Structural Steel Material Specification
Short Description
spec....
Description
Hengam Offshore Development Project EPCI For Topsides and Infield Pipelines and Subsea Cables Contract No. 4405-90-2FG STRUCTURAL STEEL MATERIAL SPECIFICATION
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STRUCTURAL STEEL MATERIAL SPECIFICATION
D0 Rev.
03.Sep.2013 Issued for Review Date
Purpose of Issue
J.W.LIM
PUREE
ARUN
Prepared
Checked
Approved
ISI / Ocean Development
Approved IOOC
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INPUTS Document Number
Title
REVISONS & HOLDS Revision
Description of Changes & Holds
Status
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Table of Contents 1.
GENERAL................................................................................................................................. 7
1.1
Introduction ...................................................................................................................................................7
1.2
Definitions ......................................................................................................................................................9
1.3
Applicable Standard .................................................................................................................................. 10
1.4
Documents And Testing ........................................................................................................................... 12
1.5
Marking ........................................................................................................................................................ 14
1.6
Impact Test of Materials........................................................................................................................... 16
1.7
Welding ........................................................................................................................................................ 18
1.8
Non Destructive Examination .................................................................................................................. 19
2.
PLATES AND HOT ROLLED SECTIONS ........................................................................... 21
2.1
General ......................................................................................................................................................... 21
2.2
Testing .......................................................................................................................................................... 22
3.
API PIPE ................................................................................................................................ 24
3.1
General ......................................................................................................................................................... 24
3.2
Chemical Cmoposition .............................................................................................................................. 25
3.3
Non Destructive Testing And Dimensional Tolerances ...................................................................... 26
4. 4.1
FABRICATION OF STRUCTURAL STEEL TUBES ............................................................. 27 General ......................................................................................................................................................... 27
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4.2
Qualification Of The Forming Procedure .............................................................................................. 28
4.3
Welding ........................................................................................................................................................ 30
4.4
Controls And Repairs ................................................................................................................................ 31
5.
FABRICATION OF STRUCTURAL STEEL SECTIONS FROM PLATES ........................... 32
5.1
General ......................................................................................................................................................... 32
5.2
Fabrication ................................................................................................................................................... 32
5.3
Dimension And Tolerances ...................................................................................................................... 33
5.4
Inspection And Repair ............................................................................................................................... 33
6.
MATERIALS FROM STOCK ................................................................................................ 34
6.1
General ......................................................................................................................................................... 34
6.2
Test ............................................................................................................................................................... 35
6.3
Non Destructive Examination .................................................................................................................. 36
7. 7.1
8.
MISCELLANEA ...................................................................................................................... 37 Bolts .............................................................................................................................................................. 37
APPENDIX A: PRODUCTION QUALIFICATION .............................................................. 38
8.1
Special Tests ................................................................................................................................................ 38
8.2
CTOD Test .................................................................................................................................................... 38
8.3
Results And Validity Of The Qualification Test .................................................................................... 39
9.
APPENDIX B: MATERIALS REFERRED TO OTHER STANDARDS ................................ 40
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9.1
EN10210 & EN10219 Pipes ...................................................................................................................... 40
9.2
ASTM Pipes ................................................................................................................................................. 40
10.
APPENDIX C: STRUCTURAL CLASSES ............................................................................. 41
11.
APPENDIX D: RECOMMENDED GRADE AND APPLICATION ..................................... 42
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1. GENERAL The Hengam Field is located in the Persian Gulf at approximately 45 km south of Qeshm Island. Iranian Offshore Oil Company (IOOC) has awarded HENGAM offshore development EPCI project to Intelligent Solutions Inc. and Ocean development LLC. Joint Venture to perform Basic & Detailed Engineering, as well as procurement, fabrication, installation, pre-commissioning & commissioning for:
Topside facilities of three offshore wellhead platforms
Infield pipe lines
Submarine composite Cable (Power, Control, Fiber optic) from offshore to onshore facilities.
1.1
Introduction
The present specification defines the supply conditions, at yards and workshops, of products assigned for the fabrication of offshore structures such as steel plates, hot rolled sections, seamless pipes, pipes and sections assembled by welding. Whenever possible, the materials are referred to European standards and, in absence of specific standards for offshore construction, additional specifications are introduced when necessary. For steel plate the reference standards are EN10025, EN10113 and prEN10225. For steel pipe the API 5L-00 specification shall be used as reference standards. Materials supplied according to other specification are acceptable, provided their compliance with the minimum requirements of this specification and of the referenced standards. Supply of materials produced with thermomechanical rolling process is allowed upon condition that these materials shall not be undergone during fabrication to thermal cycles having temperature greater than 590 ± 10℃. For thickness equal or greater than 40 mm, material properties shall be tested on simulated PWHT samples. Simulated PWHT shall be at 590 ± 10℃ with holding time of 2.5 minutes each millimetre of wall thickness, with a minimum of 1.5 hr. Structural components are divided in classes, each of which refers to defined material, depending on the thickness and service temperature. The classification is listed in the section 10 of Appendix-C “Structural Classes”. The classes of single elements as indicated on design drawings have priority on the general indication of this specification. Any cases of uncertainty in the assignment of classes shall be decided by the Company.
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For all the plates with nominal yield strength more than 360MPa and thickness equal or more than 50 mm, before starting the production weldability data of the material shall be provided to the Company, in accord to tests similar to these indicated in Appendix-A “Production Qualification”. In case of materials manufacturer can not produce weldability data, or does not have any experience in producing the materials required by this specification, a production qualification shall be carried out when expressly indicated in the order. The material described in this specification can be acquired to the steel manufacturer or by stock. In any case, required documents and certificates shall be available for the Company before using the materials for the building.
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Definitions
Project
HENGAM offshore development EPCI project
Company
Iranian Offshore Oil Company (IOOC)
EPCI Contractor
means Company mentioned in the Contract as part of the "other part" and includes its successors and permitted assignees. (ISI/ODCO)
Contract
means the “Contract” made between the “Company” and the “Contractor” and comprises the documents stated in the Agreement to form the “Contract”.
Work
means the work and other obligations to be performed by “Contractor” as described in the “Contract”.
Vendor
means anyone who provides goods or services to the “Company”. A vendor often manufactures and/or sells their products to a customer.
Shall
indicates a mandatory requirement.
Should
indicates recommended.
May
indicates a freedom of choice.
Whenever terms appear in this document as capitalized terms, they shall have the meaning ascribed to them here above.
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Applicable Standard
The standards that are listed here below forms an integral part of this specification, in the whole or only the mentioned paragraphs, and with the modifications or additions indicated by the same
EN 287
Approval testing of welding procedures for metallic materials
EN 288
Specification and approval of welding procedures for metallic materials
EN 473
Qualification and certification of NDT personnel. General principles
EN 10024
Hot rolled taper flange / section – Tolerances on shape and dimensions
EN 10027
Designation systems for steel
EN 10029
Hot rolled steel plates 3 mm thick or above – Tolerances on dimensions, shape and mass
EN 10160
Ultrasonic testing of steel flat products of thickness equal or greater than 6 mm (reflection method)
EN 10163
Delivery requirements for surface conditions of hot-rolled steel plates, sheets, wide flats and sections
EN 10164
Steel products with improved deformation properties perpendicular to the surface of the product. Technical delivery conditions
EN 10025-1: 2004
Hot rolled products of structural steels – Part 1: General technical delivery conditions
EN 10025-2: 2004
Hot rolled products of structural steels – Part 2: Technical delivery conditions for non alloy structural steels
EN 10025-3: 2004
Hot rolled products of structural steels – Part 3: Technical delivery conditions for normalized/normalized rolled weldable fine grain structural steels
EN 10025-4: 2004
Hot rolled products of structural steels – Part 4: Technical delivery conditions for thermomechanically rolled weldable fine grain structural steels
EN 10204
Metallic products. Types of inspection documents
prEN 10210
Hot finished structural hollow sections of non-alloy and fine grain structural steels
prEN 10219
Cold formed structural hollow sections of non-alloy and fine grain structural steels
EN 10225: 2001
Weldable structural steels for fixed offshore structures – Technical delivery condition
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Recommended practice for preproduction qualification for steel plates for offshore structures
API RP 2X
Recommended practice for ultrasonic examination of offshore structural fabrication and guidelines for qualification of ultrasonic technicians
API 5L-00
Specification for the line pipe
API 2B
Specification for the fabrication of structural steel pipe
BSI 7448-1
Facture toughness test – Method for determination of plane strain fracture toughness, critical tip opening displacement and critical J values of metallic materials
ISO 5817
Arc welded joints in steel – Guidance on quality levels for imperfections
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Documents And Testing
The required documents for the purchase of material are the followings: Table A – Type of Certificate Structural element class
Document referred to EN 10204
a, b, c
3.1
d
3.1
e
2.2
Documents shall have to be endorsed by Company. True copy of the original documents issued by the quality department of the steel manufacturer is considered equivalent to the original document. Copy of documents which do not fall within the previous case may be accepted as substitutive of the original only if authenticated by Company. In any case the documents of the sea fastening materials shall be also in compliance with the code and the requirements in charge of the transport certification. At Company’s request, tests shall be carried out at the presence of a Company Representatives. The testing record shall contain at least the following information: Table B – Minimum information in the test documents Type
Description
EU168 code
Identification
Mill location
A01
The purchaser’s order and item number
A07
Method of steel manufacture
C70
Heat or cast number
B07
Supply condition
B04
Dimensions
Composition
B11 / B13
Grade of steel
B02
Ladle analysis
C71 / C92
Product analysis (where applicable) Carbon equivalent
C71 / C92
Pcm
C96 / C99
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Heat treatment (only for normalized and
Details of heat treatment stating temperature,
B05
soaking times and cooling method
quenched and tempered steels) Mechanical properties
Yield strength, tensile strength, yield/tensile
C11 / C12 / C13
strengths ratio, elongation Impact test results
C42 / C43
Through thickness tensile test results, if required
C60 / C99
Strain age test where applicable Other
/ C60
D02 - 99
Nominal or actual mass Non destructive test results
D02 / C69
If during mechanical testing unexpected defects detrimental to the employment of the materials are verified, the plates, sections or pipes on which the samples have been taken, shall be submitted for verification by means of additional controls to clarify the nature and extent of the defects. Above examinations shall be extended to all the products that constitute the test unit. If the results of these controls confirm the dimension and extension of defects detrimental to the product application, all the products of the test units shall be discarded even in the case that there are positive results from other test trials. For M steel products that have been heat treated above 590 ± 10℃, mechanical test shall be repeated on samples that have been heat treated in the same way. Type and frequency of mechanical test shall be as required for the normal condition test.
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Marking
All products at the end of testing shall be pain marked and die stamped. Such marking shall be positioned at two opposite angles of the plates and at the two ends of the beams and tubular. Markings on plates shall be put at 90° with respect to the rolling direction. 1.5.1 Paint Marking The marking shall be done with white paint and letters shall be of height 40 mm at least. The indications to be reported are the following: - Purchase order number; - Length, width and thickness of the item, or shape type, or diameter and thickness; - Steel grade; - Manufacturer mark; - rolling direction (with double arrowed line). Excluding hot rolled sections. 1.5.2 Die Stamping Die stamping shall be carried out on material having thickness equal to or greater than 6 mm with punch having letters 8 mm high at least. The die stamped markings shall be ringed with white paint. The following indications shall be marked: - Type of steel and grade; - Cast number; - Plate or product nmber; - Manufacturer die stamp; - Examiner die stamp. Subsequent die stamping on semi-worked products shall be carried out with round nose dies (low stress) 1.5.3 Colour Code For each side, the thickness of plates shall be painted with 2/3 colour code stripes that with their combination give immediately visual information about the plate characteristic. Each pipe shall be painted with colour code stripes located on its internal surfaces and on thickness at both ends. Each section shall be painted on its web with colour code stripes located at both ends. The width of each stripe for plates, sections and pipes shall be at least 50 mm, and the distance between the stripes shall be 100 mm for plates and 50 mm for tubular and sections.
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Table C – Colour Code Colour
Material Grade
t℃ KCV
Properties
White
Ry ≤ 280
All
-
0
-
-20
-
-40
-
Blue Green
280 < Ry ≤ 360
Silver Yellow
360 < Ry
All
-
Red
All
All
Z
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Impact Test of Materials
Materials to be supplied according to this specification shall be submitted to Charpy-V impact test in longitudinal direction as specify in this paragraph. 1.6.1 Temperature Impact test shall be carried out at the following temperature: Table D – Impact Test Temperature (1) °Tp ≥ -5℃
°Tp ≥ +5℃
t ≤ 12.5 mm
t ≤ 15 mm
12.5 mm < t
25.4 mm < t
50.8 mm < t
70 mm < t ≤
100 mm < t
≤ 25.4 mm
≤ 50.8 mm
≤ 70 mm
100 mm
≤ 150 mm
15 mm < t ≤
30 mm < t ≤
50.8 mm < t
70 mm < t ≤
100 mm < t
30 mm
50.8 mm
≤ 70 mm
100 mm
≤ 150 mm
Structural Element
Test Temperature
Class
a
-20℃ -40℃
b
c
-20℃
0℃ (2)
0℃
d
e
Impact test not required
Not applicable
Note: (1) Impact test carry out at temperature lower than those specify in the table are acceptable if the adsorbed energy requirements of section 1.6.2 are fulfilled. (2) Thickness range applicable only for plates to be used for piles fabrication.
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1.6.2 Adsorbed Energy The adsorbed energies values during impact test (in Joules) shall be the follow: Nominal yield strength
Average adsorbed energy (J)
Remark
(Ry) 360Mpa < Ry
10% of yield strength, Maximum 42J
280MPa < Ry ≤ 360MPa
27~34
Ry ≤ 280 MPa
27
Minimum adsorbed energy of impact test single piece of base material shall be greater than 70% of the average required energy.
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Welding
The welding for the fabrication of pipes and sections shall be in accord with the requirements specified in chapter 4 and 5. Post weld heat treatment shall be applied for the cases. Welder shall be qualified according to EN287 and EN1418 by Company. Each welding process shall be qualified according to EN288 by Company. The welding procedure qualification test and the production weld test coupon shall include hardness and Charpy V-notch tests according to EN288, with the minimum requirements indicated in the section 1.6 of this specification. Table F – Impact test set location Thickness
Location
Double and single side welding
t ≤ 45 mm
cap
WM + HAZ
root
none
cap
WM + HAZ
t > 45 mm Note.
root Cap: 2 mm +/- 0.5 mm below external weld cap surface. Root: in root region of back welding. WM: weld metal in the centre of weld. HAZ means: FL, FL+2 mm, FL+5 mm.
WM + HAZ
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Non Destructive Examination
All products shall be 100% visually examined. NDT on weld class “a, b, c” shall be carried out only 48 hours after completion of welding. The same requirement for weld class “d” with thickness higher than 20 mm. NDT on weld class “e” and on all other classes not considered above may be carried out 24 hours after welding completion. Inspection and NDT prior to PWHT shall be at the Contractor discretion and shall not avoid further tests. All bevels shall be 100% visually inspected and those relevant to component “a, b, c” shall be inspected with MT and/or UT when defects are found and in any case not less than 20%, with location decided by the Client. The acceptability for the welding imperfections is defined in ISO 5817, level C (intermediate) for classes “a, b, c” and level D (moderate) for classes “d, e”. All the grave defects, e.g. cracks, shall be examined in order to establish the causes that originate them. Ultrasonic test shall be performed by operators certified at least level II according to EN473 or similar. They shall be qualified by Company. In case of automatic ultrasonic inspection the results of the control shall be certified as foreseen in the procedures. The UT shall be used for search hot, cold and chevron cracks. UT automatic equipment is accepted. UT instrument calibration shall be as per API RP2X-A. Standard of acceptability shall be as follows. - Any flaw from which echo height exceeds the DAC by 6 db shall be repaired and reexamined, regardless of size. - All flaws classified planar (cracks or lack of fusion) shall be repaired whichever is their echo height. - All echoes that exceed 50% DAC shall be classified and evaluated in size. - Any evaluated not planar flaw not exceeding the limits accepted by this specification may be left unprepared. - Echo indications of transverse defects are in any case to be regarded as defects requiring repair: this does not apply where indication can be unequivocally correlate to longitudinal defects.
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The length of acceptable volumetric flaws is as per following table. Table G – UT acceptable limits (mm) Max HD e DAC
a, b
c
D
HD > DAC
10
30
40
HD > DAC/2
20
45
60
Note: HD = maximum echo amplitude
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2. PLATES AND HOT ROLLED SECTIONS 2.1
General
The plates and hot rolled sections shall conform to the requirements of the standards EN10225:2001, EN10025-1:2004, EN10025-2:2004, EN10025-3:2004, EN10025-4:2004 and to the amendments and supplementary requirements defined in this sections. The plates and sections of Z quality shall be additionally inspected and tested in accordance with and conforms to the requirements of the standard EN10164 – Class Z35 with sample of 10 mm diameter for all the thickness. For products of Z quality that are relative to the standard EN10225:2001 the option 13 shall be applied. Steel of Z quality having thickness equal to or greater than 50 mm shall be vacuum degassed, sulphur refined and calcium or rare earth treated. The applicable tolerances on plates shall be EN10029 type A. The applicable tolerances on sections shall be EN10024. The values of the chemical composition shall be in accordance with EN10025-1:2004, EN10025-2:2004, EN10025-3:2004, EN10025-4:2004 and EN10225:2001 with the additional requirements indicated below. - If Boron content is not indicated in the ladle analysis it shall be considered equal to 0.008%. - The limited values for CEV as contained in standard EN10025-3:2004 and EN10025-4:2004 having the same yield values. For all steels with carbon content ≤ 0.12% the carbon equivalent shall be calculated both with the IIW formula (CEV) and the Ito-Bessyo formula (Pcm) included in standard EN10225:2001. Maximum allowable value of Pcm for steels of grade S275 relative to standards EN10025-1:2004, EN10025-2:2004, EN10025-3:2004 and EN10025-4:2004 is 0.22%, while for steels of grades S355 relative to standards EN10025-1:2004, EN10025-2:2004, EN10025-3:2004 and EN10025-4:2004 and steel of grade S460 relative to standards EN10025-1:2004, EN10025-2:2004, EN10025-3:2004 and EN10025-4:2004 the Pcm maximum allowable values shall be those indicated in standard EN10225:2001 respectively for steels S355G9+M and S460. - For structural class “a” and quality Z, S ≤ 0.01% and P ≤ 0.025%. For EN10025-3:2004 and EN10025-4:2004 steels, (V+Nb+Ti) ≤ 0.22% and (Mo+Cr) ≤ 0.30%
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Testing
For plates coming from ingots, the samples shall be taken from the end corresponding to the head of the ingot. 2.2.1 Impact Test One or two sets depending upon the thickness and structural element class as reported in the following table. Table H – Number of Impact Tests Element Class
1 set
2 set
a, b
t < 40 mm
t ≥ 40 mm
c
t < 60 mm
t ≥ 60 mm
d
t < 60 mm
N/A
The first set shall be taken at 2 mm below (outer) surface, while the second shall be taken at half thickness. For M steels sets shall be taken at half thickness. Impact test results shall comply with requirements of section 1.6 of this document. If the impact tests are to be carried out on samples of reduced sections 10 x 7.5, the requested average values shall be multiplied by the corrective coefficient of 0.8. 2.2.2 Strain Aging Tests For Plates Plates of structural classes “a, b, c” assigned to the fabrication by cold forming with diameter/thickness ratio less than 30. Strain aging test shall be carried out on the first produced heat for each steel grade and thickness range with a project temperature. 2.2.3 Non Destructive Tests All plates with thickness greater or equal to 50 mm and Z quality plates of any thickness, shall be ultrasonic inspected on the surface and on edges according to the standard EN10160, considering of class C for Z quality plates and class B for other plates. The above mentioned requirements shall not apply for products that are relative to the standard EN10225:2001 and the standard requirements still apply. Hot rolled sections shall be controlled according to EU186, with survey extended to A+B+C+D and quality class for acceptance 12 and 21 for classes “a, b, c” and A+B for classes “d, e”. 2.2.4 Repairs Correction of minor defects by grinding shall be as per standard EN10163.
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In order to check the complete elimination of all minor defects the ground area shall be inspected with MT method. Repairs of defects by welding shall be carried out after Company’s approval and according to standard EN10163 with the following limitations: - Welding repairs shall be carried out with qualified procedure - Weld shall be checked with MT and UT method. The acceptance limits shall be as foreseen on previous paragraph.
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3. API PIPE 3.1
General
Pipes fabricated according to API 5L-00 may be purchased if they satisfy all the requirements defined in this chapter. Pipes shall be of quality PSL2 (with exception of grade A25) and may be seamless or longitudinally welded with SAW procedure up to a maximum diameter of 508 mm (20”). For conductor pipes the limit of maximum diameter is 762 mm (30”). Generally all pipes shall have the supplementary requirements API 5L-00 SR4, only for thickness greater than 12 mm, and SR5B. In particular the supplementary requirement of SR5B shall not apply to pipes to be used in structural element class “e”. Welded pipes shall have non destructive examination according to the requirements of this specification. The mechanical properties on finished products shall conform to the API 5L-00 specification and to the impact test requirements of section 1.6 of this document (for impact properties). The pipe to be used in structural classes “b” shall be supplied in the normalized condition. UOE process is acceptable. Spiral welded pipes are not allowed. The allowed steel production processes are basic oxygen and basic electric is furnace. Welding processes for longitudinally welded pipes shall be qualified according to standard EN288 and requirements of paragraph 1 of this specification.
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Chemical Cmoposition
The chemical composition shall be in accordance with the requirements of the API 5L-00 specification and the following additional requirements. The acceptable limits for carbon equivalent are indicated in the following table. Table I – Max. Value for Carbon Equivalent Yield Strength
Thickness
CEV (%)
Pcm (%)
t ≤ 20 mm
0.41
0.22
20 < t ≤ 50 mm
0.39
0.22
280MPa < Ry ≤ 360MPa
t ≤ 50 mm
0.45
0.22
360Mpa < Ry
t ≤ 50 mm
0.45
0.23
Ry ≤ 280 MPa
For all structural classes the following limit on heat chemical analysis shall apply C
0.20% max.
Further limitations for the chemical analysis for structural classes “b, c” are as follows: Cu
0.40% max.
V
0.10% max.
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Non Destructive Testing And Dimensional Tolerances
All welding shall be inspected according to API 5L-00, section 9.7. All welded pipes to be used in structural classes “b, c” shall be controlled with UT system for the entire length along a directrix placed at 90°and along directrices placed each other at distance of 150 mm. Seamless pipes, with exception of A25Grade, shall be controlled with UT system according to requirements of section 9.7.2.6 and SR4 of API 5L-00. The acceptable defect limits shall conform to those required by standard API 5L-00 section 7.8 with the following amendments: - Longitudinal defects shall be evaluated on the reference hole of 5% the pipe thickness; - The pipe shall be free from undulations, folds, chips, cracks, scratches and other detrimental defects; - The lamination defects shall not extended for more than 1000 mm2; The repair of the defects is acceptable only after Company’s approval. The repair shall be carried out as per limits and requirements of API 5L-00, Appendix B. Dents shall not be deeper more than 3 mm or 1% of external diameter whichever is the less, with an extension not greater than 25% of the external diameter.
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4. FABRICATION OF STRUCTURAL STEEL TUBES 4.1
General
This chapter contains the minimum requirements for the fabrication of longitudinally double side welded tube of any structural class, made in one piece from plate. The fabrication shall be done in accordance with the provisions set out in API Specification 2B, with the requirements of this specification indicated below. The requirements S-2 shall be applied, with the conditions defined in this specification. Plates to be used for tube fabrication shall comply to the requirements of this specification. In particular when diameter/thickness ration is less than 30, materials shall be to strain aging test or in alternative heat treated after cold forming according to section 2 of this document.
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Qualification Of The Forming Procedure
Each forming process, including cold re-rolling for tube calibration after welding, shall be qualified with the tube in its final condition. For this purpose, an element of welded tube shall be carried out for every grade and quality of steel according to the proposed procedure, subsequent welded according to that foreseen by the fabrication specification and cold sizing, including re-rolling where used. The local deformation at weld level shall be measured by a straight gouge 300 mm long, measuring the gap between the weld and gouge itself. Deformations greater than qualified value shall require new qualification. The length of the sample shall be equal to the diameter of the tube used and can not less than 1 m. Qualification tests shall be as per following table. Table J – Mechanical Tests Thickness
Type and number of tests
≤ 16 mm
1 set for KCV impact test(1) 1 tensile test on base material 3 macro and hardness on base material and HAZ(2) 2 set for KCV impact test(1)
> 16 mm
1 tensile test on base material Note:
3 macro and hardness on base matrial and HAZ(2) (1) Impact test specimen set (KCV) shall be taken at 2 mm under the surface with axis perpendicular to the longitudinal tube axis. Specimen shall be taken on base material close to the welding. First specimens set shall be taken from the outer surface, the second specimens set shall be taken from the inner surface. Impact test shall comply with requirements of section 1.6 of this document. (2) Test shall be carried out on base material and HAZ with at least three readings for each test. Maximum allowable hardness shall be 350 HV10.
The forming procedure is valid under the following conditions: - Same fabricator; - Steel grade lower than those qualify; - Impact properties lower than specify;
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- Same manufacturing process; - D/t ratio greater than the qualification value; - Cold expansion rate or deformation after welding restored by the re-rolling not beyond the tested value; - Same calendar process. Existing qualification accepted by Company avoid new qualification.
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Welding
The requirements of the paragraph API 2B from 5.2 to 5.4 are applicable with the requirement S-2, referring to the standard EN288 and the requirements of chapter 1 of this specification. Production weld test coupon shall be carried out, starting the welding with a first coupon test and continuing every 120 m. Production weld test coupon shall be welded with same welding procedure and material used in production and the first coupon shall be checked as per qualification procedure, while for the other one the following test shall be required: - One transverse tensile test - One upright bend test - One upside-down bend test - Two side bend tests can be carried out instead of the upright and upside-down bend tests - One impact test in FL + 2 mm - One impact test in weld metal - 1 macro test In case of positive results but after Company’s approval only, production weld test coupon shall be welded after 240 m from that point onwards.
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Controls And Repairs
The 100% of each longitudinal weld shall be ultrasonically tested with the requirements given by the chapter 1 of this specification. Radiography shall be carried out on 350 mm of weld at each tubular ends. The 20% of each weld shall be MT inspected on external surfaces. Wherever possible, MT shall be carried out also on the internal surface of the weld. The requirements of the paragraph API 2B 7.4 apply with the following amendments. - Plates having surface condition that may impair the forming operation or which may have scale incorporated into its surface shall be blasted before forming. - Dents, marks or other surface damages that may appear after forming shall not exceed 3 mm in depth. - In any case superficial defects shall not have sharp corners and shall joint with a 1 to 4 transition.
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5. FABRICATION OF STRUCTURAL STEEL SECTIONS FROM PLATES 5.1
General
This chapter contains the minimum requirements for the fabrication of longitudinally welded sections of any structural class, made from steel plate conformed to the requirements of this specification. The sections are intended to be without stiffeners. The fabrication shall be done in accordance with the provisions set out in API 2B with the additional requirements here given and reading “section” instead of “pipe”. The requirements S-1 and S-2 shall be applied. Sections shall be fabricated with their longitudinal axes parallel to the plate rolling direction.
5.2
Fabrication
The requirements of the paragraph API 2B from 5.2 to 5.4 are applicable with the requirement S-2, referring to the standard EN288 and the requirements of chapter 1 of this specification. The welds shall be full double side penetration or double fillet in accordance with the indications of the drawings supplied with the purchase order. Tack weld, root passes and repair welding may be carried out with SMAW or GMAW processes. Root tack weld may be continuous. Production weld test coupon shall be carried out, starting the welding with a first coupon test and continuing every 120 m. Production weld test coupon shall be welded with same welding procedure and material used in production and the first coupon shall be checked as per qualification procedure, while for the other one the following test shall be required: - one FL +2 mm and WM Charpy-V strength test. - one macro and hardness test. In case of positive results but subject to Company’s approval, production weld test coupon shall be welded after 240 m form that point onwards.
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The requirements of the paragraph API 2B 5.2 apply, but the requirements of the Charpy V-notch shall be in accordance section 1.6 of this specification. Welding Procedure Qualifications for fillet welds shall be according to EN288 with macro and hardness test. Welding Procedure Qualifications owned by the fabricator may be submitted to the Company for acceptance without requalification.
5.3
Dimension And Tolerances
Tilt and roof-shape of flange shall be not greater than (1+0.01b) mm with 6 mm maximum; flange eccentricity shall be not greater than 0.02b with 6 mm as maximum value, where b is flange with and t is flange thickness. Twisting of web shall be not greater than (1+0.01h) mm with 10 mm maximum: bow of web shall be not greater than 0.01h with 0.5t as maximum value, where h is web height and t is web thickness.
5.4
Inspection And Repair
The 100% of each longitudinal full penetration weld shall be UT tested with the requirements indicated in the chapter 1 of this specification. The 20% of each weld, either complete penetration or fillet, shall be MT inspected. Fillet welds and partial penetration welds shall be inspected in accordance with MT 100% for components of classes “a, b” and 20% for classes “c, d” on parts chosen by Company. Plates having surface condition that may impair the fabrication operation or which may have scale incorporated into its surface shall be blasted before fabrication. Dents, marks or other surface damages that may appear after fabrication shall not exceed 3 mm in depth.
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6. MATERIALS FROM STOCK 6.1
General
Material shall be supplied with required certificates and satisfying the requirements of this specification. Such certificates shall be original or true copies of the originals issued by the quality department of the steel manufacturer. Copy of document which do not fall within the previous cases may be accepted as substitutive of the original only if authenticated by Company.
With certificates not satisfying the requirements of this specification, materials cannot be considered acceptable.
The correspondence between material and its certificate shall be verified by checking the quality control plan of supplier or by means of the repetition the mechanical tests and chemical analysis on one element of the unit test. The limits for the chemical composition and for the carbon equivalent values (CEV and Pcm) shall be applied also to the material form stock. In case of welded pipes, welding processes may be accepted if only they are qualified in accordance to standard approved by the Company upon the condition that comply with impact test requirements of section 1.6 of this specification. Welded pipes, in the absence of production testing coupons, shall be submitted to tests through specimens taken in accordance with procedures and requirements set out by this specification. The number of tests shall be agreed with the Company.
Weldability of stock materials, where required (see section 1.1 of this specification), shall be demonstrated with data referred to previous productions. Data shall comply with the applicable limits requirements of appendix A of this specification.
For stock materials of quality Z having thickness equal or greater than 50 mm a sulphur content < 0.005% is acceptable in alternative to: vacuum degassing, sulphur refining, calcium or rare earth treating (required at section 2.1 of this specification).
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Test
Any non-conformance to the above reference requirements for material from stock shall be reported to the Company, with whom a proper inspection and test programme will be agreed. This programme will normally contain the complete test of the items in compliance with the content of this specification. In case of non conformance, when the properties are outside the reference standard and specification limits, the material may be used only after repetition of mechanical tests and chemical analysis of each item. In case of API 5L-00 pipes, for every test unit a hardness control shall be carried out on a pipe chosen by the Company. If a part of a pipe presents a hardness greater than 327 BRINELL for a total area > 500mm2, the pipe shall be rejected and the hardness test shall be repeated on other three pipes chosen by the Company on the same test unit. In case that on one of the new tested pipes the measured hardness is greater the allowable limit the hardness test shall be carried out on all the pipes of the test unit, otherwise the entire test unit shall be rejected.
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Non Destructive Examination
Steel plates, pipes and sections from stock shall have satisfied non destructive examination required by this specification. On plates in absence of documents relevant to those inspections, plates with thickness greater or equal to 20 mm shall be UT inspected along lines perpendicular to the rolling direction spaced 100m, and 100% of ends on a strip of at least 50 mm width. For pipes, UT shall be carried out in agreement with the Company, along a grid according to chapter 3, with extension not less than 30% of the total length including the ends of each element. On rolled shapes available from stock non destructive examination is not required for structural element classes “d” and “e” while for structural element classes “a”, “b” and “c”(shape with web equal or greater than 300 mm). UT test shall be carried out at least on 3 shapes for heat and for type according to section 2.2.3 of this specification. In case one of this test does not give satisfactory result the UT test shall be carried out on all shapes of the heat. The acceptance criteria for UT test shall be those of this specification.
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7. MISCELLANEA 7.1
Bolts
Types, dimensions and classes of the bolts and fasteners shall be indicated on the construction drawings. Bolting materials for structural applications shall generally be carbon or low alloy steels. The following limitations shall apply: - For topside applications, the strength class shall not exceed ISO 898 class 10.9, UNI 3740 Class 10.9; - All bolts and fasteners ≤ 10 mm diameter shall be made of stainless steel; - All bolts and fasteners > 10 mm diameter shall be processed by hot dip galvanizing, minimum 50μthickness, or equivalent process in accordance with ASTM A153.
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8. APPENDIX A: PRODUCTION QUALIFICATION The qualification of the production consists of a series of tests including all the production test and a number of special test and CTOD test to be carried out only one time and before starting the steel production.
8.1
Special Tests
On the materials subject to supply, the following test for the assessment of the weldability properties shall be carried out: - Bead on Plate according to EN10225:2001; - Controlled Thermal Severity according to EN10225:2001; - Transition curves of welded joints carried out on Fusion Line, FL +2 mm and FL +5 mm. - Weldability tests only for steels that are relative to the standard EN10225:2001 with exception of CTOD test All tests shall be carried out on the thickest plate to supply within the validity of the qualification conditions specified below. The transition curve shall be carried out with at least 8 sets to be tested: one at the project temperature and the other seven at temperatures differing between them 10℃, two above and five below the design temperature. The specimens shall be taken from the flat sid of the joint carried out on K beveled seams welded with heat input of 1.5 kJ/mm. Second transition curves shall be carried out for a similar joint welded with an heat input of 5 kJ/mm.
8.2
CTOD Test
Supply of materials to be used for joint cans with thickness greater than 50 mm shall be submitted, on the thickest plate of supply and for each structural grade, to CTOD tests in accordance to the standard BS 7448 to b carry out on butt weld joint, with K bevel and 5 kJ/mm heat input, previously submitted to simulated post weld heat treatment at 590 ± 10℃. Tests shall be carried out at -10℃ and the number and position of the samples shall be in accordance to EN10225:2001.
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Results And Validity Of The Qualification Test
The results of all of the tests are subject to Company for approval. The qualification tests are valid only if carried out in the presence of a Certifying Authority appointed by the Company. The following conditions are essential parameters whose variation implies the necessity of a requalification: - Same steel-mill producer; - Same elaboration and fabrication process; - Same method of deoxidization; - Same heat treatment and supply condition; - Chemical composition of the cast not varying with respect to the sample chemical analysis exceeding the limits indicated in paragraph 2.4 of standard API RP 2Z; - The material thickness shall not be greater than 20% in relevant to the thickness of the test sample.
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9. APPENDIX B: MATERIALS REFERRED TO OTHER STANDARDS In addition to the standard EN10225:2001, EN10025-1:2004, EN10025-2:2004, EN10025-3:2004, EN10025-4:2004 and API 5L-00, that are referred by this specification, the Contractor may use other reference standards for the fabrication and qualification of steel, provided that the minimum requirements of this specification and the referred standards are satisfied. To this purpose, the Contractor shall demonstrate the equivalence of the proposed material, by means of documents additional to the inspection documents and test results that show the differences between the standards. Some alternative standards are listed below.
9.1
EN10210 & EN10219 Pipes
Pipes supplied with these standards are applicable for thickness less than 50 mm. They shall be in compliance with standards EN10210 and EN10219 with the option 1 to 9. Arc-welded pipes are not accepted. The welding procedures for longitudinally welded pipes shall be in compliance with the requirements given in the chapter 2.
9.2
ASTM Pipes
Material referred to ASTM specification and equivalent to the type indicated in this specification may be applied as follows, including in particular the requirements API 5L-00 SR4 (NDT tests) and API 5L-00 SR5 (impact test) as emended by this specification; Table K – Alternative Materials For Pipes Structural element class
ASTM standard
b, c, d
A333 GR.6 A334 GR.6 A106 GR.B A524 GR.I e II
e
A53 GR.B A500 GR.A e B A139 GR.B
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10. APPENDIX C: STRUCTURAL CLASSES Table L – Structural Classes Structural
Definition
Topside Decks
Classes a
Structural elements essential for the safety
Not typical nodes with complex geometry
of the platform with low structural redundancy, complex shape and stresses concentration not easily foreseeable b
Structural elements essential for the global
Typical nodes with simple geometry; Lifting
safety of the platform
padeyes and their connection to the deck; Legs; Tubular and beam elements situated between two legs; Main girder; Main deck node & connection; Cans; Crane pedestal; Flare and bridge supports
c
Essential structural elements for the total
Beams with height higher or equal to 300mm
structure safety with simple geometry and
or thickness higher than 15mm; Primary
with fatigue stress not dimensioning
columns and braces; Structural wall; Bridge structure and flare; Crane boom rest; rotating equipment support beam; stiffener at node on primary beam (thicker than 15mm)
d
Significant structural elements for the local
Beams with height lower than 300mm and
safety of the structure
thickness up to 15mm; secondary columns and braces, floor plate and hatch cover for strength member; sea fastening; equipment support; Handling support & monorail; stiffener of secondary structure
e
Unimportant structural elements and non-
Checkered plates; Stairs and walkway, Not
structural elements
structural walls; Draining system; Ladder; Handrail; Grating; Access & service; floor plate and hatch cover for non-strength member; Pipe & handling supports
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11. APPENDIX D: RECOMMENDED GRADE AND APPLICATION Table M – Plates and Hot Rolled Section °Tp ≥ -5℃
°Tp ≥ +5℃
t ≤ 12 mm
t ≤ 15 mm
12 mm < t ≤ 25
25 mm < t ≤ 50
50 mm < t ≤ 70
70 mm < t ≤
mm
mm
mm
100 mm
15 mm < t ≤ 30
30 mm < t ≤ 50
50 mm < t ≤ 70
70 mm < t ≤
mm
mm
mm
100 mm
Structural Element
Applicable Grade and Quality
Class EN10025:2004 S355N/NL
a(1)
S275N/NL
EN10025:2004, S355NL, S275NL EN10225:2001
S355J2
S355G8+M/N S355G10+M/N
EN10025:2004 b(2)
S460G2+Q/M
S355N/NL EN10025:2004
S275N/NL
S355J0, S275J0
S355J2
EN10025:2004 S355NL
c d e Note:
EN10025:2004, S355JR, S275JR S235JR, S185
Not Applicable
(1) For material with thickness equal to or greater than 25 mm, supplementary requirement Z quality shall be applied. (2) Only for material in nodal joints, cans and uninterrupted stubs having thickness equal to or greater than 25 mm, supplementary requirement Z quality shall be applied.
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Table N – API Pipes(1) °Tp ≥ -5℃
t ≤ 12 mm
12 mm < t ≤ 25 mm
25 mm < t ≤ 50 mm
50 mm < t ≤ 70 mm
°Tp ≥ +5℃
t ≤ 15 mm
15 mm < t ≤ 30 mm
30 mm < t ≤ 50 mm
50 mm < t ≤ 70 mm
Structural Element
Applicable Grade and Quality
Class a Not Applicable
b(2) c
API 5L X52 API 5L X42
d e Note:
API 5L B; API 5L A25 (1) All pipes with thickness greater than 12 mm shall have SR4 requirements. (2) Excludes cans with wall thickness greater than 20 mm.
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