COMMON REQUIREMENTS

STRUCTURAL STEEL FABRICATION

M-CR-101 Rev. 1, December 1994

1 FOREWORD
This standard has been developed by the NORSOK standardisation work group and agreed by the Norwegian industry for the widest possible national and international application.

2 SCOPE
This standard covers the requirements for fabrication and inspection of offshore steel structures with a minimum design temperature down to -10 C.

3 NORMATIVE REFERENCES
NPD API 2B API RP 2X ASME, Section V BS 7448;Part 1 BSI PD6493 DnV DnV DnV RP D404 EN 287 EN 288 EN 444 EN 462 EN 473 EN 719 EN 729 EN 875 prEN 970 prEN 1011 Guidelines on selection of steels and fabrication of steel structures (01.02.92). Specification for fabricated structural steel pipe. Ultrasonic examination of offshore structural fabrications. Non-destructive testing. Fracture mechanics toughness tests. Guidance on some methods for the derivation of acceptance levels for defects in fusion welded joints. Rules for classification of fixed installations, structures. Part 3. Chapter 2, Fabrication and Construction. Classification Note No 7. Ultrasonic inspection of weld connections. Unstable fracture. Approval testing of welders - Fusion welding. Specification and qualification of welding procedures for metallic materials. NDT - General principles for radiographic examination of metallic materials by X-rays and gamma rays. NDT - Image quality of radiographs. Qualification and certification of NDT personnel - General principles. Welding Coordination - Tasks and responsibilities. Quality requirements for welding - Fusion welding of metallic materials. Welding - Welded joints in metallic materials - Specimen location and notch orientation for impact tests. Welding - Visual examination of fusion welded joints. Recommendation for arc welding of ferritic steels.

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NDE of welds - Magnetic Particle Testing of welds - Method. NDE of welds - Magnetic Particle Testing of welds - Acceptance levels and criteria. prEN 1418 Welding personnel - Approval testing for fully mechanised and automatic welding. prEN 1597-1 Welding consumables - testing for classification. prEN 10025 Hot rolled products of non-alloy structural steels: Technical delivery conditions. EN 10204 Metallic products - types of inspection documents. prEN 10225 Weldable structural steels for fixed offshore structures. EN 26847 Covered electrodes for manual metal are welding. Deposition of a weld pad for chemical analysis. ISO 3690 Welding determination of hydrogen weld metal arising from the use of covered electrodes for welding mild and low alloy steels. ISO 5817 (=EN 25817) Arc welded joints in steel - Guidance on quality levels for imperfections. M-DP-001 Design Principles, "Material Selection." M-CR-120 Common Requirements, " Material Data Sheets for Structural Steel ".

prEN 1290 prEN 1291

4 DEFINITIONS AND ABBREVIATIONS

AWS CE CTOD DC DIN DnV EN HDM IIW NDT MDS PWHT SMYS WPS WPAR American Welding Society Carbon Equivalent Crack Tip Opening Displacement Design class Deutsche Industrie Normen Det norske Veritas Euronorm Hydrogen content, deposit metal International Institute of Welding Non Destructive Testing Material Data Sheet Post Weld Heat Treatment Specified Minimum Yield Strength Welding Procedure Specification Welding Procedure Approval Record

5 SELECTION OF STEELS 5.1 Design classes

The requirements for steel quality, fabrication requirements and extent of NDT shall depend on the significance of the components and the type and level of stresses. For this purpose, each component shall be classified in accordance with table 5.1. The joint between two components shall be assigned a design class equal to the highest of the joined components. M-CR-101, Rev. 1, December 1994 page 2

Table 5.1 - Classification of Structural Components and Welded Joints.

Design Class 1 Criteria for Selection of Class Examples of Components/Joints

Components and joints, essential for total Thick-walled cross-shaped connections. Complex load capacity, with low redundancy or nodes/base joints. Module stools and bearing brackets complex form and complex stress conditions. with low redundancy. Special cross-section transitions. This includes three-dimensional stresses/ tensile stress in through-thickness direction/high degree of restraint/ unpredictable detail stress distribution. Components and joints, essential for total load capacity, with simple form and very predictable stress distribution. Components and joints significant for local load capacity, with complex form and complex stress conditions. This includes combinations of three-dimensional stress/tensile stress in the direction of thickness/high degree of restraint/unpredictable detail stress distribution. Components and joints, significant for local load capacity, with simple form and very predictable stress distribution. Less significant loadbearing structures. Node, columns, diagonals, crane pedestals, chords, flanges, lifting beams, pad-eyes. bulkheads and hulls of floating installations. Node, cross-section transitions. Special section/parts of components in class 4.

Simple nodes, plate structures, elements in trusses. Hulls and bulkheads. Heavy pipe supports. Gangway, ladders stairs, platforms and railings. Pipe/equipment supports and cable ladders.

5.2 Selection of steel quality level

The minimum requirements for the steel quality level to be selected are found in table 5.2. Table 5.2 - Correlation between Design Classes and Steel Quality Level.
Design Class Steel Quality Level I 1 2 3 4 5 X (X) II X X III X X IV

(X) = Selection when there is tensile stress in the direction of thickness. Annex B gives the correlation between the steel quality levels I, II, III and IV, and designations on equivalent steels given in relevant NORSOK Material Data Sheets. In order to obtain standardisation and reduce the number of different steel grades, it should be considered to use one Quality Level I steel to the largest possible extent in fabrication, even if a lower quality steel grade or yield strength could be selected according to table 5.2.

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6 QUALIFICATION OF WELDING PROCEDURES AND WELDERS 6.1 Welding procedure specification (WPS)
WPS shall be established in accordance with EN 288 part 2.

6.2 Qualification of welding procedures

Welding procedures used for welding of structural steel in design classes 1, 2 and 3 shall be qualified in accordance with EN 288 part 3 and the additional requirements in this standard. The qualification is primarily valid for the workshop performing the welding tests, and other workshops under the same technical and quality management. It may also be transferred to and used by a subcontractor, provided the principles of EN 729 part 2 are implemented and documented.

6.3 Welding Procedure Approval Record (WPAR) - Range of approval

The WPAR is valid within the limitations specified in EN 288 part 3, with the following clarifications and modifications:

6.4 Examination of the test weld

6.4.1 General The type and number of tests shall be in accordance with table 6.1. Testing shall be performed in accordance with EN 288 and the additional requirements given below. The test weld shall be 100 % examined for both surface and volumetric defects with the relevant NDT-methods. The soundness of the weld shall comply with clause 10. Table 6.1 - Type and number of tests
Mechanical Testing Joint configura. Joint thickness Tensile test (mm) 2 2 4) 4) 4) 4) Bend tests 1) 2 2 Charpy Vnotch tests 2) 4 sets 6 sets 4 sets 3) 6 sets 4 sets 3) 6 sets Hardness and macro 1 1 2 2 2 2 2 CTOD

Buttwelds (Tubulars t<50 and plates) t>=50 T-joints (plates)5) Tubular joints5) Fillet welds t<50 t>=50 t<50 t>=50 All

Ref. 6.4.4

NOTES 1) Bend tests shall consist of 1 face and 1 root bend specimen for t < 20 mm and 2 side bend specimens for t > 20 mm 2) One set consists of three test specimens. 3) If the dimensions of the joint does not allow Charpy V-notch testing, the Charpy V-notch properties shall be documented on a butt weld joint made with the same consumable and same base material, and welding parameters and thickness within the range qualified for the joint. 4) It shall be documented on a butt weld test that the welding consumable used will have sufficient tensile strength. 5) T-joints on plates qualify for tubular joints, and vice versa.

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6.4.2 Charpy V-notch testing Sampling of Charpy V-notch impact tests shall be carried out in accordance with prEN 875, with the notch in the positions listed below. (All specimens shall be machined with the notch through the thickness, 2 mm below the surface of the material.)

Notch in centre of weld (VWT 0/2). Notch in fusion line (VHT 0/2). Notch in HAZ, 2 mm from fusion line (VHT 2/2). Notch in HAZ, 5 mm from fusion line (VHT 5/2).

(Designation in parenthesis refers to prEN 875). For welds with a joint thickness of 50 mm or more, two additional sets of Charpy V-notch tests shall be taken from the root area, with the notch in the following positions:

Notch in centre of weld (VWT 0/b1)). Notch in fusion line (VHT 0/b1)).

NOTE 1) - For single sided welds, the face of the Charpy specimen shall be 2 mm from the root face to the weld. For double-sided welds, the centre of the Charpy specimen shall be positioned in the centre of the root area. The test temperature and energy requirements shall comply with table 6.2. Table 6.2 - Charpy impact test temperatures and energy requirements for welding procedure qualifications.
Material thickness Steel Quality Level mm I SMYS <= 400 MPa t <= 12 12 < t <= 25 25 < t <= 50 t > 50 Energy Requirement 1) NOTES 1) The minimum average value is given in the table. No individual value shall be less than 70 % of the minimum average value. 0 C -20 C -40 C -40 C 36J SMYS > 400 MPa -20 C -40 C -40 C -40 C 42J II SMYS <= 400 MPa 0 C 0 C -20 C -40 C 27J SMYS > 400 MPa -20 C -20 C -40 C -40 C 42J

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6.4.3 Transverse tensile testing Testing shall be carried out in accordance with EN 288. The fracture should be located outside the weld metal (i.e. max. 20 % of the fracture surface shall consist of weld metal.) If fracture is located in weld metal, the transverse tensile test shall have a tensile strength at least 10 % above the minimum tensile strength specified for the base material. 6.4.4 CTOD testing CTOD testing shall be included in qualification of welding procedures for joints in design class 1 and 2 with a thickness above 50 mm. It shall be executed on weld assemblies in the actual heat treating condition (PWHT/as-welded) covering the following combined conditions:

Full penetration buttweld with K-, single V- or X-groove as deemed most representative for the actual fabrication. A welding procedure representing the maximum heat input to be used in fabrication. Maximum joint thickness (within 10 %).

One (1) such assembly shall be made and tested for each welding process, each welding consumable (brand) and each steel grade used except when used for root passes only. The CTOD-technique with the Bx2B, through-thickness notched type specimen according to BS 7448 should be used. Three (3) valid test specimens shall be obtained for each test position. NOTE - Test assemblies may be given a precompression and/or hydrogen diffusion treatment prior to testing. CTOD-testing of welds shall be carried out with the fatigue notch tip positioned in the coarse grained region of the heat affected zone and in the weld metal. For HAZ, positioning and determination of the actual location of the fatigue crack tip shall be performed after testing. HAZ testing can be omitted if relevant CTOD properties in HAZ have been documented previously for the base material. (I.e. on the same grade of material from the same manufacturer). CTOD- testing of weld metal can be omitted if relevant CTOD properties in accordance with requirements above have been documented by the consumable supplier. Test temperature shall be: The required CTOD value has to be decided in each case, based on a fracture mechanics evaluation for the particular structure. When the minimum single CTOD-value at the required temperature exceeds 0.25 mm (0.20 mm for welds with PWHT), the test series is normally acceptable without a detailed fracture mechanics evaluation. CTOD testing should also be performed when required for fitness for purpose evaluations according to 10.8.5.

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6.5 Welder and welding operators qualifications

The welders, welding operators and tack welders shall be qualified in accordance with EN 287, prEN 1418 or equivalent. For tack welders, an internal test may be used. For welding of single sided acute angled tubular joints with < 70, welders shall be qualified with a realistic tubular joint, representing the minimum angle to be used in production. For welding of joints in Design Class 5, a certificate for welding of plates in position PE is sufficient for welding all product forms.

7 FABRICATION AND WELDING REQUIREMENTS 7.1 General

All welding work shall be according to recommendations given in EN 1011. The manufacturer shall have a quality system, which fulfil the relevant part of EN 729 and the applicable level of EN 719. The fabricator shall apply a weld numbering system for identification on all shop drawings and as reference in all documentation.

7.2 Forming
Cold forming of steel (i.e. forming below 250 C) shall be carried out within the deformation range recommended by the steel producer. For steel quality level I and II, the deformation limit without documentation of mechanical properties is 5 %. If the deformation is more than the above given limits, either heat treatment shall be performed, or strain ageing tests shall be carried out according to the following procedure: If forming is performed at temperature above 250 C, it shall be documented that the base material properties, weldability, weldmetal and HAZ properties satisfy the actual MDS and this standard. The percentage strain due to forming is defined as follows:

7.3 Manufacturing of welded tubulars

Manufacturing of welded tubulars shall be carried out to a qualified procedure which satisfies the requirements in API 2B and this standard. The procedure shall contain the following information:

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7.4 Assembly
7.4.1 General In tubular joints, circumferential and longitudinal weld joints should not be placed in the shaded areas shown in fig. 7.1. 7.4.2 Splices Splices should not be located in highly stressed areas, unless this is shown on design drawings. 7.4.3 Tapering Tapering shall be in accordance with the requirements given in relevant standards or drawings. If no other requirements are specified, a tapering of 1:4 should be used. 7.4.4 Bolting connection Bolting material shall comply with requirements in NORSOK Standard M-DP-001 "Material Selection". Holes shall be made by machine drilling. 7.4.5 Seal/blind compartments Crevices and areas which become inaccessible after fabrication or assembly shall be sealed off from the outside atmosphere. Seal welds shall have a throat thickness of at least 3 mm. Where steel items shall be hot dip galvanised, hollow sections shall be ventilated.

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Fig. 7.1 Prohibited Location of Welds in Tubular Joints. Longitudinal or circumferential welds shall not be located in shaded area. 7.4.6 Temporary cut-outs Temporary cut-outs in highly stressed areas shall be avoided. Temporary cut outs shall have a corner radius not less than 100 mm. Temporary cut-outs shall be closed by refitting the same or an equivalent plate and employing the same welding, inspection and documentation procedures and requirements that govern the structural part in question. 7.4.7 Straightening of structural members Members distorted by welding shall be straightened according to a detailed work instruction. The base material properties shall satisfy the specified requirements after straightening. Maximum temperature for straightening shall not exceed the temperature limit recommended by the steel manufacturer, but it shall in no case be higher than 600 C. 7.4.8 Doubler plates All temporary attachments which shall be flame cut or welded under water shall be attached to the structure by using doubler plates. All attachments in the splash zone shall be attached to the structure by using doubler plates.

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7.5 Preparation for coatings

Edges of plates and structural shapes which are intended to be coated shall be rounded to approximately 2 mm radius, unless otherwise indicated on design drawings.

7.6 Preparation and fit-up of weld bevels

Permanent backing strips are not accepted, unless shown in design drawings. Buttering shall be carried out in accordance with a relevant WPAR.

7.7 Welding processes

The welding processes listed in EN 288 are acceptable.

7.8 Welding consumables

The manufacturers shall ensure that welding consumables applied for joints in design Class 1 and 2 meet the requirements for mechanical properties as specified for the welding procedure qualification. This may by achieved through (alternatively): Except for solid wires such consumables shall be classified by the supplier as extra low hydrogen, i.e. HDM <= 5ml/100g weld metal. For self shielded flux cored wire HDM <= 8ml/100g may be accepted. Hydrogen testing shall be ISO 3690 or equivalent. Consumables for joints in lower design classes (4 and 5) and for joining stainless to Carbon steel shall be selected with due consideration of base material properties, thickness and weldability, to ensure sufficient weld strength, toughness and homogeneity. Such consumables shall be delivered with type 2.2 certificate, as a minimum. All welding consumables shall be individually marked. When certification according to Annex C is used, welding consumables (except welding fluxes) shall be supplied with an Inspection Certificate (type 3.1B) in accordance with EN 10204, including a statement of compliance with the Welding Consumable Data Sheet and the chemical composition of the weld deposit (elements of the data sheet). Welding fluxes shall be supplied with a Test Report (EN 10204 type 2.2), declaring conformity with the approved product type.

7.9 Preheat and interpass temperature

Preheating above 50 C should be achieved by electric heating elements. Cutting torches are not allowed for preheating.

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The minimum interpass temperature shall not drop below the minimum required preheat temperature. If not otherwise stated in the WPS, the maximum interpass temperature shall not exceed 250 C measured at the edge of the groove. For C- and C/Mn - steels, a maximum interpass temperature of 250 C my be used, even if a lower temperature was recorded on the WPAR. The preheat temperatures used during repair welding should be minimum 50 C higher than the preheat used for the original weld.

7.10 Production welding

7.10.1 General Welding shall be carried out in accordance with the WPS and applicable drawings. Butt welds in Design Class 1,2 and 3 shall, whenever possible, be welded from both sides. If any welding is conducted after PWHT, the PWHT shall be repeated. 7.10.2 Attachments Temporary attachments as lifting lugs, lugs for scaffolding and assembly, supports for cables, equipment, ladders or other fabrication and erection aids should be removed. If indicated on design drawings that removal (full or partial) is not required, the temporary attachments may be left as is, or removed only partially. All welding of attachments shall comply with the requirements for the structure to which they are attached. Temporary attachments shall be flame cut minimum 3 mm from the base metal and ground. The ground area shall be visually examined and magnetic particle inspected.

7.11 Post weld heat treatment (PWHT)

PWHT shall be required for structural welds assigned design class 1 when the nominal thickness (as defined in EN 288-3, section 8.3.2.1) exceeds 50 mm, unless adequate fracture toughness can be documented in the as welded conditions. For restrained joints of complicated design, PWHT may be required for smaller thicknesses, independent of design class. PWHT shall be carried out in accordance with a procedure specification which shall include: The holding temperature shall be as recommended by the steel manufacturer. The holding time shall be 2.5 min per mm thickness. The temperature difference between different parts of the structure during soaking time shall not exceed 30 C within the heated area. Double sided heating shall be used as far as possible. The temperatures shall be continuously and automatically recorded on a chart.

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7.12 Grinding
When surface treatment by grinding is specified on design drawings or is instructed as a corrective action, the grinding shall be performed according to a detailed procedure. Grinding tools, direction, surface roughness and final profile shall be specified. Reference samples for typical joints and sections may be prepared and used for acceptance of treated welds.

8 PRODUCTION TESTS
Production testing should be conducted on weldments performed in critical regions to verify that the specified requirements have been meet. For welds in Inspection Category A, B and C, minimum one test coupon is required from each applied welding process. Test coupons shall be welded in a manner which realistically simulates the actual production welding, normally as extension of the production weld, and meet the requirements for welding procedure approval tests. CTOD testing is not required for production testing. If a production test fails, the reason for the failure shall be determined and remedial action implemented.

9 FABRICATION TOLERANCES
Fabrication tolerances shall be in accordance with relevant Standards and/or drawings issued for fabrication.

10 NON-DESTRUCTIVE TESTING (NDT) 10.1 General

The inspection category, as outlined in table 10.1, shall be clearly specified on the drawings, according to an established NDT notation system. Final inspection and NDT of structural steel welds shall not be carried out before 48 hours after completion except where PWHT is required. When PWHT is performed, the final NDT shall be carried out when all heat treatment have been completed. The time delay may be reduced to 24 hours for steel grades with SMYS of 355 MPa or lower and for steel grades with SMYS of 420 MPa or lower for plate thicknesses below 40 mm, if a consistent low failure rate of delayed cracking have been documented for the materials and welding consumables in question. Such a reduction is subject to acceptance by the relevant parties.

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Table 10.1 - Determination of inspection category for joints subjected to static and low fatigue stress 1).
Design class 1&2 Type of Stress, level and direction in relation to welded joint Welds subjected to normal stress transverse to typical (possible) defects. Welds that mainly transmit shear and welds subjected to low normal stress transverse to typical defects. Welds that transmit shear only. Welds subjected to normal stress transverse to typical defects. Welds that mainly transmit shear and welds subjected to moderate stress only transverse to typical defects. Welds subjected to normal stress transverse to typical defects. Welds that mainly transmit shear and welds subjected to moderate stress only transverse to typical defects. All load-bearing joints. Non load-bearing joints. Inspection category A B C B C C D D E

NOTE 1) Joints subjected to high fatigue stress are to undergo an independent assessment in order to determine the relevant inspection categories.

10.2 Approval of inspectors and NDT-operators

The NDT operators shall be qualified according to EN 473 level II. Ultrasonic operators used in examination of tubular joints shall in addition satisfy the requirements in API RP 2X, para 2.3. Personnel qualified according to EN 473 Level III should be responsible for all NDT activities.

10.3 Extent of visual examination and NDT

The required minimum extent of examination is given in table 10.2. Ultrasonic examination to reveal the presence of weld metal transverse (chevron) cracking shall be included for butt welds with thickness more than 25 mm. The examination shall be performed on minimum 5 % for SAW and FCAW.

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Table 10.2 - Minimum extent (in %) of non-destructive examination for structural welds.
Insp. category Type of conn. Vis. exam. 100 100 100 100 100 100 100 100 100 100 100 Extent of examination RT A Buttw. T-conn. Fillet/Partial Buttw. T-conn. Fillet/Partial Buttw. T-conn. Fillet/Partial All conn. All conn. 20 10 spot UT 100 100 50 50 20 20 MT 100 100 100 100 100 100 20 20 20 spot -

D E

LEGEND RT = Radiographic testing UT = Ultrasonic testing MT = Magnetic particle testing Spot means approximately 5 %.

When partial inspection is defined for welds in an area, the inspection shall be spread such that the most essential members and nodes are included in the inspection, and such that areas of welds most susceptible to weld defects are covered. In addition the following shall apply for inspection category A and B: The specified percentage to be examined in table 10.2 refers to the total length of welds in each inspection category. All WPS's used and welding personnel involved in the fabrication shall be subject to NDT. During the initial fabrication the extent of UT and MT of inspection category B and C welds shall be intensified, normally to twice the level given in table 10.2. This extent shall be maintained for a weld and test length sufficient to conclude that the weld repair percentage, is at a reasonable level. The increased initial testing may be accounted for in the overall extent provided the initial testing confirms consistent good workmanship. The extent of NDT shall be increased if repeated occurrence of cracks and other significant weld defects reflecting a systematic deviation from the welding procedure specification or inadequate workmanship are revealed. Corrective actions shall be taken to ensure that all similar defects will be detected. The required actions shall depend on the results of investigations carried out to reveal the cause of the defects and shall normally include increased testing of production welds made with the same WPS and/or by the same welders. Re-qualification of the WPS and/or the welder may be required.

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10.4 Visual examination and finish of welds

The visual examination shall be carried out in accordance with prEN 970.

10.5 Radiographic testing

Radiographic testing shall be carried out in accordance with ASME Section V, article 2; prEN 444 or equivalent. Suspect planar indications discovered by radiography shall be type determined, located and sized by ultrasonic examination. Penetrameters of wire type (according to EN 462-1) shall be utilised. Sensitivity level shall be in accordance with EN 462 part 3, Class A. However, if gamma ray sources are used, the sensitivity shall be 2% or better.

10.6 Ultrasonic testing

Ultrasonic testing of welds shall be carried out in accordance with DnV Classification Note no. 7 for plates and tubular butt welds, and API RP 2X for tubular joints. Steel produced by controlled rolling technique shall also be ultrasonic examined according to the requirements in annex A. Ultrasonic examination procedures shall contain sketches for each type of joint and dimensional range of joints which clearly show scanning pattern and probes to be used. Scanning shall be performed from both sides of the welds, and from both the root and the cap side, when accessible. All echoes exceeding 50 % of the reference curve shall be reported. The examination record shall include the imperfection position, the echo height, the dimensions (length), the depth below the surface and, if possible, the defect type.

10.7 Magnetic particle testing

Magnetic particle testing shall be carried out in accordance with prEN 1290. Magnetic yokes using alternating current shall be used. Prods are acceptable where the geometry of the welded joint prevents the use of yokes. Permanent magnets are not acceptable.

10.8 Acceptance criteria

10.8.1 Visual examination All welds shall show evidence of good workmanship. The quality shall comply with ISO 5817 (=EN 25817), Quality level B ("stringent").

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10.8.2 Radiographs The soundness of the welded joint shall comply with DnV Rules for Classification of Fixed Offshore Installations, Part 3, Chapter 2, Table D4. "Primary" in the DnV table D4 shall mean the acceptable limits for welds in inspection category A+B and "secondary" shall mean the acceptable limits for welds in inspection category C (and also D and E, if applicable). 10.8.3 Ultrasonic testing acceptance criteria The acceptance criteria for plate, profile and tubular butt welds shall comply with table 10.3. The acceptance criteria for tubular joints shall comply with API RP 2X level C. Table 10.3 - Ultrasonic acceptance criteria for weld defects in plate and tubular butt welds.
Description General Inspection Category A+B If the type of defect can not be ascertained with certainty the defect shall be repaired when the length exceeds 10 mm and A: The echo height exceeds the reference curve when examined from both sides of the weld. or B: The echo height exceeds 50 % of the reference curve when examined from one side of the weld only. Not acceptable. Internal Defects: A: The echo height exceeds the reference curve when examined from both sides of the weld. 1 Max length t, max 25 mm Max length 2t, max 50 mm 2 3 Inspection Category C Notes 1 2 3

Cracks Lack of fusion or incomplete penetration

B: The echo height is equal to or less than the reference curve when examined from both sides of the weld. Max length 50 mm Max length 100 mm SURFACE DEFECTS are not acceptable except: Root defects in single sided welds accessible from one side of the weld: Independent of echo height Max length t, max 25 mm Slag inclusions When echo height exceeds the reference curve: Max length t, max 25 mm Max length 2t, max 50 mm Max length 2t, max 50 mm 1 2 3 4 5 1 2 3 4

Porosity

Repair is required if porosity may mask for other defects.Otherwise see notes.

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NOTES 1 Type of defect shall be decided by I: Supplementary non-destructive testing. or II: The ultrasonic operator's assessment of the defect and mechanical sampling of production welds (repair, cut-outs). 2 If elongated defects are situated on line and the distance between them is less than the length of the longest indication, the defects shall be evaluated as one continuous defect. 3 The defect limits given in the table shall not be used more than one time within a continuous length equal to five times the actual acceptable defect length. 4 When a defect obviously exceeds the width of slag inclusions or the acceptance limits of porosity as stated in table D4 in the DnV Rules for Classification of Fixed Offshore Installation, Part 3, Chapter 2, it shall be repaired. 5 The length of a slag inclusion indication shall be determined by the distance for which the echo amplitude exceeds 50 % of the reference curve.

10.8.4 Magnetic particle testing The acceptance criteria shall be according to prEN 1291. Acceptance level 1 shall apply for inspection category A, B and C. Acceptance level 2 shall apply for inspection category D and E (if applicable). 10.8.5 All methods All defects shall be repaired according to clause 11. Defects may be accepted by the relevant parties when repair work is considered detrimental to the total integrity of the weld. Such acceptance shall be based on a fitness for purpose evaluation in accordance with BSI PD6493, DnV RP D404 or other recognised methods.

11 REPAIR 11.1 Defintions

Weld discontinuities: Irregularities in the body of the weld or on the weld surface classified as either weld imperfection or as weld defect. Weld imperfection: Discontinuities that are within the acceptance criteria defined in clause 10 and are considered to have no practical limitations on the intended use of the product. Weld imperfections may be left without remedial work. Cosmetic grinding may be performed at the discretion of the fabricator. Weld defect: Discontinuity with a size and/or density that is equal or greater than the acceptance criteria defined in clause 10.

11.2 Correction of welds containing defects

All repairs shall be carried out in accordance with established procedures. Welds containing cracks shall not be repaired, until the reason for the cracking has been determined. If necessary, the defective part of the weld shall be cut out for further examination.

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Crater cracks may be repaired by grinding followed by NDT and subsequent repair welding according to an accepted repair welding procedure. Other defects shall be corrected by grinding, repair welding or re-welding. When weld defects are removed by grinding only, the final weld surface and the transition to the base material shall be smooth. Removal of defects shall be verified by local visual inspection, aided by applicable NDT methods. If applicable, the remaining thickness in the ground area shall be measured. Repair welding is required if the remaining thickness is less than that specified.

11.3 Repair by welding

11.3.1 Repair and re-repair welding Before repair welding, the defect shall be completely removed. The excavated area shall have smooth transitions to the metal surface and allow good access for both NDT after excavation and subsequent repair welding. After excavation, complete removal of the defect shall be confirmed by MT or PT. PWHT shall be performed after repair if specified for the original weld. The excavated groove shall be minimum 50 mm long, measured at defect depth even if the defect itself is smaller. Defects spaced less than 100 mm shall be repaired as one continuous defect. After repair welding the complete weld shall be subjected at least to the same NDT as specified for the original weld. Repair welding may only be carried out twice in the same area. 11.3.2 Re-welding Re-welding shall be performed in accordance with the procedures and WPS utilised for the original weld, and includes complete removal of the original weld and HAZ.

11.4 Repair welding procedure

Repair and re-re-repair welding may be performed using the same WPS as for the original weld, or a separately qualified procedure. For repairs using a different process, and/or consumable, a separate WPS shall be qualified if required by 6.2. Mechanical testing may be limited to HAZ Charpy V-notch testing in the original weld, provided the process/consumable is backed up by other WPAR's.

11.5 Correction of distortion

Improperly fitted parts should be cut apart and re-welded in accordance with the applicable qualified WPS.

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Parts distorted by welding, beyond the tolerances, should be straightened in accordance with the requirement in clause 7. ANNEX A

ULTRASONIC EXAMINATION OF CONTROLLED ROLLED STEEL PLATES ANGLE BEAM TECHNIQUE

A ANNEX A - ULTRASONIC EXAMINATION OF CONTROLLED ROLLED STEEL PLATES ANGLE BEAM TECHNIQUE A.1 ANGLE PROBES AND FREQUENCY RANGE 45 and 60 angle probes shall be used for the examination. However, 70 angle probes shall also be used when required for full coverage of the area to be examined. When 70 angle probes are used, calibration of angle and amplification (sensitivity) shall be carried out on reference blocks of the same thickness as the material being examined and according to DnV Classification Note No. 7, taking the rolling direction into consideration. The increased attenuation of the ultrasonic signals by using 70 angle probe and examination longitudinal to the rolling direction may make the examination impossible at larger material thicknesses. Angle probes with frequency 2 and/or 4 MHz shall be used. A.2 ATTENUATION Difference in ultrasonic attenuation between transverse and longitudinal to rolling direction shall be checked when ultrasonic examination changes from transverse to longitudinal of rolling direction or inverse. A.3 REFERENCE BLOCKS Reference blocks according to DnV Classification Note No. 7 (and API RP 2X for tubular joints) shall be made both in longitudinal and transverse to the rolling direction. A.4 CORRECTION OF ANGLE REFRACTION The angle refraction shall be corrected in accordance with DnV classification Notes, Note No. 7, para 4.3. A.5 LOCATION OF DEFECTS When the location of defects is determined, the actual refraction angle shall be used and not the nominal angle. Deviation from the nominal refraction angle shall be measured when necessary (fig. A1).

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A.6 NORMAL PROBES No precaution is necessary for ultrasonic testing of controlled rolled steel plates by use of normal probes. A.7 REPORTING Reporting shall be in accordance with clause 10.

Fig. A1 Location of defect

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ANNEX B

CORRELATION BETWEEN STEEL QUALITY LEVEL, MDS STEEL GRADE/DESIGNATIONS

B ANNEX B - CORRELATION BETWEEN STEEL QUALITY LEVEL, MDS STEEL GRADE/DESIGNATIONS
Steel Quality Level NORSOK MDS No.1) Y20 Y21 Y22 Y30 Y31 Y32 I Y40 Y41 Y42 Y50 Y51 Y52 prEN 10225 Reference Standard Product Type Steel Grade

Plates Rolled Sections Seamless Tubulars Plates Rolled Sections Seamless Tubulars Plates Rolled Sections Seamless Tubulars Plates Rolled Sections Seamless Tubulars

S355NLO5 S355NLO5 S355NLO5 S420QLO4 S420QLO4 S420QLO2 (mod.) S460QLO4 S460QLO4 S460QLO2 (mod) S500QLO4 S500QLO4 S500QLO4

Y25 Y26 Y27 Y35 Y36 Y37 Y45 II Y46 Y47 Y55 Y56 Y57 prEN 10225

Plates Rolled Sections Seamless Tubulars Plates Rolled Sections Seamless Tubulars Plate Rolled Sections Seamless Tubulars Plates Rolled Sections Seamless Tubulars

S355NLO3 S355NLO3 S355NLO3 S420QLO2 S420QLO2 S420QLO2 S420QLO2 S420QLO2 S420QLO2 S500QLO2 S500QLO2 S500QLO2

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III

Y03

EN 10025 EN 10025 prEN 10225

Plates Rolled Sections Seamless Tubulars

S355J2G3 S355J2G3 NO1

Y01

EN 10025

Plates Rolled Sections Seamless Tubulars

S235JRG2

IV

Y02

EN 10025

Plates Rolled Sections Seamless Tubulars

S275JR

1)

NORSOK Material Data Sheets are in NORSOK Standard M-CR-120 . ANNEX C

QUALIFICATION OF WELDING CONSUMABLES BY DATA SHEETS

C ANNEX C - QUALIFICATION OF WELDING CONSUMABLES BY DATA SHEETS C.1 SCOPE The purpose of certification is to verify that each batch of consumables has a chemical composition within limits as specified by the supplier in conformance with a recognised classification standard. By controlled and certified chemistry the supplier also confirms that mechanical properties of the weld metal fulfil the minimum requirements specified for the product. For this specification a batch (or lot) is defined as the volume of product identified by the supplier under one unique batch/lot number, manufactured in one continuous run from batch controlled raw materials. Each individual consumable (brand name and dimension) shall be certified per batch, except for solid wire (GTAW, GMAW, SAW), originating from the same heat, where one diameter may represent all. C.2 DATA SHEET Each welding consumable or combination of consumables shall have a unique Data Sheet, issued as a controlled document within the suppliers Quality System. The purchaser shall base his selection, ordering and receiving of consumables upon reviewed and accepted Data Sheets.

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The Data Sheet shall give guaranteed limits and/or minimum values for composition and mechanical properties, determined under defined reference conditions. Specifically this shall include, as applicable: The analysis shall include limits for all elements specified in the relevant classification standard and/or intentionally added and for residual elements known to influence weld metal quality. Minimum: C, Si, Mn, S, P, Cu, Ni, Cr, Mo, V, Nb. For SAW fluxes the analysis shall be given as ranges for all main ingredient and flux basicity. Data Sheets shall also contain product classification according to recognised standards, relevant approvals and information on packing, storage etc. as required for correct application and use of the product. C.3 CERTIFICATE Every batch of consumables shall be supplied with an inspection certificate 3.1.B, containing as a minimum the specific tested chemical composition of the wire or weld metal, as applicable. The chemical elements shall conform to those of the Data Sheets, with a statement below specified maximum acceptable for residual elements. The supplier may optionally add information about mechanical properties, based on specific or nonspecific type of control. (Ref. EN 10204). Other tests may also be agreed between supplier and purchaser. Certificates shall be actively used by the purchaser to control received consumables against the accepted Data Sheet. Full conformance of chemical composition shall be required to release each batch for fabrication welding. ANNEX D

WELDING CONSUMABLE DOCUMENTED BY BATCH TESTING

D ANNEX D - WELDING CONSUMABLE DOCUMENTED BY BATCH TESTING D.1 SCOPE The purpose of the batch testing is to verify that the consumables remains nominally equivalent to that used for welding procedure qualification, with respect to chemistry and mechanical properties. For this specification a batch (or lot) is defined as the volume of product identified by the supplier under one unique batch/lot number, manufactured in one continuous run from batch controlled raw materials.

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Each individual product (brand name and dimensions) shall be tested once per batch, except for solid wire originating from the same heat, where one diameter may represent all. SAW fluxes do not require individual testing, while SAW wires shall be tested in combination with a selected, nominal batch of flux. Chemical Analysis For solid wires and metal powders the analysis shall represent the product itself. For coated electrodes and cored wires the analysis shall represent the weld metal, deposited according to EN 26847. The analysis shall include: D.2 MECHANICAL PROPERTIES Unless otherwise specified the properties shall represent all weld metal, deposited and tested according to prEN 1597 part1. Properties tested shall include: The need for other types of tests, such as: shall be evaluated for the application in question. D.3 DOCUMENTATION Batch tests shall be documented by an inspection certificate 3.1B to EN 10204, with reference to a recognised product classification standard and containing all specified test results.

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