Structural Steel Material Specification

Document No: BD-00-S-S-0001 Date : 15-09-09 Page : 2 of 15 Rev :0

TABLE OF CONTENTS

1.0 2.0 3.0 4.0 5.0

INTRODUCTION ..................................................................................................................... 3 REFERENCES TO CODES, STANDARDS AND PROJECT SPECIFICATIONS ................. 4 MATERIAL GRADES.............................................................................................................. 6 REQUIREMENTS.................................................................................................................... 7 INSPECTION & TESTING .................................................................................................... 12

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Structural Steel Material Specification

Document No: BD-00-S-S-0001 Date : 15-09-09 Page : 3 of 15 Rev :0

1.0 1.1

INTRODUCTION APPLICATION Bien Dong Petroleum Operating Company is operator of Blocks 05.2 and 05.3 approximately 340km south of the coast of Vietnam. This specification applies to all Development Projects in these Blocks.

1.2

ACRONYMS AND ABBREVIATION BD POC Bien Dong Petroleum Operating Company

THIRD PARTY Classification Society or other such body as appointed by BD POC MWS HSE QA/QC API ASTM BS CE CTOD EEMUA OD WPS TMCP 1.3 SCOPE This specification defines the minimum technical requirements for the manufacture and supply of structural steel materials for BDPOC. The material grade and categories are in section 3.0 below. The requirements are in section 4.0. 1.4 INTENT The Supplier/Vendor shall comply with the requirements of this specification unless otherwise instructed by the Purchaser in writing. 1.5 UNITS SI units shall be used. 1.6 LANGUAGE All documentation and communication shall be in the English language. Marine Warranty Surveyor Health, Safety and Environment Quality Assurance/Quality Control American Petroleum Institute American Society for Testing and Materials British Standard carbon equivalent crack tip opening displacement Engineering Equipment & Materials Users Association outside diameter weld procedure specification thermo- mechanical control process

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Structural Steel Material Specification

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2.0 2.1

REFERENCES TO CODES, STANDARDS AND PROJECT SPECIFICATIONS CODES AND STANDARD The following listed Codes, Recommended Practices, specifications and Standards are referenced as part of this specification. The latest revisions and amendments of these documents, as of the Contract document date, are applicable unless otherwise noted herein.

2.1.1

EEMUA EEMUA 158 Construction Specification for Fixed Offshore Platforms.

2.1.2

American Petroleum Institute (API) API RP2A "Planning, Designing and Constructing Fixed Offshore Platforms, Working Stress Design." Recommended Practice for Ultrasonic Examination of Offshore Structural Fabrication and Guidelines for Qualification of Ultrasonic Technicians Recommended Practice for Preproduction Qualification for Steel Plates for Offshore Structures "Carbon Manganese Steel Plate for Offshore Platform Tubular Joints". "Specification for Steel Plate for Offshore Structures Produced by Thermo-Mechanical Control Processing Method". "Line Pipe". "Fabrication of Structural Steel Pipe".

API RP2X

API RP2Z

API Specification 2H API Specification 2W

API Specification 5L API Specification 2B 2.1.3

American Society of Testing Material (ASTM) ASTM A6/A6M "General Requirement for Rolled Steel Plates, Shapes, Sheet Piling and Bars for Structural Use". "Structural Steel". "Seamless Carbon Steel Pipe for High Temperature Service". "Zinc (hot Galvanized) Coatings on Iron and Steel Products". "Alloy-Steel and Stainless Steel Bolting Materials for High Temperature Service". "Carbon and Alloy Steel Nuts for Bolts for High Pressure and High Temperature Service". "Carbon Steel Bolts and Studs". "High Strength Bolts for Structural Steel Joints". "Mechanical Testing of Steel Products".

ASTM A36/A36M ASTM A106 ASTM A123 ASTM A193/A193M

ASTM A194/A194M

ASTM A307 ASTM A325 ASTM A370

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Structural Steel Material Specification

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ASTM A563 ASTM A572

"Carbon and Alloy Steel Nuts". "High Strength Low-Alloy Columbium-Vanadium steels of Structural Quality". "Standard Test Method of Salt Spray (Fog) Testing". "Hardened Steel Washers for use with High Strength Bolts".

ASTM B117 ASTM F436 2.1.4

American National Standards Institute (ANSI) ANSI B1.1 ANSI B18.2.2 ANSI B18.22.1 "United Screw Threads (UN & UNR form)". "Square and Hex Nuts". "Lock Washers".

2.1.5

American Welding Society AWS D1.1 "Structural Welding Code".

2.1.6

British Standards Institute BS 7448 Fracture Mechanics Toughness Tests Part 1: Methods for Determination of KIC critical CTOD and critical J values of Metallic Materials Weldable Structural Steels for Fixed Offshore structures Metallic products-Types of Inspection Documents

BS 7191 BS:EN10204 2.2

PROJECT SPECIFICATIONS This specification shall be read in conjunction with the Structural Steel Fabrication Specification, BD-00-S-S-0002.

2.3

CONFLICT Where equal but conflicting requirements are specified, these shall be brought to the attention of the Purchaser in writing. The order of precedence shall be: 1. Purchase order and subsequent change orders 2. This specification 3. Project specifications 4. National standards and codes

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Structural Steel Material Specification

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3.0

MATERIAL GRADES
STEEL TYPE GENERAL DESCRIPTION TYPICAL USES MATERIAL GRADE ASTM OR API API 2W GR 50 S1 ,S3, S5 & S11 Supplements (KT= - 40C + CTOD = -10C) API 5L X52 PSL 2 (KT=-40C) API 2W GR 50 S1 ,S3, S4, S5 & S11 Supplements (KT= - 40C + CTOD = -10C)

TYPE I

PRIMARY HIGH STRENGTH

PLATES ROLLED TUBULARS SEAMLESS TUBULARS 406 (16) & BELOW

TYPE II

PRIMARY HIGH STRENGTH WITH THROUGH THICKNESS PROPERTIES SECONDARY MILD STEEL SECONDARY MILD STEEL

LEGS & CANS DECK NODE & LIFT POINTS THICKNESS 25MM PLATES ROLLED TUBULARS SEAMLESS TUBULARS 406 (16) & BELOW

TYPE III

ASTM A36 API 5L GR B PSL 1 ASTM A572 Gr 50 S5, S28, S31 (CE 0.43) Supplements Killed, Fine grained Thk >19mm to be normalized (KT= - 10C)

TYPE IV

TYPE V

PRIMARY HIGH STRENGTH

ROLLED SHAPES

TYPE VI

PRIMARY HIGH STRENGTH PRIMARY HIGH STRENGTH WITH THROUGH THICKNESS PROPERTIES

PLATES ROLLED TUBULARS COLUMN, LEGS & CANS DECK NODE & LIFT POINTS THICKNESS 25MM

API 2W GR 60 S1 ,S3, S5 & S11 Supplements (KT= - 40C + CTOD = -10C) API 2W GR 60 S1 ,S3, S4, S5 & S11 Supplements (KT= - 40C + CTOD = -10C)

TYPE VII

KT indicates temperature at which Charpy V-notch impact testing in transverse direction is required. Types I, II, VI and VII shall exhibit minimum energy 30 Joules or as required by the material specification whichever is higher. Type V shall exhibit minimum energy 20 Joules or as required by the material specification whichever is higher. CTOD indicates temperature at which CTOD testing is required. Types I and VI require successful CTOD testing for material greater than 50mm thick, including any repair procedure. Types II and VII require successful CTOD testing for material greater than 40mm thick, including any repair procedure. Suppliers attention is drawn to the requirements of Appendix A in the Structural Steel Fabrication Specification, BD-00-S-S-0002 for fabrication of steel Types VI and VII .

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Structural Steel Material Specification

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4.0 4.1

REQUIREMENTS GENERAL All structural steel shall meet the requirements of ASTM A6/A6M and any additional requirements of the appropriate API or ASTM standard specified in Section 3 along with the relevant additional or specific test requirements as stated in this specification for each steel type. Prior to the commencement of production the Supplier shall provide a detailed summary of the process to be used for the production of all steel to this specification. As a minimum the following detailed information shall be submitted with the Tender: a) Location and name of steel mill b) Recent production data to support that the values proposed for ladle and product analysis are achievable. c) Steel manufacturing procedures d) Segregation procedures for continuously cast steel e) Control of sequential casting (for continuous casting) f) Ingot or slab size including plate thickness ranges for each size g) Details of sulphur printing or alternative method of quality grading and frequency of checks for continuous casting h) Rolling procedures i) Dehydrogenation procedures j) Normalisation or alternative procedures k) Recent production data to demonstrate that Charpy V-notch impact values specified herein are achievable l) Information on the effect of extended times at stress relieving temperatures on tensile and Charpy V-notch impact properties m) Details of the quality control procedures to be implemented during production which should clearly identify all inspection points. n) Details of proposed chemical analysis control o) Weldability information including mechanical testing results (macro hardness, Charpy V-notch, CTOD, cross weld tensile) For fabricated sections and welded tubulars all Weld Procedure Specifications (WPS) shall be submitted to the Purchaser for review and agreement prior to the commencement of the work. Requalification of welding procedures shall be required for fabrication of primary items unless otherwise agreed with the Purchaser. Welded tubulars and fabricated sections furnished to this specification shall comply with EEMUA-158.

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Structural Steel Material Specification

Document No: BD-00-S-S-0001 Date : 15-09-09 Page : 8 of 15 Rev :0

Steel Types shall have maximum carbon equivalent (CE) values as follows: Type I & II Thickness up to 40mm 40mm 75mm > 75mm up to 40mm up to 40mm up to 40mm >40mm Max CE 0.39 0.41 0.43 0.39 0.43 0.42 0.45

III & IV V VI & VII

Where, CE = C +Mn/6 + (Cr+Mo+V)/5 + (Ni+Cu)/15 All steel shall be new and shall be free from defects impairing strength, durability or appearance and of the best commercial quality for the purpose specified. Reject steel is not acceptable. 4.2 SECTIONS Rolled sections of Type I, Type II, Type VI and Type VII shall be in accordance with the requirements of ASTM A6. These shall not be weld repaired. 4.3 4.3.1 TUBULARS Seamless Tubulars Tubulars equal to and smaller than 406mm OD shall be seamless and manufactured in accordance with API 5L. 4.3.2 Welded Tubulars Pipe larger than 406mm OD shall be fabricated per structural fabrication specification document no BD-00-S-S-0002, using plate meeting the requirements of this specification. All weld seams shall use appropriately qualified and Purchaser approved welding procedures. Tubulars shall be welded using submerged arc welding (SAW). All welding and weld procedure qualification shall be carried out in accordance with EEMUA-158. Hydrostatic testing of structural pipe is not required. Fabricated structural pipe shall not have more than one (1) longitudinal seam except where diameter precludes. Weld seam locations for large diameter pipe shall be in accordance with the drawings and subject to Purchaser approval. Pipe may be hot formed or cold formed. For the purposes of this specification, the definition of hot forming is when the material is deformed by line heating or external force while at a surface temperature greater than 425C. When material is supplied through the TMCP route, heating shall not exceed 595C or any lower temperature advised by the Supplier.

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Structural Steel Material Specification

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4.3.3

Cold Forming a. b. If cold (200C) forming strain exceeds 3 percent, a cold forming procedure qualification must receive written approval from the Purchaser before forming proceeds. The Purchaser acceptance criteria for the procedure qualification requires the as-formed plate to satisfy all mechanical tests specified in BS 7191 or relevant API or ASTM specifications and any optional specifications contained herein. Cold forming strain shall be calculated by the following formula: E = t OD-t x 100

c.

Where: E t OD 4.3.4 Hot Forming

= = =

cold forming strain in percent plate thickness outside diameter of member

1. Prior to hot forming, the Supplier shall submit to the Purchaser for approval, a written hot forming procedure and written approval from the steel manufacturer of the procedure. 2. The Purchaser acceptance criteria for the procedure requires the as formed plate to satisfy all mechanical tests specified in the relevant BS, API and ASTM specifications and any optional or supplemental specifications contained herein. 3. Plate steel shall not be heated between the upper and lower critical temperatures, and forming in the range between 250 and 425C shall not be done. 4. If the forming temperature exceeds 650C for as-rolled or normalised steels, or 595C for TMCP steels, or falls within 25C less than the tempering temperature for quenched and tempered steels mechanical property, tests shall be run to ensure that the mechanical properties of the steel conform to the relevant BS, API or ASTM specifications. If the results are satisfactory, no further tests shall be required, unless the forming temperature is increased. Test results failing to meet the specification requirements shall be cause for rejection of the entire heat. 4.3.5 Jacket Node Cans All primary nodes in the jackets shall be type II steel and in accordance with API RP2A. All welding shall be in accordance with EEMUA 158. Circumferential weld locations (if required) shall be in accordance with the drawings and Purchaser approved. 4.4 STORAGE All material shall be stored above ground on suitable skids or platforms and protected from the weather. 4.5 CHEMICAL COMPOSITION The acceptable limits of the chemical composition shall be revised to the following requirements:

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Structural Steel Material Specification

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Grade Type III, Type IV, Type V Type I, Type VI Type II, Type VII

S 0.015 max. 0.005 max.

P 0.025 max. 0.015 max.

Al 0.015/0.055 0.015/0.055 0.015/0.055

The maximum permissible nitrogen content for rolled sections and seamless tubular shall not exceed 0.010% 4.6 WELDABILITY This clause applies to steel types I, II, VI and VII. At the time of the Tender, the Supplier shall submit weldability data of the material offered. In the absence of such data, the Supplier shall advise his proposed methods and schedule for producing the required information. This data shall include CTOD data for the offered steel plate that has been obtained in accordance with the requirements of API RP2Z. 4.7 STEEL PLATES AND ROLLED SHAPES Steel plates and rolled shapes shall be free of rolling defects, burrs, rough spots and other surface imperfections. Surface finish for steel surfaces shall be such that only blasting and no grinding is required to achieve an acceptable surface for painting. Plate edges shall be even, smooth and free of laminations. Edge shearing of plates of 25mm (1") thickness or greater is not permitted. 4.8 MECHANICAL TESTING Supplier shall provide historical testing data with their Tender documents to demonstrate that their steel is capable of meeting the requirements of this specification. Testing shall generally be in accordance with the requirements of the API or ASTM specification. 4.8.1 Tensile Testing Tensile tests are required for all steel types. 4.8.2 Strain Aged Impact Testing Strain aged impact testing is required for Types I and II steel. 4.8.3 Through Thickness Tensile Testing Through thickness tensile testing shall be in accordance with supplement S4 of API 2W. The test samples shall represent the maximum thickness being produced.

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Structural Steel Material Specification

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4.8.4

CTOD Testing Where CTOD testing for weld procedure qualification is required it shall be in accordance with Supplement S11 of API 2W and EEMUA 158 and the recommended acceptance values met.

4.8.5

Hot Forming Procedure The manufacturer shall supply the information indicated in clause 4.3 to confirm the suitability of the material for the hot forming.

4.9 4.9.1

DIMENSIONAL TOLERANCES Plates Tolerances for plate shall comply with ASTM A6

4.9.2

Welded tubulars Tolerances for Type I, Type II, Type VI and Type VII welded tubulars shall be as per EEMUA 158

4.9.3

Seamless Tubulars Tolerances for seamless tubulars shall be as per API 5L

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Structural Steel Material Specification

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5.0 5.1

INSPECTION & TESTING GENERAL Supplier shall perform inspection and tests as specified in this specification and/or referenced codes, standards and specifications. Material certification and traceability shall be in accordance with BS:EN10204 as follows: Type 3.2 Type 3.1 For material Types I, II, VI and VII For material Types III, IV and V

Once certified, by an acceptable certification authority, copy of mill certificates covering the chemical, physical, Charpy V-notch properties, CTOD results and the heat treatment data (as applicable) of all steel shall be provided upon delivery of the material. All testing shall be done on the finished product, in accordance with the relevant specification. Certified Mill Certificates shall include the following:

Purchase order number and item number. Material size and Specification. Melting Practice. Mill heat numbers and control numbers. Ladle analysis and check chemical analysis, together with calculated Carbon equivalents. Heat treatment. Grain size. Tensile and Yield strengths and elongation. Impact testing specimen size, orientation, impact values and test temperature (when required). CTOD test report. Other information required by referenced specifications. Supplemental information relating to the manufacturing process.

Where welding has been performed, non destructive examination (NDE) certificates shall also be provided. All steel surfaces shall be subject to 100 % visual inspection. The material to be furnished under this specification shall be subject to the inspection requirements of the relevant referenced Specification. Purchaser shall be permitted access at all times to any part of the manufacturing process and shall reject any steel that does not comply with this Specification.

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Structural Steel Material Specification

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5.2

INTERNAL SOUNDNESS The internal soundness for all plates and sections shall be verified by ultrasonic testing in accordance with the requirements of the API RP2X or ASTM specification. Plates and sections shall be sound and free from cold laps or other surface defects and from internal defects such as segregation, cracks and laminations.

5.3

MERCHANT SUPPLY If any secondary steel is supplied from a merchants stock, the Supplier shall be responsible for the following. 1. Supplying to the Purchaser a copy of the original order requirements placed on the mill and the subsequent sales history of the product. 2. Supplying to the Purchaser all documentation required by this specification including an original copy of the mill certificate or a copy verified by the certification authority. 3. Satisfying the Purchaser by means of numbers or identification marks on the steel that such steel has been tested and complies with this specification.

5.4

IDENTIFICATION AND MARKING Identification and markings on materials shall include the name of the producer, the steel type and grade, heat number, and the plate number. For identification and marking of materials ASTM A6 shall apply. All steel shall be marked by die stamping and painting in accordance with the relevant standard or Specification. It shall always be possible to match structural steel material by heat number with its certified mill test reports. Stencil marking of all structural steel shall be with white paint on black painted background in letters minimum of 35mm high with a protective coating of clear varnish applied only on the stenciled area. Stencil data shall be as indicated below: BDPOC P.O. NO. MADE IN . Year. Month TAG NO. One color band shall be made at both ends of all structural steel items on the outside surface as follows: Type I Type II Type III Type IV Type V Type VI Type VII Dark Blue Red Black Green Yellow Light Blue Purple

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Structural Steel Material Specification

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A)

Tubulars: 1. Stencil marking shall be made on the inside surface of both ends of tubulars beginning 75mm from the end of the tubular. 2. Fabricated tubulars made up from more than one plate shall have the Die-Stamp marking as appropriate on each component plate on the outside of the tubular.

B)

Plate Stencil Marking 1. Stencil marking shall meet the requirements of API 2W (including API monogram stencil marking) 2. Stencil marking shall be made at each end of the plate and on both sides of the plate beginning 75mm from the end of the plate and away from the die-stamp.. 3. For plate greater than or equal to 25mm both ends of the plate shall have the Tag Number stenciled in white letters 20mm high on a black ground and coated with varnish. Die-stamp Marking Die-stamp shall be made at one end of the plate approximately 75mm from any edges and include the following items. Normal die-stamp is to be used. Mill brand Specification Heat No. Z (if S-4 is required) or LS Z (if S-4 & S-5 are required)

D)

Structural Shapes Die-stamp marking Die stamping of for steel Types I, II, V, VI and VII shall be as follows: Mill brand Specification Heat No.

Stencil marking 1. Stencil marking shall meet the requirements of API (including API monogram stencil marking) 2. Stencil marking shall be made at each end of the shape on both sides of the web 75mm from the end of the shape.

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Structural Steel Material Specification

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5.5

PACKING Tubulars shall be packed as follows: [*] Bundling OD 182mm OD 185 mm Bundled Loose

[*]

Bevel protection Mills standard bevel protector shall be provided for each pipe end.

Stacking of tubulars for shipping shall be such that the tubular roundness shall still meet the specification requirements upon delivery. All tubulars shall be securely stowed when being shipped so as not to cause damage during transport. Structural shapes shall be packed Bare in loose, but small size shapes shall be fastened with steel wire.

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