Norsok M 122 Ed 2012 Cast Structural Steel - Compress
Norsok M 122 Ed 2012 Cast Structural Steel - Compress
Norsok M 122 Ed 2012 Cast Structural Steel - Compress
Foreword 2
Introduction 2
1 Scope 3
2 Normative and informative references 3
2.1 Normative references 3
2.2 Informative references 3
3 Terms, definitions and abbreviations 4
3.1 Terms and definitions 4
3.2 Abbreviations 4
4 Qualification 4
4.1 General 4
4.2 Basis for qualification of steel foundries 5
4.3 General requirements 5
4.4 Manufacturing 5
4.5 Qualification based upon a test program 6
4.5.1 General 6
4.5.2 Qualification of the manufacturing process 6
4.5.3 Validity of qualification 6
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4.5.4 Selection of material for testing 7 2 -
4.5.5 Extent of testing 7 6
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4.5.6 Base material 7 4
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4.5.7 Weldability 7 0
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4.5.8 Qualification test record 7 ils
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5 Requirement to cast structural steel 8 o
5.1 Steel making process 8 b
5.2 Heat treatment 8 ta
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5.2.1 General 8 +
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5.2.2 Heat treatment procedures 8 ito
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5.2.3 Post weld heat treatment (PWHT) 8 n
5.3 Chemical composition 8 Ig
5.4 Mechanical testing 9 r
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5.4.1 General 9 S
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5.4.2 Frequency of testing 10
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5.4.3 Position of test specimens 10 iln
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5.4.4 Test methods 10 O
5.4.5 Mechanical properties 10 dr
5.5 Retesting and criteria for rejection 11 a
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6 Non – destructive testing (NDT) 11 n
6.1 General 11 ta
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6.2 Surface requirements 11 y
6.3 Qualification of NDT personnel 11 b
6.4 Extent of testing 12 d
6.5 Test methods 12 e
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6.5.1 Visual inspection 12 v
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6.5.2 Magnetic particle testing 12 P
Foreword 3
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The NORSOK standards are developed by the Norwegian petroleum industry to ensure adequate safety, 0 -
value adding and cost effectiveness for petroleum industry developments and operations. Furthermore, 4
NORSOK standards are, as far as possible, intended to replace oil company specifications and serve as 1
references in the authorities’ regulations. 0
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The NORSOK standards are normally based on recognised international standards, adding the provisions
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deemed necessary to fill the broad needs of the Norwegian petroleum industry. Where relevant, NORSOK o
standards will be used to provide the Norwegian industry input to the international standardisation process. b
Subject to development and publication of international standards, the relevant NORSOK standard will be ta
withdrawn. S
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The NORSOK standards are developed according to the consensus principle generally applicable for most ito
standards work and according to established procedures defined in NORSOK A-001. a
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The NORSOK standards are prepared and published with support by The Norwegian Oil Industry Ig
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Association (OLF), The Federation of Norwegian Industry, Norwegian Shipowners’ Association and The
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Petroleum Safety Authority Norway.
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NORSOK standards are administered and published by Standards Norway. e
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Introduction O
This NORSOK standard is based on former company specifications and experience from deliveries and dr
operation. a
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1 Scope
This NORSOK standard defines the requirements for qualification of foundries and the technical delivery
requirements for cast structural steel for use in offshore structures where steel quality level I or II is required.
3.1.2
may
verbal form used to indicate a course of action permissible within the limits of this NORSOK standard
3.1.3
shall
verbal form used to indicate requirements strictly t o be followed in order to conform to this NORSOK
standard and from which no deviation is permitted, unless accepted by all involved parties
3.1.4
should
verbal form used to indicate that among several possibilities one is recommended as particularly suitable,
without mentioning or excluding others, or that a certain course of action is preferred but not necessarily
required
3.2 Abbreviations
ACCP ASNT Central Certification Program 3
AOD argon oxygen decarburisation 2 -
ASME American Society Mechanical Engineers Standard 6
ASNT American Society for Non-destructive Testing 0 -
ASTM American Society for Testing and Materials 4
BS British Standard
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CTOD crack tip opening displacement 2
EN European Standard ils
FATT fracture appearance transition temperatures u
HAZ heat affected zone o
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IEC International Electrotechnical Commisssion
IIW International Institute of Welding S
ISO International Organization for Standardization +
MT magnetic particle testing s
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NDT non-destructive testing
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PWHT post weld heat treatment n
RT radiographic testing Ig
VAD vacuum argon decarburisation r
VODC vacuum oxygen decarburisation converter fo
UT Ultrasonic testing S
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4 Qualification iln
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4.1 General O
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The purchaser may accept the foundry’s qualification based on general information described in 4.2-4.4
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combined with a verification or audit at the foundry. d
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However, depending on the criticality and complexity of the casting and the experience of the foundry, the ta
purchaser may require the foundry to perform a qualification as described in 4.5. S
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documented knowledge and previous experience with the material and the manufacturing;
manufacturing facilities and equipment;
established manufacturing procedures covering all important manufacturing steps from melting to
finished products;
manufacturers quality system, which shall fulfill the requirements related to product realization in
ISO 9001;
results of testing in compliance with this NORSOK standard.
Prior to qualification a complete report, with information and results of testing as required by this standard
shall be available for review.
Experience should be supported by statistical data or relevant test records for the size range to be qualified.
The steel shall have been produced to manufacturing procedures and with equipment intended used for the
actual manufacturing.
Facilities and equipment shall be fit for purpose, regularly maintained and calibrated as required. The
assessment shall concentrate on facilities and equipment for moulding, melting, refining, welding, heat
treatment, etc. 3
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Foundries shall have heat treatment facilities on their own premises or such facilities shall be located in their 0 -
close vicinity. 4
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If parts of the production are carried out at a sub-supplier, the manufacturer is responsible for ensuring that
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the sub-supplier meets the requirements of this standard for the manufacturing steps that he is performing.
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The manufacturer shall have a Manufacturing Summary for each production route. The Manufacturing ta
Summary shall describe, step by step in a logical and correct sequence all important manufacturing activities S
with reference to detailed procedures. A short description and the main parameters for each activity shall be +
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included. The production route shall be illustrated with a flow chart. The scope of the manufacturing
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summary shall be clearly defined:
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name and address of manufacturer; Ig
grade of material; r
type and size range of products for which the manufacturing summary applies; fo
identification of the manufacturing process. S
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The manufacturing summary shall include procedures for e
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moulding method, type of sand, binding agent and method of casting, O
melting and refining processes, d
heat treatment, including r
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loading temperature, heating rate, holding temperature (range) and time, d
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loading and stacking of components in furnace,
type and identification of furnace(s), S
maximum operation temperature for furnace(s), y
temperature control and calibration of furnace(s), b
cooling facilities and max. time from furnace to quenching bath (if relevant), d
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sketch of heat treatment facilities/furnace which also shall show location of pyrometers and/or d
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thermocouples in the furnace(s) and on the component(s). v
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If the manufacturer has different plants or different production routes for a product, separate documentation
is required for each of these. If essential parts of the work such as e.g. heat treatment are subcontracted,
this shall be identified in the documentation.
Whenever a change is made in the equipment or procedures, the documentation shall be updated
accordingly.
The casting shall not be subject to any plastic deformation during manufacturing including handling at high
temperatures.
4.5.1 General
For critical structural castings or castings intended for welding, base material and weldability data shall be
required documented according to 4.5.2 to 4.5.8.
4.5.6.1 General
The material used for the examinations to document properties shall be representative, implying that the
steel making process, casting methods and heat treatment condition shall be equal to that proposed for the
actual delivery. The section thicknesses shall be representative for the thinnest and thickest portion in the
casting for the actual delivery.
5.2.1 General
All castings shall be delivered in homogenised, normalised and stress relieved condition, or in homogenised,
quenched and tempered condition, also including any post weld heat treatment after repair welding.
The heat treatment variables shall be selected to promote uniform microstructure, correct mechanical
properties for the different section thicknesses and to reduce residual stresses. 3
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Heat treatment temperatures shall be measured and recorded by means of thermocouples attached to the 0 -
castings. 4
The temperature in the furnace at the time of loading the castings shall not exceed 200 °C. The heating and 1
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cooling rates for temperatures above 300 °C shall not exceed 70 °C and 50 °C per hour respectively except 2
for quenching. Below 300 °C the castings may be cooled in still air. ils
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The heat treatment furnaces shall be calibrated according to ASTM A991 or ISO 10423, Annex M. o
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5.2.3 Post weld heat treatment (PWHT) ta
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PWHT shall be carried out after any repair welding. All PWHT shall be carried out in a closed furnace. The +
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soaking temperature shall be as qualified during the repair welding procedure. The soaking time shall be
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minimum 2 min/mm of the thickest wall at the actual weld repair location.
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5.3 Chemical composition Ig
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Chemical composition for the three cast steel grades are given in Table 1. The values apply to both ladle
and product analysis. Any modification from Table 1 shall be agreed in each case. Ladle analysis shall be
performed for each heat and product analysis performed for each casting. S
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The test block(s) shall be an integral part of the casting. The test block(s) shall not be gated onto the casting.
The thickness of the integral test block(s) shall represent the maximum weld member end thickness and/or
critical thickness to ensure representative microstructure and mechanical properties.
The location (sketch) and size of the integral test block(s) shall be agreed with the purchaser prior to start of
production. If there are more than one test sample on a casting, the blocks shall be located as far away from
each other as possible.
If retesting fails, the casting will be rejected. However the manufacturer may choose to carry out a reheat
treatment once followed by full set of mechanical testing. If any results still are not acceptable, the casting or
lot will be rejected.
6.1 General
All NDT shall be carried out in accordance with the established procedures.
The NDT reports shall show examined areas, size and nature of defects and reportable indications.
The surface of the castings shall be examined visually and shall be free of adhering sand, scale, cracks and
hot tears.
Other surface discontinuities shall meet the requirements specified for MT.
Surface roughness shall as a minimum be as follows (see Recommandation Technique No. 359-01 du 3
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Bureau de Normalisation des Industries de la Fonderie (BNIF)): 6
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4S1 on surfaces subject to UT with normal probes; 4
3S2 on surfaces subject to UT with angle probes; 1
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3S2 on transition zones/fillets surfaces subject to MT; 2
4S1 on general surfaces subject to MT and Visual inspection; ils
3S1 on surfaces subject to RT only. u
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When surfaces are machined the roughness shall as a minimum be as follows (see BS 2634-1): ta
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Ra 12 m on surfaces subject UT with normal probes; +
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Ra 6 m on surfaces subject UT with angel probes; ito
Ra 12 m on general surfaces subject to MT and visual inspection. a
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6.3 Qualification of NDT personnel Ig
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All NDT personnel shall be qualified according to EN 473/Nordtest level II in product sector (c) or an industry fo
sector containing product sector (c) ASNT ACCP level 2 accredited NDT. Personnel performing RT S
exposures only, may, however, be qualified to level I. A
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Personnel qualified to level III, shall be r esponsible for all NDT activities. ASNT-TC-1A level III personnel iln
shall hold valid ASNT-TC-1A level III Certificate (i.e. Management appointed level III is not accepted). n
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Contractor shall keep an updated list of all NDT personnel engaged in the work, with reference to possessed dr
certificates and expiry dates. This list shall be made available to Purchaser on request. a
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6.5.4.2 Procedures
The ultrasonic testing procedures shall additionally include at least the following information:
sensitivity setting;
typical sketches of section (with dimensions) to be examined which clearly show scanning pattern and
probes to be used;
acceptance criteria;
reporting and identification system.
6.5.4.3 Probes
The frequency value shall be selected to suit the test and shall be within the range 0.5 MHz to 5 MHz. Higher
frequency can be used for testing wall thicknesses of less than 20 mm or areas close to the surface. For the
detection of near-surface discontinuities, the use of dual-element and/or angle probes shall be used.
The probes for ultrasonic testing shall be selected in accordance with Table 4.
7 Repair
The maximum extent of repair welding shall not exceed 20 % of the total surface area unless otherwise
agreed with the purchaser.
The excavations shall be suitably shaped to allow good access for welding. The groove shall be ground
smooth and be free from dirt, grease, oil, etc.
Welding consumable of low hydrogen content (maximum 5 ml/H DM pr. 100 g, IIW-method) shall be used for
repair welding. The welding consumable shall be handled according to the consumable manufacturer's
recommendations.
Repair welding procedures shall be established and qualified according to ISO 15607, ISO 15609-1 and
ISO 15614-1, with the following additional requirements. The repair welding procedure shall be qualified on 3
the same grade of material as the delivered component: 2 -
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Charpy V-notch impact tests with notch locations in weld metal, fusion line and heat affected zone 0 -
+ 2 mm and + 5 mm from fusion line, respectively. Test results shall meet the requirements specified for 4
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the parent metal; 0
macro section; 2
hardness values shall not exceed 350 HV10. ils
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Welders shall be qualified according to EN 287-1. b
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Castings repaired by welding shall be post weld heat treated at a temperature at least 15 °C below the S
tempering temperature. On completion of heat treatment the weld repairs and adjacent material shall be +
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ground smooth. All weld repairs shall be magnetic particle tested and major repairs shall additionally be ito
ultrasonic (or radiographic) tested. Weld repairs shall meet the quality level designated for that particular a
zone of the casting. n
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The foundry shall maintain records of repair welding, subsequent heat treatment and inspections traceable r
to each casting repaired. fo
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8 Tolerances for dimensions and weight e
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Dimensions and required tolerances shall be as given on the relevant drawing of the casting or other
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information supplied. If nothing is specified, ISO 8062, Grade CT, 13 shall apply.
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The weight tolerances shall be within agreement with the purchaser.
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9 Surface protection ta
Castings shall before delivery, be degreased, shot blasted to bright metal and protected by a shop primer S
with a dry film thickness of approximately 20 μm. All sharp edges shall be rounded and smoothed by y
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grinding to a minimum radius of 2 mm to assure full film thickness on all edges. d
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Machined surfaces shall be protected by a rust protection coating (water soluble Tectyl or equivalent). d
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10 Marking
Castings shall be marked for identification against a certificate. The marking shall include Contractor’s
identification and heat number.
All markings shall be carried out by die stamping or as cast in marks, and be framed by white painting. The
letters used for the stamping should be 15 mm in height.
11 Certificate
Certificate according to 3.1 (see EN 10204) is required.
The certificate shall contain all relevant information including, but not restricted to the following:
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