NORSOK STANDARD M-122

Edition 2, October 2012

Cast structural steel

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This NORSOK standard is developed with broad petroleum industry participation by interested parties in the S
Norwegian petroleum industry and is owned by the Norwegian petroleum industry represented
represented by The Norwegian y
Oil Industry Association and The Federation of Norwegian Industry. Please note that whilst every effort has been b
made to ensure the accuracy of this NORSOK standard, neither The Norwegian Oil Industry Association nor The d
Federation of Norwegian Industry or any of their members will assume liability for any use thereof. Standards e
Norway is responsible for the administration and publication of this NORSOK standard. d
i
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Standards Norway Telephone: + 47 67 83 86 00 o
r
Strandveien 18, P.O. Box 242 Fax: + 47 67 83 86 01 P
N-1326 Lysaker Email: petroleum@standa
[email protected]
rd.no
NORWAY Website: www
www.standard.no/petroleum
.standard.no/petroleum
Copyrights reserved
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NORSOK standard M-122 Edition 2, October 2012

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
3
4.5.4 Selection of material for testing 7 2 -
4.5.5 Extent of testing 7 6
0 -
4.5.6 Base material 7 4
1
4.5.7 Weldability 7 0
2
4.5.8 Qualification test record 7 ils
u
5 Requirement to cast structural steel 8 o
5.1 Steel making process 8 b
5.2 Heat treatment 8 ta
S
5.2.1 General 8 +
s
5.2.2 Heat treatment procedures 8 ito
a
5.2.3 Post weld heat treatment (PWHT) 8 n
5.3 Chemical composition 8 Ig
5.4 Mechanical testing 9 r
fo
5.4.1 General 9 S
A
5.4.2 Frequency of testing 10
e
5.4.3 Position of test specimens 10 iln
n
5.4.4 Test methods 10 O
5.4.5 Mechanical properties 10 dr
5.5 Retesting and criteria for rejection 11 a
d
6 Non – destructive testing (NDT) 11 n
6.1 General 11 ta
S
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

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NORSOK standard M-122 Edition 2, October 2012

6.5.3 Radiographic testing 12

6.5.4 Ultrasonic testing 12
6.6 Acceptance criteria 13
6.6.1 General 13
6.6.2 Visual examination 14
6.6.3 Radiographic testing 14
6.6.4 Ultrasonic testing 14
6.6.5 Magnetic particle testing 14
7 Repair 15
7.1 Repair by grinding 15
7.2 Repair by welding 15
8 Tolerances for dimensions and weight 15
9 Surface protection 15
10 Marking 16
11 Certificate 16

Foreword 3
2 -
6
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
2
The NORSOK standards are normally based on recognised international standards, adding the provisions
ils
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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
n
The NORSOK standards are prepared and published with support by The Norwegian Oil Industry Ig
r
Association (OLF), The Federation of Norwegian Industry, Norwegian Shipowners’ Association and The
fo
Petroleum Safety Authority Norway.
S
A
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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NORSOK standard M-122 Edition 2, October 2012

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.

2 Normative and informative references

The following standards include provisions and guidelines which, through reference in this text, constitute
provisions and guidelines of this NORSOK standard. Latest issue of the references shall be used unless
otherwise agreed. Other recognized standards may be used provided it can be shown that they meet the
requirements of the referenced standards.

2.1 Normative references

ASME V, Article 5, Ultrasonic Examination Methods For Materials And Fabrication
ASME V, Article 7, Magnetic Particle Examination
ASTM A609, Standard Practice For Castings, Carbon, Low-Alloy And Martensitic Stainless
Steel, Ultrasonic Examination Thereof
ASTM A991, Standard Test Method for Conducting Temperature Uniformity Surveys of
Furnaces Used to Heat treat Steel products
ASTM E112, Standard Test Method for Determining Average Grain Size
ASTM E45, Standard Test Methods for Determining the Inclusion Content of Steel
ASTM E125 – 80, Standard Reference Photographs For Magnetic Particle Indications On Ferrous
Castings
ASTM E446, Reference Radiographs For Steel Castings Up To 51 mm In Thickness
ASTM E186, Reference Radiographs For Heavy-Walled (51 to 112 mm) Steel Castings 3
ASTM E280, Reference Radiographs For Heavy-Walled (112 to 305 mm) Steel Castings 2 -
EN 287-1, Qualification test of welders – Fusion welding – Part 1: Steels 6
EN 473/Nordtest/ASNT, Qualification of NDT operators 0 -
EN 10204, Metallic products – Types of inspection documents 4
1
EN 10225, Weldable structural steels for fixed offshore structures – Technical delivery 0
conditions 2
ISO148, Steel – Charpy impact test (V-notch) ils
ISO 6892, Metallic material – Tensile testing at ambient temperature u
ISO 8062, Castings – System of dimensional tolerances and machining allowances o
b
ISO 9001, Quality management systems – Requirements ta
ISO 10423, Petroleum and natural gas industries – Drilling and production equipment – S
Wellhead and Christmas tree equipment +
s
ito
ISO 15607, Specification and qualification of welding procedures for metallic materials –
General rules
a
ISO 15609-1, Specification and qualification of welding procedures for metallic materials – n
Welding procedure specification – Part 1: Arc welding Ig
ISO 15614-1, Specification and qualification of welding procedures for metallic materials – r
Welding procedure test – Part 1: Arc and gas welding of steels and arc welding fo
of nickel and nickel alloys S
ISO/IEC 17025, General requirements for the competence of testing and calibration laboratories A
MSS-SP 55, Visual Inspection Guide For Steel Castings e
NORSOK M-101, Structural steel fabrication iln
Recommandation n
Technique No. 359-01 du O
Bureau de Normalisation dr
des Industries de la a
d
Fonderie (BNIF), n
ta
S
2.2 Informative references y
b
None d
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NORSOK standard M-122 Edition 2, October 2012

3 Terms, definitions and abbreviations

For the purposes of this NORSOK standard, the following terms, definitions and abbreviations apply.

3.1 Terms and definitions

3.1.1
can
verbal form used for statements of possibility and capability, whether material, physical or casual

3.1.2
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
1
0
CTOD crack tip opening displacement 2
EN European Standard ils
FATT fracture appearance transition temperatures u
HAZ heat affected zone o
b
ta
IEC International Electrotechnical Commisssion
IIW International Institute of Welding S
ISO International Organization for Standardization +
MT magnetic particle testing s
ito
NDT non-destructive testing
a
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
a
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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4.2 Basis for qualification of steel foundries

The basis for qualification is as follows:

 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.

4.3 General requirements

The manufacturer shall have knowledge and experience within relevant metallurgical aspects of the
applicable steel grades including welding, heat treatment parameters, etc. as applicable for his
manufacturing process.

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
2 -
6
Foundries shall have heat treatment facilities on their own premises or such facilities shall be located in their 0 -
close vicinity. 4
1
If parts of the production are carried out at a sub-supplier, the manufacturer is responsible for ensuring that
0
2
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the sub-supplier meets the requirements of this standard for the manufacturing steps that he is performing.
u
4.4 Manufacturing o
b
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 +
s
included. The production route shall be illustrated with a flow chart. The scope of the manufacturing
ito
summary shall be clearly defined:
a
n
 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
A
The manufacturing summary shall include procedures for e
iln
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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
a
 loading temperature, heating rate, holding temperature (range) and time, d
n
ta
 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
e
 sketch of heat treatment facilities/furnace which also shall show location of pyrometers and/or d
i
thermocouples in the furnace(s) and on the component(s). v
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NORSOK standard M-122 Edition 2, October 2012

 blasting/cleaning equipment, incl. type of grit,

 repair welding,
 PWHT (if applicable),
 NDT and inspection,
 material testing. Type of tests and test sampling,
 design and position of test coupons.

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 Qualification based upon a test program

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.

4.5.2 Qualification of the manufacturing process

The manufacturing process as described in the manufacturing summary shall be qualified by testing of 3
actual products or of test blocks, if accepted by the purchaser, to 2 -
6
 demonstrate that the proposed manufacturing route and production parameters results in products 0 -
meeting specified requirements, 4
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 verify that the proposed production test sampling gives results which are representative of the properties 0
in the actual components which they represent. 2
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4.5.3 Validity of qualification u
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4.5.3.1 General ta
S
The qualification shall be repeated if there are changes in the production route, the manufacturing +
procedures or the specified composition or properties of the products which exceeds the limits given below. s
ito
4.5.3.2 Plant and location a
n
If production is carried out at different plants/locations, a separate qualification is required for each plant. Ig
This applies also for change of subcontractors for essential operations as e.g. heat treatment, etc. r
fo
4.5.3.3 Thickness limitations S
The maximum thickness qualified is the thickness of the tested product or test block plus 25 %.
A
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4.5.3.4 Material grade n
A change from one steel grade to a higher grade requires requalification. O
dr
4.5.3.5 Type of melting and refining equipment a
d
A change of the melting/refining process requires a requalification. n
ta
4.5.3.6 Manufacturing equipment S
A major change of manufacturing equipment requires requalification, unless the new equipment can be y
b
regarded as comparable to the old one with respect to its influence on the product properties. This applies d
also if the manufacturer has several alternative manufacturing routes for a product. e
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4.5.3.7 Heat treatment

A change of heat treatment method, (e.g. a change from normalising to quenching and tempering) will
require requalification. This also includes change in PWHT operations, when applicable.

4.5.4 Selection of material for testing

Selection of components or test blocks for testing and positioning of test samples shall be agreed between
purchaser and the manufacturer.

4.5.5 Extent of testing

Testing for qualification shall comprise

 production testing with test sampling as specified in this NORSOK standard,

 additional testing for qualification as required by this NORSOK standard,
 non-destructive testing as specified in this NORSOK standard.

4.5.6 Base material

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.

4.5.6.2 Chemical composition and mechanical properties

The chemical composition and mechanical properties shall be as per clause 5. 3
2 -
6
4.5.6.3 Charpy V-notch impact test transition curves 0 -
Charpy V-notch impact test transition curves (÷ 80 °C, ÷ 60 °C, ÷ 40 °C and ÷ 20 °C) shall be made for both 4
the thinnest and thickest material section. The position and number of the test specimens shall be as 1
0
specified in 5.4.3. Both the energy absorption (J) and the FATT, defined as 50 % crystallinity, shall be 2
reported. ils
u
4.5.6.4 Micrographic examinations o
b
The base material microstructure shall be documented by micrographs at magnification 500 X from ta
subsurface, 1/4 thickness and 1/2 thickness position. The type of structure, grain size and inclusion level S
shall be reported. Examination shall be carried out according to ASTM E112 and ASTM E45. +
s
ito
4.5.7 Weldability a
Weldability data are required for castings with a weld bevel thickness above 25 mm. The thickness to be n
used for the weldability test shall be agreed, but shall not to less than 10 % below the weld bevel thickness Ig
r
to be delivered The documentation of the weldability shall be in accordance with EN 10225, Annex E.
fo
The heat input shall be 3,5 ± 0,2 kJ/mm (EN 10225, Table E.3). S
A
e
For weld bevel thicknesses above 50 mm the testing shall be carried out both in the as welded and PWHT iln
condition. n
O
CTOD testing is required for weld bevel thickness above 50 mm and shall meet a requirement of minimum d
0,25 mm (as-welded) and 0,20 mm (PWHT), at ÷ 10 °C unless a lower value has been accepted by the r
a
purchaser. CTOD testing is limited to only grain-coarsened HAZ. d
n
4.5.8 Qualification test record ta
S
The manufacturer shall present a qualification test record containing results of all required tests as well as y
details about test sampling and test procedures. b
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5 Requirement to cast structural steel

5.1 Steel making process

The steel shall be made by basic oxygen or electric arc furnace process and shall be fully killed and fine
grain treated. A further treatment by ladle desulphurization and secondary refining using AOD/ VODC/ VAD
or equal, shall be performed to secure a base material with very close controlled chemistry and low levels of
elements like phosphorous, sulphur, oxygen and hydrogen.

5.2 Heat treatment

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.

5.2.2 Heat treatment procedures

All heat treatments shall be carried out according to an accepted procedure containing at least the following
information:

 description of furnaces and quenching facilities;

 location and support of the castings in the furnace;
 locations and number of thermocouples;
 all temperature cycles.

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
2 -
6
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
0
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
u
The heat treatment furnaces shall be calibrated according to ASTM A991 or ISO 10423, Annex M. o
b
5.2.3 Post weld heat treatment (PWHT) ta
S
PWHT shall be carried out after any repair welding. All PWHT shall be carried out in a closed furnace. The +
s
soaking temperature shall be as qualified during the repair welding procedure. The soaking time shall be
ito
minimum 2 min/mm of the thickest wall at the actual weld repair location.
a
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5.3 Chemical composition Ig
r
fo
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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Table 1 – Chemical composition

Steel Grade 310 420 460

C 0,14 0,14 0,14
Si 0,60 0,60 0,50
Mn 1,60 1,60 1,60
S 0,008 0,008 0,005
P 0,012 0,012 0,012
Cr 0,20 0,25 1,3
Ni 1,10 1,10 2,7
Mo 0,08 0,30 0,55
Al 0,05 0,05 0,05
N 0,010 0,010 0,010
Cu 0,25 0,25 0,25
b)
Nb 0,03 0,03 0,03
b)
V 0,05 0,05 0,05
Ti 0,04 0,04 0,04
Sb 0,01 0,01 0,01
Sn 0,015 0,015 0,015
Pb 0,005 0,005 0,005
As 0,02 0,02 0,02
Bi 0.005 0,005 0,005
B 0,0010 0,0010 0,0010
a)
Pcm 0,24 0,26 0,28
a)
CE 0,41 0,48 0,55
3
2 -
All values are maximum values unless a range is given, all in weight percent.
6
0 -
a) 4
Si Mn  Cu  Cr Ni Mo V 1
Pcm  C       5B 0
30 20 60 15 10 2
ils
Mn Cr  Mo  V Ni  Cu u
CE  C    o
b
6 5 15
ta
b) S
Nb  V  0,05% +
s
ito
5.4 Mechanical testing a
n
Ig
5.4.1 General r
All mechanical testing shall be carried out in the final delivery condition (including PWHT). fo
S
The test blocks shall not be removed from the castings until all quality heat treatments have been carried A
out. It is acceptable that the test blocks are given a simulated PWHT. e
iln
All mechanical testing for certification shall be performed by a laboratory that complies with ISO/IEC 17025 n
or an accredited laboratory O
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5.4.2 Frequency of testing

Product testing shall be carried out for each cast item. Other frequencies of mechanical testing might be
agreed with the purchaser in case of large series of castings or weight less than 1 ton.

The number of test blocks shall be:

A. Integral test block(s):

Weight of castings “G” (tonnes) Number of test block(s)

G<2* 1
2  G < 10 2
10  G < 20 3
G  20 minimum 4
*Minimum 1 off integral test block for each casting.

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.

B. Separate cast test block(s): 3

2 -
6
Two separately cast test blocks shall be cast per heat/heat treatment batch with equivalent thickness to the 0 -
maximum casting section in the heat treatment batch (up to a limit of 500 mm). 4
1
5.4.3 Position of test specimens 0
2
1 tensile test and 3 Charpy V-notch tests shall be carried out from each of the three following positions of the ils
test blocks: u
o
b
ta
Thin section:  50 mm - Mid thickness (T/2)
Thick section: > 50 mm - Sub surface (2 mm below surface) and T/3 S
+
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5.4.4 Test methods
The tensile testing shall be carried out according to ISO 6892. a
n
The Charpy V-notch testing shall be carried out according to ISO 148. The longitudinal axis of the specimen Ig
shall be parallel to the cast surface with the notch perpendicular to the same. r
fo
5.4.5 Mechanical properties S
A
Requirements for mechanical properties are given in Table 2. e
iln
Table 2 – Mechanical properties n
O
Steel Yield Tensile Elongation Reduction Impact test KV Ratio dr
grade strength strength A5 min of area KV min test Re/Rm a
Re min* Rm min % Z min J temp. maximum d
o n
MPa MPa % average/single C
ta
310 310 450 20 50 36/27 ÷40 0,85 S
420 420 540 20 40 42/35 ÷40 0,90 y
460 460 560 18 40 42/35 ÷40 0,90 b
d
For section thicknesses above 100 mm, lower values for Re and Rm may be agreed. e
* Re = ReH or Rp 0,2 d
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5.5 Retesting and criteria for rejection

If one or more of the results fails to meet the requirements, the manufacturer may carry out double set of
additional tests, preferably from the same test coupon and position. All results from retest shall meet the
requirements.

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 Non – destructive testing (NDT)

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.

6.2 Surface requirements

All surfaces shall be free from irregularities which may interfere with the performance of the examinations.

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
2 -
Bureau de Normalisation des Industries de la Fonderie (BNIF)): 6
0 -
 4S1 on surfaces subject to UT with normal probes; 4
 3S2 on surfaces subject to UT with angle probes; 1
0
 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
o
b
When surfaces are machined the roughness shall as a minimum be as follows (see BS 2634-1): ta
S
 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
n
6.3 Qualification of NDT personnel Ig
r
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
e
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
O
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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6.4 Extent of testing

The extent of NDT shall be as per Table 3.

Table 3 - Extent of NDT

Methods Areas and volume to be Extent of ime for examination

examined NDT NOTE 1
%
Visual Surface from inside and outside. 100 F
examinations
Magnetic particle Surface from inside and outside. 100 F
testing Excavated grooves before start
of repair welding. 100
Radiographic Weld end zones. 100
testing Area 3 x thickness of the edge, NOTE 2
or minimum 100 mm
Questionable indications 100
detected by ultrasonic testing
Ultrasonic testing Normal probes. Volumetric 100
testing (from all accessible
inside and outside
Angle probes. Areas where the 100
angles between front and back
surfaces of the casting exceed
15 (non-parallel)
Angle probes. Areas where loss 100 3
2 -
of back wall echo occurs.
6
Angle probes. Indications from 100 0 -
the testing with normal probes. 4
Repaired areas where the 100 F 1
0
defects were detected by 2
radiography or ultrasonic testing. ils
NOTE 1 F means that the NDT shall be carried out in the final repair welded and PWHT u
condition. Otherwise, the NDT may be carried out before the final repair welding o
and PWHT. b
NOTE 2 100 % radiography of weld end zones may be deleted provided ultrasonic testing ta
(UT) is carried out in accordance with NORSOK M-101 and the acceptance S
+
criteria as specified in 9.8/Table 5 Inspection Category A+B. s
ito
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6.5 Test methods n
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6.5.1 Visual inspection fo
Visual inspection shall be in accordance with MSS SP-55 S
A
6.5.2 Magnetic particle testing e
iln
Magnetic particle testing shall be carried out according to ASME Section V, Article 7. An NDT procedure n
shall be prepared. The procedure shall show the acceptance criteria. O
dr
6.5.3 Radiographic testing a
Radiographic testing shall be carried out in accordance with ASME Section V, Article 2. A written procedure d
n
ta
shall be prepared as specified in T-221.1.
S
6.5.4 Ultrasonic testing y
b
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6.5.4.1 Procedures e
Ultrasonic testing shall be carried out in accordance with ASME Section V, Article 5, using normal probes d
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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.

Table 4- Probes for ultrasonic testing

Section Normal probes Angle probes

thickness
< 100 mm 4 MHz, crystal size 2 Mhz to 4 Mhz, 45  to 70 crystal
diameter 10 mm to 24 mm size, approximately 8 mm x 9 mm
> 100 mm 2 Mhz, crystal size 2 Mhz to 4 MHz, 45 to 70 crystal
diameter 10 mm to 24 mm size, approximately 20 mm x 22 mm
NOTE 1 Crystal size shall be selected to give optimum coverage and coupling to test
3
surface. 2 -
NOTE 2 Twin crystal probes shall be used for evaluation of indications close to the
6
surface. 0 -
NOTE 3 All available probes shall be used for assessment of indications. 4
1
0
2
ils
6.5.4.4 Calibration blocks u
The flat bottom holes in the reference blocks in ASTM A609, Figure 1, shall have a diameter equal to 3 mm o
b
ta
for sensitivity setting for normal probes.
S
One additional reference block is required having metal distance equal to 10 mm for assessment of +
indications close to the surface. s
ito
a
6.5.4.5 Ultrasonic attenuation n
The ultrasonic attenuation in the casting shall be checked at different typical locations of the casting. The Ig
difference in attenuation shall be taken into consideration during the testing. r
fo
6.6 Acceptance criteria S
A
e
6.6.1 General iln
Contractor shall review the defined acceptance criteria in 6.6.2, 6.6.3 and 6.6.4 and secure that these meet n
the design requirements for the cast steel materials. Manufacturer shall be informed if more stringent O
acceptance criteria have to be applied. Revised acceptance criteria shall be implemented on drawings, NDT dr
procedures and NDT reports. a
d
n
The castings are divided in Zone 1, 2 and 3 as follows, unless otherwise shown on drawings: ta
S
Zone 1: 0 mm to 30 mm from all finished surfaces and all critical zones independent of thickness y
Zone 2: Depths greater than 30 mm from all finished surfaces. b
Zone 3: Weld end zones: Full thickness of end (preparation) for a distance of 3T or minimum 100 mm d
e
from the (preparation) end. d
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6.6.2 Visual examination

All surfaces shall show evidence of good workmanship and satisfy the following:

 surface requirements as per 6.2;

 visual appearance shall also satisfy 6.6.5;
 MSS-SP-055.

6.6.3 Radiographic testing

Acceptance criteria related to type of discontinuity and zones are given in Table 5

Table 5 – Acceptance criteria for radiographic testing

Zone Type of Acceptance standard

discontinuity
1 Cracks Not acceptable
Gas porosity ASTM E186, ASTM E280, ASTM E446, level A2
Inclusions ASTM E186, ASTM E280, ASTM E446, level B2
Shrinkage ASTM E186, ASTM E280, ASTM E446, level C2
2 Cracks Not acceptable
Gas porosity ASTM E186, ASTM E280, ASTM E446, level A4
Inclusions ASTM E186, ASTM E280, ASTM E446, level B4
Shrinkage ASTM E186, ASTM E280, ASTM E446, level C4
3 Cracks Not acceptable
Gas porosity Shall meet the requirements of NORSOK M 101:
Inclusions Inspection category A + B Section 9.8, Table 6. 3
Shrinkage Shrinkage: ASTM E186, ASTM E280, ASTM E446, 2 -
level C1 6
0 -
4
1
6.6.4 Ultrasonic testing 0
2
Acceptance criteria for ultrasonic testing are given below:
ils
Zone 1 ASTM A609, Table 2 - Level 1 Linear indications are not acceptable. u
o
b
Zone 2 ASTM A609, Table 2 - Level 3 Linear indications are not acceptable. ta
S
+
Zone 3 Indications shall meet the requirements of NORSOK M 101 - Inspection category A + B Table 7. s
ito
6.6.5 Magnetic particle testing a
n
Acceptance criteria for magnetic particle testing are given in Table 6
Ig
r
Table 6 – Acceptance criteria for fo
magnetic particle testing S
A
Type of indications Acceptance standard e
linear not acceptable iln
shrinkage ASTM E125, level 2 n
inclusions ASTM E125, level 3 O
chills and chaplets ASTM E125, level 1 dr
porosity ASTM E125, level 1 a
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7 Repair

7.1 Repair by grinding

Repair by arc gouging and grinding may be carried out to a depth of maximum 10 % of the wall thickness (at
the location of the defect) or maximum 15 mm, whichever is less. It is a provision that the design wall
thickness is maintained. Arc-air gouged areas shall be ground. The ground area shall be 100 % magnetic
particle tested to ensure complete elimination of the defective material. All grinding shall be carried out in a
way that ensures smooth transitions.

7.2 Repair by welding

Defects shall be repaired by welding if they are deeper than 15 mm or 10 % of the wall thickness. All repair
welds shall be recorded.

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 -
6
 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
1
the parent metal; 0
 macro section; 2
 hardness values shall not exceed 350 HV10. ils
u
o
Welders shall be qualified according to EN 287-1. b
ta
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 +
s
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
Ig
The foundry shall maintain records of repair welding, subsequent heat treatment and inspections traceable r
to each casting repaired. fo
S
A
8 Tolerances for dimensions and weight e
iln
Dimensions and required tolerances shall be as given on the relevant drawing of the casting or other
n
information supplied. If nothing is specified, ISO 8062, Grade CT, 13 shall apply.
O
dr
The weight tolerances shall be within agreement with the purchaser.
a
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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
b
grinding to a minimum radius of 2 mm to assure full film thickness on all edges. d
e
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:

 purchaser’s name and order number;

 delivery condition;
 heat number/casting number;
 description of product, dimension and weight;
 yield strength, tensile strength, elongation and reduction of area;
 Charpy V-notch values and test temperature;
 chemical composition, carbon equivalent/Pcm;
 visual inspection and NDT, or reference to separate reports;
 weld repairs, or reference to separate reports.

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