NORSOK M-650 (Ed. 2011)_Qualification of Manufacturers of Special Materials...
NORSOK STANDARD
M-650 Edition 4, September 2011
Qualification of manufacturers of special materials
This NORSOK standard is developed with broad petroleum industry participation by interested parties in the Norwegian petroleum industry and is owned by the Norwegian petroleum industry represented by The Norwegian Oil Industry Association (OLF) and The Federation of Norwegian Industry. Please note that whilst every effort has been made to ensure the accuracy of this NORSOK standard, neither OLF nor The Federation of Norwegian Industry or any of their members will assume liability for any use thereof . Standards Norway is responsible for the administration and publication of this NORSOK standard. Standards Norway Strandveien 18, P.O. Box 242 N-1326 Lysaker NORWAY Copyrights reserved
Telephone: + 47 67 83 86 00 Fax: + 47 67 83 86 01 Email:
[email protected] Website: www.s www.standard.no/petroleum tandard.no/petroleum
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3 2 6 0 4 1 0 2 s i l u o b a t S + s o i t a n g I r o f S A e n i l n O d r a d n a t S y b d e d i v o r P
NORSOK standard M-650
Edition 4, September 2011
Foreword
4
Introduction
4
1
Scope
5
2
Normative and informative references 2.1 Normative references 2.2 Informative references
5 5 5
3
Terms, definitions and abbreviations 3.1 Terms and definitions 3.2 Abbreviations
5 5 7
4
Responsibilities 4.1 Purchasers responsibility 4.2 Manufacturers responsibility 4.3 Responsibilities of Qualifying Company
8 8 8 8
5
Qualification of manufacturers 5.1 Basis for qualification of manufacturers 5.2 Evaluation for acceptance 5.3 Acceptance of qualification 5.4 Proof of acceptance
8 8 8 8 8
6
Validity of qualification 6.1 Term of validity 6.2 Renewal of qualification 6.3 Transitional arrangements
9 9 9 9
7
General requirements 7.1 Knowledge and relevant experience 7.2 Manufacturing facilities and equipment 7.3 Sub-contractors 7.4 Quality requirements for test laboratories and manufacturers of welded products
9 9 10 10 10
8
Manufacturing Summary 8.1 Requirements for Manufacturing Summary 8.2 Content of the Manufacturing Summary
10 10 10
9
Heat treatment 9.1 Heat treatment facilities and equipment 9.2 Heat treatment procedure 9.3 Verification of heat treatment procedure
12 12 13 14
10 10.1 10.2 10.3 10.4
Qualification of the manufacturing process Objective of qualification testing Essential variables Qualification testing Welding procedure qualifications
15 15 15 17 20
11.1 11.2 11.3
Qualification test record (QTR) General Content of qualification test record (QTR) Required copies and distribution of qualification test record (QTR)
20 20 20 21
Annex A (Informative) Manufacturing Summary front page and example
22
11
Annex B (Normative) Additional requirements to API Spec 6A:2010/ISO 10423:2009 , Annex M, and ASTM A 991 27 Annex C (Informative Verification of heat treatment procedure – procedure – Example
28
Annex D (Normative) Form for Qualification Test Record (QTR) Front Page
29
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NORSOK standard M-650
Edition 4, September 2011
Foreword The NORSOK standards are developed by the Norwegian petroleum industry to ensure adequate safety, value adding and cost effectiveness for petroleum industry developments and operations. Furthermore, NORSOK standards are, as far as possible, intended to replace oil company specifications and serve as references in the authorities’ regulations. The NORSOK standards are normally based on recognised international standards, adding the provisions deemed necessary to fill the broad needs of the Norwegian petroleum industry. Where relevant, NORSOK standards will be used to provide the Norwegian industry input to the international standardisation process. Subject to development and publication of international standards, the relevant NORSOK standard will be withdrawn. The NORSOK standards are developed according to the consensus principle generally applicable for most standards work and according to established procedures defined in NORSOK A-001. The NORSOK standards are prepared and published with support by The Norwegian Oil Industry Association (OLF), The Federation of Norwegian Industry, Norwegian Shipowners’ Association and The Petroleum Safety Authority Norway. NORSOK standards are administered and published by Standards Norway.
Introduction This edition replaces NORSOK M-650, Rev. 3. The main changes in Edition 4 are related to the following items:
clarification of scope; definitions included or changed for Company, equalization time, heat sink, holding time, main contractor, manufacturer, Qualifying Company, soak time and test directions; clarification of responsibilities; clarification of transitional arrangements between Revision 3 and Edition 4 of this NORSOK standard; more stringent requirements to manufacturers knowledge; requirements to test laboratories and manufacturers of welded products included; type of etchants to be used and preparation of samples for micro examination, as applicable, shall be stated in the Manufacturing Summary; new clause about heat treatment with requirements to equipment, heat treatment procedure and verification of heat treatment procedure; changes in essential variables of the qualification tests especially regarding manufacturing equipment, heat treatment, hipped products and start material; changes in test requirements for flanges, other type of forgings, plates, rolled bars and valves machined from forgings; changes in extent and requirements to additional testing at mid-thickness for bars, forgings and hipped (HIP) products; otherwise editorial changes for clarification.
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NORSOK standard M-650
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Edition 4, September 2011
Scope
This NORSOK standard establishes a set of qualification requirements to verify that the manufacturer has sufficient competence and experience of the relevant material grades, and necessary facilities and equipment to manufacture these in the required shapes and sizes with acceptable properties. This standard is applicable to the following material grades and product forms: a) b) c) d)
Duplex SS: High alloyed austenitic SS: Nickel base alloys: Titanium and its alloys:
all grades, product forms and dimensions all grades, product forms and dimensions castings castings
This NORSOK standard is also applicable to critical components or product forms in other materials and for special manufacturing/fabrication processes, e.g. titanium and nickel alloys in other product forms than casting, carbon steel and low alloy steel products and induction/cold bending.
2
Normative and informative references
The following standards include provisions and guidelines which, through ref erence in this text, constitute provisions and guidelines of this NORSOK standard. Latest issue of the references shall be used unless otherwise agreed. Other recognized standards may be used provided it can be shown that they meet the requirements of the referenced standards.
2.1
Normative references
API Spec 6A:2010/ ISO 10423:2009,
ASTM A370-11, ASTM A 703, ASTM A 991, EN 10204, ISO 3834-2, ISO 9001, ISO/IEC 17025, NORSOK M-630, PED 97/23/EC,
2.2
Specification for Wellhead and Christmas Tree Equipment/Petroleum and natural gas industries – Drilling and production equipment – Wellhead and christmas tree equipment Standard Test Methods and Definitions for Mechanical Testing of Steel Products Steel Castings, General Requirements, for Pressure-Containing Parts Conducting Temperature Uniformity Surveys of Furnaces Used to Heat Treat Steel Products Metallic products – Types of Inspection Documents Quality Requirements for Fusion Welding of Metallic Materials – Part 2: Comprehensive quality requirements Quality Management Systems – Requirements General requirements for the competence of testing and calibration laboratories Material Data Sheet for Piping Pressure Equipment Directive
Informative references
API 6HT,
Heat Treatment and Testing of Large Cross Section and Critical Section Components
ASTM E407,
Standard Practice for Microetching Metals and Alloys
3
Terms, definitions and abbreviations
For the purposes of this NORSOK standard, the following terms, definitions and abbreviations apply.
3.1
Terms and definitions
3.1.1 can verbal form used for statements of possibility and capability, whether material, physical or casual 3.1.2 company owner or organization that is responsible for development of and/or operation of an installation/facility
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NOTE For the purpose of this standard this is normally an oil company.
3.1.3 equalization time the time used to ensure a uniform pre-set temperature throughout a heat treatment load and/or throughout all section thicknesses of a component (see also figure in Annex C) 3.1.4 heat sink separate block of material made from the same generic type of material as the parts being heat treated to monitor temperature during heat treatment 3.1.5 high alloyed austenitic SS austenitic SS with PREN ≥ 40 or Ni + 2 x Mo > 30 (Mo > 2) EXAMPLES
SS type 6Mo, UNS S31266, UNS S32654, UNS S34565, UNS J95370.
3.1.6 holding time time from the controlling thermocouple (normally furnace thermocouple) has reached set temperature until the specified soaking time is completed. NOTE Holding time consist of equalization time + soaking time. (see also figure in Annex C).
3.1.7 main contractor party, which carry out all or part of the design, engineering, procurement, construction, commissioning or management of a project, or operation or maintenance of a facility on a contract awarded by Company 3.1.8 manufacturer party, including sub-contractors, which carry out operations affecting the material properties of the finished product NOTE These operations can include forming, heat treatment, etc.
3.1.9 may verbal form used to indicate a course of action permissible within the limits of this NORSOK standard 3.1.10 pitting resistance equivalent PREN PREN = %Cr + 3.3 x %Mo + 16 x %N 3.1.11 purchaser party that purchase a product from a manufacturer 3.1.12 Qualifying Company party which monitor the qualification exercise and in the end accept the resulting qualification test record (QTR) by signing and stamping the QTR front page The Qualifying Company can be the Company, the main contractor, the purchaser or a party authorised to act on their behalf. Qualifying Company shall be independent of the manufacturer. 3.1.13 shall verbal form used to indicate requirements strictly to be followed in order to conform to this NORSOK standard and from which no deviation is permitted, unless accepted by all involved parties NORSOK standard
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3.1.14 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 necessarily required 3.1.15 soaking time time that the entire part being heat treated (throughout its cross sections) remains at the specified set temperature 3.1.16 type 22Cr duplex ferritic/austenitic stainless steel alloys with 22 % Cr EXAMPLES
UNS S31803 and UNS S32205.
3.1.17 type 25Cr duplex ferritic/austenitic stainless steel alloys with 25 % Cr and PREN
≥ 40
NOTE Often referred to as “super duplex”. EXAMPLES
UNS S S32505, UNS S32550, UNS S32750, UNS S32760 and UNS S39274.
3.1.18 type 6Mo austenitic stainless steel alloys with 6 % Mo and PREN EXAMPLES
≥ 40
UNS S31254, UNS N08367 and UNS N08926.
3.1.19 test directions test directions are defined relative to the geometry of the component to be tested For the purpose of this NORSOK standard the definitions in AST M A370-11, sect. 4, apply with axial defined as the longitudinal axis of test specimen located parallel to the main axis of the component.
3.2
Abbreviations
API ASTM CD EN HIP IEC ISO MDS MOM NDE PREN PWHT QTR SS UNS WPQR WPS
American Petroleum Institute American Society for Testing and Materials compact disc European Standard hot isostatic pressed International Electrotechnical Commission International Organization for Standardization material data sheet minutes of meeting non-destructive examination pitting resistance equivalent post weld heat treatment qualification test record stainless steel unified numbering system welding procedure qualification record welding procedure specification
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NORSOK standard M-650
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Responsibilities
4.1
Purchasers responsibility
Edition 4, September 2011
The purchaser is responsible for ensuring that the manufacturers engaged are qualified within the essential variables of this NORSOK standard. Acceptance of a manufacturer is at the discretion and determination of the purchaser.
4.2
Manufacturers responsibility
The manufacturer is responsible for establishing and maintaining required documentation and carry out verifications and testing in accordance with this NORSOK standard. A manufacturer acquiring a "NORSOK M-650 qualification" assumes an obligation to carry out manufacturing in accordance with the qualified Manufacturing Summary including its referred procedures. If an order requiring "NORSOK M-650 qualification" is outside the qualified range, as defined in 10.2, the purchaser shall be informed.
4.3
Responsibilities of Qualifying Company
The qualification exercise itself shall be carried out in co-operation with and verified by a Qualifying Company. The Qualifying Company shall monitor the qualification exercise, review and in the end accept the resulting qualification test record (QTR) and as proof of the acceptance sign and stamp the QTR front page. It is important for acceptance of the QTR by other customers that the verification exercise is carried out by a recognized Qualifying Company.
5
Qualification of manufacturers
5.1
Basis for qualification of manufacturers
Basis for qualification of manufacturers including their nominated sub-contractors shall be as follows: a) knowledge and relevant manufacturing experience with the type of material to be qualified (see Clause 7); b) acceptable manufacturing facilities and equipment (see Clause 7 and Clause 9); c) established Manufacturing Summary (procedure) covering all manufacturing steps from melting or semi product to finished products (see Clause 8); d) an established heat treatment procedure (see Clause 9); e) manufacturers quality system, which shall fulfil the requirements of ISO 9001; f) results of testing in compliance with this NORSOK standard (see Clause 10).
5.2
Evaluation for acceptance
The Qualifying Company shall carry out a review of the manufacturers facilities, equipment, implementation of procedures and documentation as required by this NORSOK standard at the m anufacturers and subsuppliers premises. The evaluation for acceptance shall concentrate on facilities and equipment for m elting, refining, forming, welding, heat treatment, etc. The review shall be carried out by technical competent personnel, with knowledge of metallurgical aspects of the applicable alloys, including precipitation diagrams, effect of hot forming, welding, heat treatment, etc., and who has experience relevant for the manufacturing process to be evaluated. The result of the evaluation shall be documented in an evaluation report or a MOM.
5.3
Acceptance of qualification
A complete QTR with content in compliance with Clause 11 shall be established for possible acceptance.
5.4
Proof of acceptance
The original signed and filled in QTR front page is the only valid proof of being accepted according to this NORSOK standard.
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NOTE There is no official listing in the name of NORSOK of accepted manufacturers according to this NORSOK standard.
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Validity of qualification
6.1
Term of validity
The validity of a qualification is 5 years from the date of acceptance (signing) of the QTR front page. The qualification is valid within the parameters specified in 10.2.
6.2
Renewal of qualification
Renewal of the qualification shall be carried out as follows: a) a manufacturer with regular production of the originally qualified products and alloys is considered requalified and additional testing is normally not required. It is a pre-requisite that all test requirements in the current revision of this NORSOK standard are complied with; b) evaluation and review at the manufacturers and sub-suppliers premises according to 5.2 shall be carried out by the Qualifying Company; c) the Manufacturing Summary and referred procedures shall be reviewed, updated and a decision made whether retesting is required; d) the heat treatment procedure and its corresponding verification, see 9.3, shall be reviewed, and a decision made whether a new verification is required; e) a minutes of meeting (MOM) listing actual parts of the QTR which shall be updated and with conclusions for renewal of the qualification shall be included in the re-qualified QTR; f) a new QTR front page shall be established and properly signed.
6.3
Transitional arrangements
Subject to purchasers acceptance, Revision 3 qualifications are considered to fulfil the Edition 4 requirements of this NORSOK standard until the validity of the Revision 3 qualification expires on the c onditions stated below. There are no transitional arrangements for flanges or valves machined from forgings. For these products it is presupposed that the qualification shall be in accordance with Edition 4 of this NORSOK standard. Transitional conditions are as follows: a) the Manufacturing Summary, see 8.2, is updated, and a heat treatment procedure, see 9.2, is established/updated; b) verification of the heat treatment procedure, as specified in 9.3, has been carried out; c) the additional test requirements in 10.3.3, as specified for selected product forms in Table 2, are fulfilled. In such case a statement shall be included in the box “Other information” on the original Revision 3 QTR front page and signed off by the Qualifying Company. The original Revision 3 validity date shall be maintained.
7
General requirements
7.1
Knowledge and relevant experience
7.1.1
Knowledge
The manufacturer shall have in-house knowledge of relevant metallurgical aspects of the applicable alloys including precipitation diagrams, effects of hot forming, welding, and heat treatment parameters, etc. as applicable for his manufacturing process. 7.1.2
Relevant experience
The manufacturer shall have relevant experience with manufacture of the type of material to be qualified. Relevant experience should be supported by statistical data presented in the form of a histogram for key parameters, e.g. tensile strength, impact thoughness, corrosion resistance, etc. In addition a relevant reference list from the last 2 years production for the products, materials and the range of sizes to be qualified shall be included.
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New manufacturers with less than 2 years of documented production for actual product and material may be qualified to this NORSOK standard, but with a validity period limited to 2 years, after which a new evaluation shall be carried out. A note to this effect shall be included on the QTR front page.
7.2
Manufacturing facilities and equipment
Facilities and equipment shall be fit for purpose, regularly maintained and calibrated as required. Requirements for heat treatment facilities and equipment are further described in 9.1.
7.3
Sub-contractors
If parts of the production are carried out by a sub-contractor, the manufacturer is responsible for ensuring that the sub-contractor meets the requirements of this NORSOK standard for the manufacturing steps that the sub-contractor is performing.
7.4 7.4.1
Quality requirements for test laboratories and manufacturers of welded products Test laboratories
Test laboratories shall have a quality system in accordance with the principles in ISO/IEC 17025 or equivalent. The laboratories should hold a national accreditation. 7.4.2
Manufacturers of welded products
Manufacturers of welded products shall comply with the principles specified in ISO 3834-2.
8
Manufacturing Summary
8.1
Requirements for Manufacturing Summary
The manufacturer shall have a Manufacturing Summary for each production route, type of product, grade of material and size range. NOTE Sometimes it can be convenient to combine several production routes, type of products and/or grade of materials into one Manufacturing Summary, e.g. as shown in the flow chart in Annex A.
The Manufacturing Summary shall describe, step by step in a logical and correct sequence, all important manufacturing activities with reference to detailed procedures. A short description and the main parameters for each activity shall be included. Each production route shall be illustrated with a flow chart. If the manufacturer has different plants or different production routes for a product, separate documentation is required for each of these. If essential parts of the work (e.g. form ing, heat treatment, pickling, etc.) are subcontracted, this shall be identified in the documentation. The documentation shall then include the name and address of each subcontractor and the relevant documentation from the subcontractor’s equipment and procedures. The Manufacturing Summary is the property of the manufacturer. Distribution is at the manufacturer's discretion.
8.2 8.2.1
Content of the Manufacturing Summary Scope
The scope of the Manufacturing Summary shall be clearly defined by stating a) b) c) d)
name and address of manufacturer, grade of material (UNS number) with reference to standard and MDS, type and size range of products for which the Manufacturing Summary applies, identification of the manufacturing process.
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NORSOK standard M-650 8.2.2
Content
8.2.2.1
General
Edition 4, September 2011
The Manufacturing Summary shall include, but not be limited to, the requirements in 8.2.2.2 to 8.2.2.15. 8.2.2.2 The product type and the manufacturer ’s requirements (purchasing specification) regarding start material. Apply especially when semi finished products such as ingot, bar, pipe, plate, strip, etc., are used as a basis for the manufacture. In such cases the manufacturer of the start material shall also be given. 8.2.2.3
Manufacturers inspection of start material on reception.
8.2.2.4
Melting shop including
a) melting and refining processes, b) casting method, e.g. ingot, continuous cast, etc. 8.2.2.5 a) b) c) d)
Foundry including
melting and refining processes, handling of and maximum percentage of eventual return scrap, casting process, e.g. investment, centrifugal, sand castings, etc., moulding method, type of sand, binding agent and method of casting.
8.2.2.6
Hot forming including
a) all hot forming processes such as forging, pressing and rolling with information about size and thickness range of each hot forming process, b) maximum and minimum hot forming temperatures and how these temperatures are controlled, c) possible reheating cycles, d) method of cooling after completion of the hot forming process, e) minimum forging ratio including how the forging ratio is calculated, f) sketch illustrating each step in the forming process, see Annex A. 8.2.2.7
Heat treatment including
a) description of heat treatment cycle, e.g. loading temperature, heating rate, set temperature with tolerances and holding- and soaking times. For continuous and semi continuous furnaces according to 9.2.4, b) cooling details, e.g. cooling medium (water, air or combination thereof, etc.), type of cooling (quenching, spraying, etc.), relevant parameters (temperatures of quenching bath, for spraying medium velocity, type and size of nozzles, etc.), c) reference to the specific heat treatment procedure according to 9.2. 8.2.2.8
Blasting/cleaning equipment, including the type of grit.
8.2.2.9
Pickling.
8.2.2.10
Welding (including weld repair). The W PS and PQR applicable for the qualification shall be listed.
8.2.2.11
PWHT (if applicable).
8.2.2.12
Type of NDE and inspection methods.
8.2.2.13
Production testing including
a) type of tests to be carried out, b) test sampling, which shall be identified as a separate activity and described in the correct sequence in the Manufacture Summary, c) sketches showing typical samples with dimensions for production tests with location and orientation of test specimens, d) procedure for preparation of specimens, etching and examination of microstructure including types of etchants used preferably with reference to one of the etchants listed in ASTM E407.
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For duplex steels in particular more than one etchants m ay be required for detecting intermetallic phases, carbides and nitrides. 8.2.2.14
Description of the material traceability system.
8.2.2.15 A list of applicable procedures. An excerpt from a typical Manufacturing Summary is included in Annex A as an example.
9
Heat treatment
9.1
Heat treatment facilities and equipment
9.1.1
General
Heat treatment facilities and equipment shall fulfil the requirements in 9.1.2 to 9.1.8. In addition, API 6HT should be used as a guideline. 9.1.2
Foundries
Foundries shall have heat treatment facilities within their own premises or they shall be located in their close vicinity. 9.1.3
Heat treatment furnaces
Heat treatment furnaces shall be adequately dimensioned for the loads to be heat treated. Electrical furnaces shall have mechanical means of circulating the air during heating. The only exception is cases where it can be documented through verifications (see 9.3) that uniform heating is achieved without forced circulation. Furnaces shall be equipped with automatic temperature indicating, controlling and recording devices, which shall possess an accuracy of ± 1 % of their full scale range. A temperature uniformity survey of the quality heat treatment furnaces shall be carried out annually in accordance with API Spec 6A:2010/ISO:2009, Annex M, ASTM A 991 or equivalent and additional requirements given in Annex B. The initially temperature uniformity survey shall be carried out with maximum load in the furnace. Subsequent temperature uniformity surveys may be carried out with empty furnace. 9.1.4
Thermocouples
Thermocouples shall be calibrated and fulfil the requirements of API 6A (Twentieth Edition)/ISO 10423:2009, Annex M. 9.1.5
Quenching baths
Quenching baths shall have dimensions and cooling facilities adequate to keep the water temperature below 50 ºC at any time during the quenching operation. The quench tank shall be equipped with pumps or propellers to ensure satisfactory circulation and agitation during quenching. Quenching facilities should include provisions for internal cooling for the quenching of products with penetrating bores such as pipes. The quenching bath shall be equipped with continuous temperature monitoring/recording devices. 9.1.6
Loading of components
Pallets or other fixtures shall be used for placing parts during heat treatment and quenching to ensure free circulation of air and water between each component. Parts shall not be placed directly onto the furnace floor. Piling of components in baskets is not allowed. 9.1.7
Transfer time between furnace and quenching bath
The equipment shall be capable of transferring materials from heat treatment furnace into quenching bath within a maximum of 60 s for alloys requiring water quenching.
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For large components it is recognised that a transfer time of 60 s may be difficult to achieve. In such cases a longer transfer time may be specifically qualified. Qualification tests shall comprise both thin and heavy sections of such components as agreed with the Qualifying Company. Details of the extended transfer time including for, which products it is applicable for, shall be highlighted on the QTR front page. The transfer time is measured from the time the furnace door is fully open or the furnace roof is fully removed and until the component(s) is completely submerged into the quenching bath. 9.1.8
Continuous furnaces and induction furnaces
Continuous furnaces and induction furnaces shall generally fulfil the prin ciples stated above. A specific evaluation shall be made in each case.
9.2 9.2.1
Heat treatment procedure General
A specific heat treatment procedure shall be established. Content of the procedure shall as a minimum be as given in 9.2.2 to 9.2.6. 9.2.2
Description of heat treatment facilities and equipment
The following information shall be included: a) type and identification of furnace(s); b) sketch of furnace showing, overall dimensions, working zone and location of burners as applicable; c) location and identification of pyrometers and/or thermocouples in the furnace for control and recording respectively. For continuous furnaces the heating zone and the working zone shall be clearly defined; d) maximum operating temperature of furnace(s); e) description of how temperature is controlled; f) cooling facilities; g) sketch of heat treatment facilities showing furnace(s) and quenching bath relative to each other. 9.2.3
Loading and unloading of components and transfer between furnace and quenching bath
The following information shall be included: a) stacking of components in furnace and during quenching (sketch to be prepared); b) method(s) for unloading of components from furnace. If several pallets/components are heated in the furnace at the same time the unloading of these should be especially addressed; c) maximum transfer time of components from open furnace door until components are completely submerged in quenching bath. 9.2.4
Description of heat treatment cycle
The following information shall be included: a) loading temperature, heating rate, set temperature with tolerances and holding- and soaking time; NOTE
For definition of holding- and soaking time see figure in Annex C, 3.1.6 and 3.1.15.
b) cooling details, e.g. cooling medium (water, air, gas or a combination thereof, etc.), type of cooling (quenching, spraying, etc.), relevant parameters (temperatures of quenching bath, for spraying medium velocity, type and size of nozzles, etc.); c) for continuous and semi continuous furnaces: travel speed and minimum soaking time as function of size (e.g. thickness, diameter, cross section, etc.) of products to be heat-treated and other relevant parameters. 9.2.5
Production testing and traceability
The following information shall be included: a) principles for selection of components to be used for production testing within each heat treatment load. (sketch to be prepared) taking into account that selection should be from the center close to the bottom of a heat treatment load; b) description of NORSOK standard
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1) how traceability of heat and heat treatment lot is ensured throughout the whole heat treatment process, 2) how components within each heat treatment load are identified, 3) how components used for production testing in each heat treatment load are identified. 9.2.6
Documentation of heat treatments
A description of the following shall be included: a) b) c) d)
how the temperature cycle is recorded and documented; follow up and documentation of maximum temperature of quenching bath during quenching; how documentation of the heat treatment loads is carried out [via photographs (preferred) or loading map]; actual location of components used for production testing in each heat treatment load.
9.3 9.3.1
Verification of heat treatment procedure General
Verification is required of procedures for heat treatment except for stress relieving heat treatment in accordance with this NORSOK standard. 9.3.2
Objective
The objective of the verification is to ensure that the specified parameters in the established heat treatment procedure are correct by comparing the readings of the furnace controlling thermocouple and the contact thermocouples fixed onto the load/components. The verification shall especially verify that a) all components in a heat treatment load reach the specified set temperature throughout their thickness, b) the soaking time is not started before the load/components have actually reached the minimum heat treatment temperature specified in the procedure. For guidance see API 6HT (first edition), sect. 6.3.1.6. 9.3.3
Extent of verification
The verification shall be carried out for each furnace used for quality heat treatment using the heaviest load and/or most dense packed load to be heat treated. Manufacturers or heat treatment contractors having several heat treatment procedures shall verify the most extreme conditions (e.g. a combination of shortest soaking time, shortest heating time, highest set temperature) in their procedures to minimise the number of verifications required. After a major re-furbishment of a f urnace or after a furnace modification changing the heating parameters, a new verification shall be carried out. 9.3.4
Procedure for the verification
The verification shall be carried out as follows: a) contact thermocouples shall be fixed onto the surface of at least three components which are respectively located in the middle of the heat treatment load and in two corners of the load diametrically opposite to each other; b) for heavier components holes shall be drilled into the components down to mid-thickness and the thermocouples placed into the holes. The holes should be at least 100 m m from the second surface of the component. To avoid damaging the components heat sinks may be used, which shall be made from the same general type of material as the parts being heat treated. The cross section of the heat sink shall be equal to that of the heaviest cross section of the parts being heat treated and the dimensions such as to allow for location of the drilled hole as specified above. The number and location of the heat sinks shall be as specified in a) above; The definition of “heavier” component varies with the type of component (e.g. plate, pipe, fitting, forging, casting, etc.) of the component and shall be agreed in each case also taking into consideration the proposed soaking time in the heat treatment procedure for the component. c) readings from the contact thermocouples shall be compared with the readings from the controlling thermocouple of the furnace by superimposing the time temperature curves from the contact thermocouples onto the curve from the controlling thermocouple of the furnace. NORSOK standard
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NORSOK standard M-650
Edition 4, September 2011
See the example in Annex C; d) the manufacturer shall establish a procedure describing how the verification is proposed to be carried out including how the mid-thickness temperature will be checked. The procedure shall be accepted by the Qualifying Company prior to start of the verification. 9.3.5
Reporting
A report shall be established identifying the furnace verified, describing the heat treatment load used and location of thermocouples within the load (photograph). The superimposed time temperature curves from the contact thermocouples and the controlling thermocouple(s) of the furnace shall be included in the report. 9.3.6
Witnessing
The verification of the heat treatment procedure shall be witnessed by the Qualifying Company, who also shall sign the final report onto completion of the verification exercise.
10
Qualification of the manufacturing process
10.1
Objective of qualification testing
The manufacturing process as described in the Manufacturing Summary shall be qualified by testing of actual products in order to a) demonstrate that the proposed manufacturing route and production parameters result in products meeting the specified requirements, b) verify that the proposed production test sampling gives results, which are representative of the properties of the actual components they represent.
10.2 10.2.1
Essential variables General
A change in one or more of the manufacturing parameters stated in 10.2.2 to 10.2.13 requires re-qualification of the manufacturing process. 10.2.2
Thickness limitations and weight
The maximum qualified weight and thickness shall be according to limits given in Table 1, but shall in no case exceed the limits specified in the Manufacturing Summary.
Table 1 - Qualified maximum thickness and weight for applicable products Type of product
Strip, plate, pipe, tube and wrought fittings
Type of material
High alloyed austenitic SS + SS type 25Cr duplex SS type 22Cr duplex
Castings, forgings, bars and HIP
High alloyed austenitic SS, Nialloys + SS type 25Cr duplex SS type 22Cr duplex
NORSOK standard
Tested thickness (T)
Qualified thickness
mm
mm
T 40
T + 25 %, maximum 40
T > 40 T 60
T T + 25 %, maximum 60 T T + 10 %, maximum 60
T > 60 T 60
T > 60 T 120
T T + 10 %, maximum 120
Weight of tested component (G) kg
Qualified weight
N/A
N/A
N/A
N/A
G 250
G + 100 %
G > 250 G 250
All G + 100 %
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NORSOK standard M-650 Type of product
Type of material
Titanium Investment castings
10.2.3
All
Edition 4, September 2011 Tested thickness (T)
Qualified thickness
mm
mm
T > 120 T T
Weight of tested component (G) kg
Qualified weight
G > 250 G 150 G > 150 N/A
All G + 100 % All N/A
T T + 25 % T + 25%, maximum 60 mm. Above 60 mm as for Castings.
Material grade
A change from one material grade to another, e.g. change from one UNS No. to another UNS No. 10.2.4
Melting and refining equipment
A change in the final melting/refining process. 10.2.5
Manufacturers of start materials
A change of manufacturer of start material. The start material is defined as ingots, billets, blooms, plates, pipes, etc. used to manufacture a final product as flanges, fittings, valve bodies, etc. This requirement may be disregarded if a) the manufacturer of start material holds a valid NORSOK M-650 qualification for the specific start material, b) it can be documented that the specific start material from a manufacturer already has been used in other qualifications for the same grade of material. 10.2.6
Manufacture at different plants and/or locations
If production is carried out at different plants/locations, a separate qualification is required for each plant. This applies also for a change of sub-contractors for essential operations such as heat treatment, HIPing, etc. 10.2.7
Manufacturing equipment
A change in manufacturing equipment, as described in the Manufacturing Summary, that can negatively influence the product properties. This applies also if the manufacturer has several alternative manufacturing routes for a product. 10.2.8
Castings
Change of moulding method typically between a) b) c) d)
sand moulding (sand castings), ceramic moulding (investment castings, e.g. lost wax-, unicast-, shaw method, etc.), graphite moulding (titanium castings only), change of casting technique between static casting, centrifugal casting, or vacuum casting. This is not applicable for titanium castings, which shall always be cast in vacuum, e) change of HIPing parameters (significant changes in temperature, pressure, time, vacuum ) or HIP equipment (titanium castings only). 10.2.9
Forgings
Change of the following: a) open die and ring rolled product forms; Separate qualifications shall be carried out for flanges, bars, rings, discs, etc.
NORSOK standard
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NORSOK standard M-650
Edition 4, September 2011
b) closed die forgings. Components for testing shall have a section thickness in the upper thickness range specified by the Manufacturing Summary. 10.2.10
Hot isostatic pressed (HIP) products
Change of a) the manufacturer of powder for HIP, b) HIP parameters (significant changes in temperature, pressure, time, vacuum) or HIP equipment. 10.2.11
Hot forming
A change from one forming method to another and a change of forging temperature outside the established and qualified tolerances. Typical examples are a) b) c) d) e) f)
from rolling to forging or vice versa, from die forging to open die forging or vice versa, from hammer forging to press forging or vice versa, from hot pressing to extruding or vice versa, from hot to cold forming/rolling or vice versa, change of cooling method after hot forming from water quenching to any other cooling method.
10.2.12
Welded products
For manufacture of welded pipe and fittings a change of WPS does not require re-qualification, provided the requirements of NORSOK M-630 are fulfilled, except f rom the following: a) changes from double sided to single sided welds; b) change in welding method or combination of welding methods. 10.2.13
Heat treatment
The following apply: a) change of heat treatment temperature outside the allowable range. The allowable range of heat treatment temperature shall be within –10 C to +30 C from the temperature used for the qualification testing of the component; b) change of heat treatment cycle, e.g. from a one step to a two step cycle or vice versa; c) reduction of holding and/or soak time to a time shorter than that established during the verification of the heat treatment procedure; d) change from furnace heat treatment to induction heat treatment or vice versa; e) change from batch furnace heat treatment to continuous furnace heat treatment or vice versa; f) for hot finished seamless pipes only: change from furnace heat treatment to direct quench from hot finish operation or vice versa; g) change in quench medium from water to polymer, oil, nitrogen, air and similar or vice versa; h) change in quenching method from quenching in bath to spray quenching or vice versa. Change or re-furbishment of the heat treatment furnace within the same premises does not require requalification provided the requirements in Clause 9 are fulfilled.
10.3 10.3.1
Qualification testing Selection of components for testing
The selection of components for testing and test sampling shall be as agreed with Qualifying Company. Components for testing should have a section thickness in the upper thickness range specified by the Manufacturing Summary. Except for castings and open die forgings the components shall be representative in geometry of what actually shall be m anufactured. Castings and open die forgings selected for testing shall be actual products, i.e. not test blocks. For castings qualification should be carried out on a cored component, e.g. valve body. For forged flanges, contour forged valves and similar products where production testing is planned to be carried out on an integral prolongation such a prolongation shall be integrated in the qualification test forging. NORSOK standard
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NORSOK standard M-650
Edition 4, September 2011
Components for testing shall be from regular production or from test production m anufactured according to the normal manufacturing route and with regular production equipment. 10.3.2
Testing
10.3.2.1
Certification of test sampling and test results
All extraction of test samples and testing specifically related to the qualification tests shall be certified in accordance with EN 10204, Type 3.2. 10.3.2.2
Extent of testing for qualification
Testing for qualification shall as a minimum comprise a) production testing with test sampling as specified in NORSOK M-630: MDSs, other applicable standard and/or the Manufacturing Summary, b) additional testing for qualification according to Table 2, c) for forged flanges, contour forged valves and similar products with integral prolongations testing shall be carried out on both the prolongation and the product itself. d) non-destructive testing as specified in NORSOK M-630 and relevant MDSs and/or other relevant material specifications. The type of tests to be performed and minimum requirements shall be as specified in NORSOK M-630 and relevant MDS (or material standard/specification if materials are not covered by a MDS). 10.3.2.3
Requirements for materials requiring impact testing
For materials requiring impact testing, the requirement for base material shall be 20 J higher than the production test requirements. This does not apply to the additional testing specified in 10.3.3 or to the testing in position 2 for flanges. NOTE For qualification of dimensions outside the range specified by the respective MDSs special acceptance requirements may be agreed, e.g. exception to the requirement for the impact test results to be 20 J higher during qualification than the production test requirements. In such cases this shall be clearly stated onto the QTR front page.
10.3.2.4 Acceptance of production testing from integral prolongations from forged products To accept production testing to be taken from the prolongation the test results from the prolongation shall be representative of the properties obtained from the sam e position of the sacrificial product, e.g. position 1 (TH /2) for flanges. It is at the discretion of the Qualifying Company to decide what is “representative”, i.e. an acceptable difference between results from tests located in the prolongation and in the product itself. Table 2 – Testing required for qualification Type of product All products
Castings
Dished heads
NORSOK standard
Sample for Additional tests for qualification production test Test sampling as Type, number and location of tests as specified in the MDS specified in the MDS and material specification unless otherwise specified in this and/or the table. Manufacturing Summary. A sketch shall be prepared with dimensions of production test samples and tested components tested for qualification. The location and orientation of test specimens shall be shown. The components used for qualification should in addition be documented with photographs. Tests from thin and thick sections of a sacrificial casting. Integral or gated test blocks. Production test blocks shall be tested as part of the qualification testing. From over-length of the component.
Tests shall be carried out from the over-length and from the deformed area of the component. For dished heads made of
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NORSOK standard M-650 Type of product
Flanges – all manufacturing methods
Forgings – closed die.
Sample for production test
Sacrificial flange or an integral prolongation.
Sacrificial forgings.
Forgings - open die
Tests from prolongation on actual forging or from sacrifical forging .
HIP components except flanges
Integral test blocks.
Plates
Cut from plate.
Ring rolled products
Rolled and forged bars
Tests from prolongation on actual forging or separate forged test ring. Cut from over-length of bar.
Seamless pipe and tube Strip
Cut from over-length of pipe Cut from strip.
Valves machined from forgings
Tests from prolongation on actual forging
Welded pipe and tube
Cut from over-length of pipe or from test plate welded as prolongation of the pipe/tube weld. Cut from sacrificial fitting, over-length of fitting or for welded fittings test plates welded as a prolongation of the fitting weld.
Wrought fittings seamless and welded
NORSOK standard
Edition 4, September 2011 Additional tests for qualification plates and welded together prior to forming the tests shall include a weld. Qualification testing shall encompass testing of a sacrificial flange in both the flange neck and flange ring, position 1 (TH /2) and position 2 (T B/2) respectively, as shown in the respective MDSs. In position 1 impact testing shall be taken in both axial and tangential direction. The minimum absorbed energy for impact tests in Pos. 1, tangential direction, shall be minimum 27 J/20 J (average/single values) tested at -46 ºC . Additional testing according to 10.3.3 shall be carried out if section thickness exceeds 50 mm for all materials requiring impact- or corrosion testing according to MDS/ applicable specifications. Other additional testing may be required depending on shape and functionality of the forging as agreed with purchaser and Qualifying Company. Additional testing according to 10.3.3 shall be carried out if section thickness exceeds 50 mm for all materials requiring impact- or corrosion testing according to MDS/applicable specifications. Other additional testing may be required depending on shape and functionality of the forging as agreed with purchaser and Qualifying Company. Testing shall be made from thin and thick sections of a sacrificial product. Except for the additional testing test results shall fulfil the requirements in the respective MDSs . Additional testing according to 10.3.3 shall be carried out if section thickness exceeds 50 mm for all materials requiring impact- or corrosion testing according to MDS/applicable specifications . Both ends on one plate shall be tested with three sets of tests at each end located in the middle and at each edge. Test specimens shall be located in the mid-thickness. Additional testing according to 10.3.3 shall be carried out if section thickness exceeds 50 mm for all materials requiring impact- or corrosion testing according to MDS/applicable specifications. Tests shall be carried out at one end and in the mid-length position of one bar. Additional testing according to 10.3.3 shall be carried out if section thickness exceeds 50 mm for all materials requiring impact- or corrosion testing according to MDS/applicable specifications . One pipe/tube shall be tested at one end and in the mid-length position. One end on one coil shall be tested with three set of tests at each end located in the middle and at each edge. Testing according to the applicable MDSs. Additional testing may be required depending on shape and functionality of the forging as agreed with purchaser and Qualifying Company. Weld and base material shall be tested at one end and in the midlength position on one pipe.
One fitting of each type shall be tested at one end as a minimum. In addition different locations with different deformation ratio should be tested, e.g. inner- and outer radii and neutral zone for elbows. Tees should be tested both on one end and in the crotch area. For welded fittings testing shall comprise base material and weld(s).
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NORSOK standard M-650 10.3.3
Edition 4, September 2011
Additional testing
Additional testing shall be carried out as required in Table 2. For all materials having section thickness/diameter exceeding 50 mm and requiring impact- or corrosion testing according to MDS/applicable specifications, additional testing shall be carried out as follows using specimens located in the mid thickness position (T/2) and at a distance from any second surface of T or at least 100 mm: a) impact testing in axial and tangential direction. The minimum absorbed energy shall be minimum 27 J/20 J (average/single values) tested at -46 ºC; b) corrosion and micro-examination in accordance with the requirements specified by the applicable MDS. NOTE It is recognized that for certain applications corrosion properties and microstructure in mid-thickness are not important for the functionality of the component as agreed with purchaser and Qualifying Company. In such cases it may be agreed that the tests shall be carried out for information only and a note about this shall be included on the QTR front page.
10.4
Welding procedure qualifications
The qualification exercise shall include the supporting WPQR for the WPS for the following: a) welded products in accordance with the applicable MDS; b) repair welding of welds in accordance with the applicable MDS; c) minor and major repair welding as defined in ASTM A 703 for castings.
11
Qualification test record (QTR)
11.1
General
The manufacturer shall establish a qualification test record (QTR) with content as listed in 11.2. The QTR shall be issued with document and revision numbers. The QTR shall be prepared with a front page with format and content as shown in Annex D. It is essential that all documentation be accurate, specific and in accordance with this NORSOK standard. The documentation will otherwise be rejected and thereby also the qualification.
11.2
Content of qualification test record (QTR)
The content of QTR shall contain the following: a) QTR front page. See format and content as shown in Annex D. b) Sect. 1
Table of content
c) Sect. 2
Manufacturing Summary, see Clause 8, including 1) process flow chart, 2) sketches showing typical samples with dimensions of production test samples and location and orientation of test specimens.
d) Sect. 3
Heat treatment procedure, see Clause 9, including 1) report on the verification of heat treatment procedure, see 9.3, 2) report on the temperature uniformity test, see 9.1.3 and Annex B.
e) Sect. 4
Results of qualification testing including 1) description of component(s) tested for qualification. Sketch(es) shall be prepared showing dimensions of test sample and location and orientation of test specimens, 2) heat treatment chart(s) from the heat treatments of the components used for the qualification testing, 3) test reports with results from qualification testing, 4) start material certificate (when applicable).
f) Sect. 5
WPSs and WPQRs
NORSOK standard
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NORSOK standard M-650
g) Sect. 6
Edition 4, September 2011
1) welded products: a list of WPSs/W PQRs shall be included, 2) castings: the actual WPS/W PQRs for repair welding of minor and major repairs shall be included. Specific reference list, see 7.1.2
h) Sect. 7
Documentation of quality assurance system including 1) ISO certificate(s) according to ISO 9001, 2) Certificate of compliance to PED 97/23/EC, Annex I, paragraph 4.3, as available.
i) Sect. 8
MOM(s) from visit(s) to manufacturer by purchaser as required in 5.2.
11.3
Required copies and distribution of qualification test record (QTR)
After acceptance one electronic copy, e.g. a CD, and one paper copy shall be issued to the Purchaser having initiated or ordered the qualification at the manufacturer and to the Qualifying Company, if different from the Purchaser, which monitored the qualification exercise and accepted the QTR by signing the QTR front page. Additional distribution is at the manufacturer’s discretion.
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NORSOK standard M-650
Edition 4, September 2011
Annex A (Informative) Manufacturing Summary front page and example
Example of information, which shall be included on the front page:
Plant(s) and location(s):
Actual plants, locations and equipment facilities where this procedure is relevant.
Product(s):
e.g. CLOSED DIE FORGINGS
Specification(s):
e.g. NORSOK M-630, MDS D44 Rev. 4
Limitations in the procedure: Weigth: Length: Thickness: Other:
Qualification documentation:
Ref. to the relevant document(s)/reports/test result(s) which confirm that manufacturing of materials in accordance with this procedure will ensure s atisfactory results per the actual specification.
Other relevant information:
Revision:
Date:
Made by:
Checked by:
Approved by:
Manufacturing Summary No.:
NORSOK standard
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NORSOK standard M-650
Edition 4, September 2011
EXAMPLE OF MANUFACTURING SUMMARY (4 pages) Doc. No: MS-03 Page 1 of 4 MANUFACTURING SUMMARY TEE MADE BY FORGING Seamless pipe Size 1” to 24” / Thickness 10 mm to 31,25 mm ASTM A 815 UNS S31803 – MDS D43 REV. 24 (Prototype Tee 6” sch. 160) N°
PHASE
DESCRIPTION
PROCEDURE
2
PMI
Pipe to ASTM A 790 S31803 MDS D41 Rev. 24 N = 0,14 % to 0,20 % Manufacturer: 100 % raw material.
3
Cutting
Cutting to required length by saws.
POQ-09
4
Hard stamping of last two number of heat number.
POQ-05
5
Identification marking Heating
6
Ovalization
7
Re-heating
8
Forming
9
Cooling
Ovalization of pipe by pressing Equipment = 60 t; 100 t; 150 t; 200 t; 250 t; 300 t; 400 t; 900 t; 1200 t. Reheating at xxxx °C to xxxx °C, holding time minimum 1 min for each mm thickness. Temperature controlled by optical pyrometer. Forging by presses Start forming temperature xxxx°C to xxxx°C Equipment = 60 t; 100 t; 150 t; 200 t; 250 t; 300 t; 400 t; 900 t; 1200 t. After forming the temperature shall not be less than 950 °C. Quenching in cold water.
10 11
Cutting hole Re-heating
12
Extrusion
13
Cooling
14
Cutting
1
Identification of base material
NORSOK standard
POQ-05
PMI-01 Rev.0
Heating at xxxx °C to xxxx 0 °C, holding time minimum 1 min for POQ-09 each mm thickness. I.O. 13 Rev.2 Temperature controlled by optical pyrometer. Equipment = furnace bloss N° 3 furnace gibbon N° 2
Cutting of bulge. Re-heating at xxxx °C to xxxx °C, holding time minimum 1 min for each mm thickness. Temperature controlled by optical pyrometer. Extrusion of branch by press After extrusion the temperature shall not be less than xxx °C. Re-heating at xxxx °C if more than one step is necessary. Quenching in cold water.
POQ-09 I.O. 13 Rev. 2 POQ-09 I.O. 13 Rev.2 POQ-09 I.O. 13 Rev.2
POQ-09 I.O. 13 Rev.2 POQ-09 I.O. 13 Rev.2
Cutting to final dimensions by plasma, except section connecting test samples to body of tee.
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Edition 4, September 2011 Doc. No.: MS-03 Page 2 of 4 MANUFACTURING SUMMARY TEE MADE BY FORGING Seamless pipe Size 1” to 24” / Thickness 10 mm to 31,25 mm ASTM A 815 UNS S31803 – MDS D43 REV. 4 (Prototype Tee 6” sch. 160)
N°
PHASE
DESCRIPTION
PROCEDURE
15
Heat treatment
16 17
Shot blasting Sampling
Heat treatment: Solution annealing in gas heating f urnace Equipment: Sottri truck-hearth with dimension of Furnace loading temperature: room temperature Heating rate: xxx°C/h (above xxx°C) Holding temperature: xxxx°C Holding time: 1h/1” wall thickness or minimum 15 min Quenching: In cold water max xx °C within 60 s. Stainless steel grit. Removal of material for test samples.
HT-01 Rev.3
18
Mechanical test
According to NORSOK MDS D43 Rev.4
19
Pickling
20 21
Machining Dye penetrant test
22
PMI
Immersion in acid solution at temperature of xx °C Equipment: N° 2 pickling vat 900 mm x 1600 mm x 1000 mm Working of the ends as per purchase order. According to ASTM A 815 Supplementary requirement S7 ASME VIII Div.1 Accept criteria: ASME VIII Div.1 App.8 100 % of the fittings. 100 % of the fittings. PMI-01 Rev.0
23
Marking
Marking by low stress stamping according P.O.
MDS D43 Rev.4
24
By calibrated equipment.
25
Visual and dimensional Pickling
POQ-05 Drw. No. 972 PK-01 Rev.0
26 27
MDS D43 Rev. 24 Test sample plan N° SP-01 Rev.1 MDS D43 Rev. 4 Test sample plan N° SP-01 Rev.1 PK-01 Rev.0
Final dossier
Re-immersion in acid solution for final cleaning and passivation. Inspection certificate plus NDE certificates.
EN 10204, 3.1B
Packing
According order requirements.
ASTM E 700
Revision No.
Date
NORSOK standard
Made by
Approved by
Note Flow chart is shown at page 4 coloured route.
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NORSOK standard M-650
Edition 4, September 2011 Doc. No.: MS-03 Page 3 of 4
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NORSOK standard M-650
Edition 4, September 2011 Doc. No.: MS-03 Page 4 of 4
EXAMPLE OF MANUFACTURING FLOW CHART Manufacture flow chart for elbow and tee manufacture SEAMLESS PIPE CUTTING MARKING ELBOW REDUCING & CAP BY FORGING
ELBOW BY MANDREL HEATING
HEATING EXPANDING OVALIZATION (ELBOWS ONLY)
CALIBRATION
RE-HEATING ELBOWS ONLY
QUENCH
FORMING
CUTTING OF ENDS
TEE BY EXTRUSION
HEATING
OVALIZATION RE-HEATING FORMING
QUENCHING CUTTING HOLE
QUENCH
HEATING
CUTTING OF ENDS
EXTRUSION QUENCHING CUTTING OF ENDS HEAT TREATMENT SAMPLING
MECHANICAL TEST PICKLING
MACHINING NDE EXAMINATION
MARKING FINAL CLEANING
FINAL DOSSIER PACKING
NORSOK standard
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NORSOK standard M-650
Edition 4, September 2011
Annex B (Normative) Additional requirements to API Spec 6A:2010/ISO 10423:2009 , Annex M, and ASTM A 991
B.1
General
Temperature uniformity survey of quality heat treatment furnaces shall be performed according to API Spec 6A:2010/ISO 10423:2009, Annex M, or ASTM A 991 with the following additional requirements: a) the alternatives of attaching thermocouples to the extremities of each load, see ASTM A 991, Para 1.4, or the alternative surveying techniques described in ASTM A 991, Para 7.7, are not acceptable as an alternative to the specified temperature uniform ity survey; b) the temperature uniformity survey shall be carried out at the maximum set point temperature for the actual materials to be processed in the furnace. The m aximum limit of 1 100 ºC stated in ASTM A 991, Para 6.1.1.2, shall not apply; c) the calibration shall be carried out with maximum load in the furnace. This is to demonstrate that the required temperature uniformity and the maximum temperature specified can be reached. Subsequent calibrations, which shall be carried out annually, may be carried out with empty furnace; d) the documentation of the temperature uniformity survey shall include sketch of the furnace with working zone of furnace and number and location of thermocouples used for the survey, see API Spec 6A:2010/ISO 10423:2009, Annex M, subclause M 3.3, or ASTM A 991, Paras 8.2.7 and 8.2.8; e) uniformity survey shall to be performed annually for actual furnaces included in Manufacturing Summary for solution heat treatment; f) the manufacturer shall establish a procedure for how to carry out the temperature uniformity survey.
B.2
Batch type furnaces
The following additional requirements to ASTM A991 apply: a) for furnaces with set point temperature in the working zone above 800 ºC the temperature at any point shall not vary by more than ± 14 ºC from the furnace set point temperature after the furnace working zone has been brought up to temperature; b) for furnaces with set point temperature in the working zone below 800 ºC shall not vary by more than ± 8 ºC from the furnace set point temperature after the furnace working zone has been brought up to temperature; c) once the furnace temperature has reached the set point temperature, the temperature of all test locations shall be recorded at maximum 2 min intervals for at least 10 min. Then readings shall be taken at maximum 5 min intervals for sufficient time to determine the recurrent temperature pattern of the furnace working zone for at least 30 min.
B.3
Continuous conveyance and semi continuous conveyance furnaces
The temperature uniformity check may be carried out as verification of the heat treatment procedure, see 9.3. In any case the following requirements apply: a) the survey shall verify that 1) the specified heat treatment temperature for a material can be kept uniform within specified tolerances through the working zone of the furnace as defined in the heat treatment procedure, 2) the defined component travel speeds in the heat treatment procedure results in the minimum specified soaking time being achieved, measured from when the set temperature is reached. b) the temperature survey shall be carried out on actual products. A minimum of two surveys shall be carried out with products representing respectively the smallest (thinnest) and largest (thickness) sizes to be heat treated.
NORSOK standard
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NORSOK standard M-650
Edition 4, September 2011
Annex C (Informative Verification of heat treatment procedure – Example
Comparison of time temperature curves of the contact thermocouples (3 of f) fixed to the load itself with the furnace thermocouple. Note the time difference to reach set temperature between the furnace thermocouple and the contact thermocouples fixed onto the load. NORSOK standard
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NORSOK standard M-650
Edition 4, September 2011
Annex D (Normative) Form for Qualification Test Record (QTR) Front Page
This form is available as a word file at the NORSOK home page http://www.standard.no/. At the attached form examples of how to fill in the form is given. Manufacturer logo
Qualification Test Record (QTR) NORSOK M-650
QTR. No.: Rev. No.:
Manufacturer name/address/ Web page: Reference standard
NORSOK M-650, Edition 4
Material designation and MDS No.: Manufacturing Summary doc. No.:
Example: ASTM A182 Gr. F55; MDS D54, Revision 4.
Products and manufacturing process(es):
Example: Die forged flanges, Production route No. xx Forged discs, Production route No. xx Rolled rings, Production route No. xx Example: Heat treatment by: XXXXXXXX Forgings shall be machined as close as possible to final shape prior to quality heat treatment.
Mandatory conditions and sub- contractors:
Other information:
Rev. No.:
Example: Pickling by XXXXXXX .
Qualification expires:
Tested and qualified thickness and weight Products and manufacturing process(es): Die forged flanges Forged discs Rolled rings
Test record No. Abs 56 Abs 57 Abs 58
Tested thickness mm 170 55 130
Qualified thickness mm 170 60 130
Test piece weight kg 250 70 300
Qualified weight kg All 140 All
Qualification/acceptance signatures Manufacturer:
Prepared by/Date:
Checked by/Date:
The manufacturer and this QTR are evaluated and found to be in compliance with the requirements of NORSOK M-650 for supply of the above listed products and materials. This acceptance does not exempt any purchaser from his responsibility to ensure that this qualification is valid for his products within the essential variables of NORSOK M-650. Qualified/Accepted by (company name /address): Signature/Date:
NORSOK standard
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