects which are located more than 6mm from the nearest surface. A defect is classified as a "surface defect" if any part of the defect is located less than 6 mm or t/4, whichever is smaller, from the nearest surface.
10.8.5 Magnetic particle testing Linear indications (i.e. indications with a length/width ratio above 3 and length above 1.5mm) are not acceptable. Any linear indications shall be ground and re-examined. Rounded indications shall be evaluated in accordance with the requirements of table 10.3. 10.8.6 All methods All defects shall be repaired according to clause 11. Defects may be accepted by the relevant parties when repair work is considered detrimental to the total integrity of the weld. Such acceptance shall be based on a fitness for purpose evaluation in accordance with BSI PD6493, DnV RP D404 or other recognised methods.
Weld defect: Discontinuity with a size and/or density that exceeds the acceptance criteria defined in clause 10.
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For repairs using a different process, and/or consumable, a separate WPS shall be qualified if required by 6.2. Mechanical testing may be limited to HAZ Charpy V-notch testing in the original weld, provided the process/consumable is backed up by other WPAR's.
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ANNEX B CORRELATION BETWEEN STEEL QUALITY LEVEL, MDS NUMBER AND STEEL GRADE/DESIGNATIONS (NORMATIVE)
Reference standard
Product type Plates Rolled sections Seamless tubulars Plates Rolled sections Seamless tubulars Plates Rolled sections Seamless tubulars Plates Rolled sections Seamless tubulars Plates Rolled sections Seamless tubulars Plates Rolled sections Seamless tubulars Plates Rolled sections Seamless tubulars Plates Rolled sections Seamless tubulars Plates Rolled sections Seamless tubulars
Steel grade
Y20 Y21 Y22 Y30 Y31 Y32 Y40 Y41 Y42 Y50 Y51 Y52
prEN 10225
S355NLO5 S355NLO5 S355NLO5 S420QLO4 S420QLO4 S420QLO2 (mod.) S460QLO4 S460QLO4 S460QLO2 (mod) S500QLO4 S500QLO4 S500QLO4
II
Y25 Y26 Y27 Y35 Y36 Y37 Y45 Y46 Y47 Y55 Y56 Y57
prEN 10225
S355NLO3 S355NLO3 S355NLO3 S420QLO2 S420QLO2 S420QLO2 S460QLO2 S460QLO2 S460QLO2 S500QLO2 S500QLO2 S500QLO2
III
Y03
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Y01 IV Y02
EN 10025
Plates Rolled sections Seamless tubulars Plates Rolled sections Seamless tubulars
S235JRG2
EN 10025
S275JR
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Chemical analysis limits for solid wires and metal powders. For information also typical weld metal analysis, using a relevant shielding gas or flux. Chemical analysis limits of weld metal from coated electrodes and cored wires, deposited according to EN 26847. For information also specified limits for S, P and N in the core wire or strip.
The analysis shall include limits for all elements specified in the relevant classification standard and/or intentionally added and for residual elements known to influence weld metal quality. Minimum: C, Si, Mn, S, P, Cu, Ni, Cr, Mo, V, Nb. For SAW fluxes the analysis shall be given as ranges for all main ingredient and flux basicity.
Mechanical properties (range or/and guaranteed minimum) of the weld, deposited and tested according to prEN 1597 part 1 and including tensile strength, yield strength elongation, notch toughness Charpy-V at -40C. For information also typical properties of a relevant butt weld should be added. Diffusible hydrogen content HDM max., including any information on drying, restricted welding parameters etc. required to ensure this value in practice. When relevant for the product, basic information about CTOD properties, to be supported by separate test reports as required and agreed.
Data sheets shall also contain product classification according to recognised standards, relevant approvals and information on packing, storage etc. as required for correct application and use of the product. C.3 CERTIFICATE Every batch of consumables shall be supplied with an inspection certificate 3.1.B, containing as a minimum the specific tested chemical composition of the wire or weld metal, as applicable. The chemical elements shall conform to those of the data sheets, with a statement "below specified maximum" acceptable for residual elements. The supplier may optionally add information about mechanical properties, based on specific or nonspecific type of control. (Ref. EN 10204). Other tests may also be agreed between supplier and purchaser. Certificates shall be actively used by the purchaser to control received consumables against the accepted data sheet. Full conformance of chemical composition shall be required to release each batch for fabrication welding.
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All elements specified in the relevant classification standard and /or intentionally added. The main impurities S, P and N.
D.2 MECHANICAL PROPERTIES Unless otherwise specified the properties shall represent all weld metal, deposited and tested according to prEN 1597 part1. Properties tested shall include:
Tensile strength, yield strength and elongation. Impact strength Charpy-V, at temperatures -40C, or as specified by purchaser.
The need for other types of tests shall be evaluated for the application in question, such as:
Mechanical properties based on a defined butt weld rather than all weld metal test. Mechanical properties in the PWHT condition. CTOD testing. Testing of hydrogen level.
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D.3 DOCUMENTATION Batch tests shall be documented by an inspection certificate 3.1B to EN 10204, with reference to a recognised product classification standard and containing all specified test results.
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