NORSOK STANDARD COMMON REQUIREMENT

STRUCTURAL STEEL FABRICATION

M-CR-101 Rev. 2, January 1996

Please note that whilst every effort has been made to ensure the accuracy of the NORSOK standards neither OLF nor TBL or any of their members will assume liability for any use thereof.

1 FOREWORD
NORSOK (The competitive standing of the Norwegian offshore sector) is the industry initiative to add value, reduce cost and lead time and remove unnecessary activities in offshore field developments and operations. The NORSOK standards are developed by the Norwegian petroleum industry as a part of the NORSOK initiative and are jointly issued by OLF (The Norwegian Oil Industry Association) and TBL (The Federation of Norwegian Engineering Industries). NORSOK standards are administered by NTS (Norwegian Technology Standards Institution). The purpose of this industry standard is to replace the individual oil company specifications for use in existing and future petroleum industry developments, subject to the individual company's review and application. The NORSOK standards make extensive references to international standards. Where relevant, the contents of this standard will be used to provide input to the international standardization process. Subject to implementation into international standards, this NORSOK standard will be withdrawn. Annex A is informative. Annexes B, C and D are normative.

2 SCOPE
This standard covers the requirements for fabrication and inspection of offshore steel structures with SMYS < 500MPa and with a minimum design temperature down to -10C. Note: For highly fatigue utilized structures, more severe requirements may apply, and these shall be shown on the design drawings.

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3 NORMATIVE REFERENCES
API 2B API RP 2X ASME, Section V BS 7448 Part 1, BSI PD6493 DnV DnV RP D404 EN 287 EN 288 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. Unstable fracture.

Approval testing of welders - Fusion welding. Specification and qualification of welding procedures for metallic materials. EN 444 NDT - General principles for radiographic examination of metallic materials by X-rays and gamma rays. EN 462 NDT - Image quality of radiographs. EN 473 Qualification and certification of NDT personnel - General principles. EN 719 Welding coordination - Tasks and responsibilities. EN 729 Quality requirements for welding - Fusion welding of metallic materials. EN 875 Welding - Welded joints in metallic materials - Specimen location and notch orientation for impact tests. prEN 970 Welding - Visual examination of fusion welded joints. prEN 1011 Recommendation for arc welding of ferritic steels. prEN 1290 NDE of welds - Magnetic particle testing of welds - Method. prEN 1291 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 arc 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. NS 477 Welding. Rules for approval of welding inspectors. M-DP-001 Material selection. M-CR-120 Material data sheets for structural steel.

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N-CR-001

tructural design.

4 DEFINITIONS AND ABBREVIATIONS 4.1 Definitions

Normative references Informative references Shall Should May Can Pcm Shall mean normative in the application of NORSOK standards. Shall mean informative in the application of NORSOK standards. Shall is an absolute requirement which shall be followed strictly in order to conform with the standard. Should is a recommendation. Alternative solutions having the same functionality and quality are acceptable. May indicates a course of action that is permissible within the limits of the standard (a permission). Can-requirements are conditional and indicates a possibility open to the user of the standard. Carbon equivalent equation

4.2 Abbreviations
AWS CE CTOD DAC DC DIN DnV EN FSH HDM IIW NDT MDS PWHT SMYS WPS WPAR American Welding Society Carbon Equivalent Crack Tip Opening Displacement Distance Amplitude Curve Design Class Deutsche Industrie Normen Det norske Veritas Euronorm Full Screen Height 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
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5.1 Design classes

The design classes will be decided by the designer and shall form the basis for selection of steel quality level (SQL). Reference is made to NORSOK standard N-CR-001.Selection of steel quality level The steel quality level will be decided by the designer in compliance with N-CR-001. Table 5.1 below is shown for information only. Annex B gives the correlation between the steel quality levels I, II, III and IV, and designations on equivalent steels given in NORSOK standard M-CR-120, Material data sheets. Selection of a better steel quality level in fabrication than the minimum required by the designer shall not lead to more stringent requirements in fabrication. Table 5.1: Correlation between design classes and steel quality level (informative)
Design class

Steel quality level I II X (X) X X X III IV X

1 2 3 4 5

(X) = Selection when there is tensile stress in the direction of thickness.

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 structures requiring steel quality level I and II, 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.

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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: a) Control of heat input according to EN 288 part 3, section 8.4.7, shall apply. If an approval testing have been performed at both a high and a low heat input level (with all specified mechanical testing), then all intermediate heat inputs are also qualified. b) When the steel to be welded has a Pcm >= 0.21%, or a carbon content C >= 0.13%, then an increase of more than 0.02 Pcm units or 0.03% carbon equivalent (IIW formula) over the value on the approval test shall require a new qualification test. c) A change from wrought (rolled, forged) steel to cast steel or converse shall require a new qualification test. d) A change in delivery condition (normalised, thermomechanically controlled processed or quenched and tempered) shall require a new qualification test. e) A change in steel supplier, microalloying element or manufacturing technique for steel with minimum specified yield strength >= 400Mpa. f) A change in groove angle more than +20deg./-10deg. g) A qualification of fillet welds carried out on plate thickness equal to or greater than 30mm, applies for all plate and throat thicknesses. Single layer fillet welds qualifies multi-layer, but not the converse. Note: The changes specified in d) and e) need not require re-qualification if HAZ properties for the material to be welded have been documented from the steel supplier for relevant thicknesses and heat input ranges. If sufficient documentation from the steel supplier is not available, a change of material shall require re-qualification of a reduced number of procedures. The number of procedures to be re-qualified shall be sufficient to verify that the HAZ properties of the new material is comparable with that used for the previous qualifications.

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.

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Table 6.1 Type and number of tests Joint configuration Buttwelds (Tubulars and plates) T-joints (plates) 5) Tubular joints 5) Fillet welds Notes: 1. Bend tests shall consist of 1 face and 1 root bend specimen for t < 20mm and 2 side bend specimens for t >= 20mm 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. 6. For welds on submerged structures with cathodic protection, the hardness limits in NORSOK M-DP-001 (i.e. max 350 HV10) shall apply in addition to the requirements of EN 288. Joint thickness (mm) t < 50 t => 50 t < 50 t => 50 t < 50 t => 50 All 2 2 4) 4) 4) 4) Mechanical testing Tensile test Bend tests 1) 2 2 Charpy V- Hardness and notch tests 2) macro 6) 4 sets 6 sets 4 sets 3) 6 sets 4 sets 3) 6 sets 1 1 2 2 2 2 2 CTOD Ref. 6.4.4

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.) (Designation in parenthesis refers to prEN 875).

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

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For welds with a joint thickness of 50mm 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: For single sided welds, the face of the Charpy specimen shall be 2mm 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. Steel quality level Material thickness mm t 12 12 < t 25 25 < t 50 t > 50 Energy Requirement Note: 1. The minimum average value is given in the table. No individual value shall be less than 70% of the minimum average value.
1)

I SMYS <= 400 MPa 0C -20C -40C -40C 36J SMYS > 400 MPa -20C -40C -40C -40C 42J SMYS <= 400 MPa 0C 0C -20C -40C 27J

II SMYS > 400 MPa -20C -20C -40C -40C 42J

6.4.3 Transverse tensile testing Testing shall be carried out in accordance with EN 288. The fracture shall be located outside the weld metal (i.e. max. 20% of the fracture surface shall consist of weld metal). 6.4.4 CTOD testing CTOD testing shall be included in qualification of welding procedures for joints requiring steel quality level I and II, with a thickness above 50mm for steels with SMYS < 460MPa, and with a thickness above 30mm for steels with SMYS > 460MPa.

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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 combination of steel grade, each welding process and each welding consumable (brand) used, except welding consumables 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 previously. Test temperature shall be:

-10C for splash zone and above. 0C for submerged parts.

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 10.8.6.

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.

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For welding of joints where steel quality level IV is required, 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 prEN 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 250C) shall be carried out within the deformation range recommended by the steel manufacturer. 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:

The material shall be permanently strained locally to the actual deformation. The material shall be artificially aged at 250C for 1 hour. One set of 3 impact test specimens shall be tested from the base material in the strained plus artificially aged condition. The notch shall be located within the plastically strained portion of the material, in the part of the cross section which have received the highest strain. The impact testing temperature shall be as specified for the actual steel grade in question. The Charpy-V impact value shall comply with the minimum requirements for the steel grade and shall not be more than 25% lower than the impact value for the material before deformation and strain ageing.

If forming is performed at temperature above 250C, 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:

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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:

Sequence of operation. Equipment to be used. Cold rolling method. Methods for avoiding "flats" along the longitudinal seam. Method for avoiding local thinning, steps or wavy edges. Welding procedure. Visual inspection and NDT. Mechanical testing. Splices. Dimensional inspection and acceptance criteria, both at tubular ends and intermediate sections.

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.

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W1 = 150mm or min. 2 times chord thickness W2 = 300mm or min. D/4 W3 = 600mm or min. D Fig. 7.1 Prohibited location of welds in tubular joints. Longitudinal or circumferential welds shall not be located in shaded area. 7.4.2 Splices Splices shall not be located in restricted areas, as 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.

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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 3mm. Where steel items shall be hot dip galvanised, hollow sections shall be ventilated. 7.4.6 Temporary cut-outs Temporary cut-outs shall not be located in restricted areas as shown on design drawings. Temporary cut outs shall have a corner radius not less than 100mm. 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.

7.5 Preparation for coatings

Edges of plates and structural shapes which are intended to be coated shall be rounded to approximately 2mm 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.

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7.8 Welding consumables

The manufacturers shall ensure that welding consumables applied for joints where steel quality level I or II are required, meet the requirements for mechanical properties as specified for the welding procedure qualification, in both as welded and (where applicable) PWHT condition. This may be achieved through (alternatively):

Batch testing including chemical analysis and mechanical properties, see annex D. An established and reliable system of batch certification against accepted supplier data sheets, see annex C.

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, provided preheating temperature and post weld holding temperature and time is assessed to avoid hydrogen cracking. Hydrogen testing shall be according to ISO 3690 or equivalent. Consumables for joints in steel quality level III and IV 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 homogenity. Such consumables shall be delivered with EN 10 204 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 10 204 type 2.2), declaring conformity with the approved product type.

7.9 Preheat and interpass temperature

Preheating above 50C should be achieved by electric heating elements. Cutting torches are not allowed for preheating. The minimum interpass temperature shall not drop below the minimum required preheat temperature. If not otherwise stated in the WPS, and qualified by the WPAR, 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 250C may be used, even if a lower temperature was recorded on the WPAR. The preheat temperatures used during repair welding should be minimum 50C higher than the preheat used for the original weld.

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7.10 Production welding

7.10.1 General Welding shall be carried out in accordance with the WPS and applicable drawings. Butt welds in joints where steel quality level I or II are required shall, whenever possible, be welded from both sides. If any welding is conducted after PWHT, the PWHT shall be repeated. For joints in inspection category A, the "straight" edges of K- and 1 /2 V-butt weld grooves shall have a groove angle of at least 10O , unless it is documented that possible defects can be detected by the UT technique used . (For K-grooves, the 10O should be machined from the root to each plate surface.) 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 3mm 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 where steel quality level I or II are required, when the nominal thickness (as defined in EN 288-3, section 8.3.2.1) exceeds 50mm, 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 steel quality level. PWHT shall be carried out in accordance with a procedure specification which shall include:

Heating rate. Cooling rate. Soaking temperature and time. Heating facilities. Insulation. Control devices. Recording equipment. Configuration of structure to be PWHT or details if local PWHT shall be carried out. Number and location of thermocouples to be used during PWHT.

The holding temperature shall be as recommended by the steel manufacturer. The holding time shall be at least 2.5 min per mm thickness (of the thickest member).

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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.

7.12 Grinding
When 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. Typical examples for requirements for grinding of joints are given in annex A.

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 where steel quality level I or II are required, 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 shall be decided by the designer in accordance with NORSOK N-CR-001 ,and shall be specified on the design drawings. Final inspection and NDT of structural steel welds shall not be carried out before 48 hours after completion except where PWHT is required. The time delay may be reduced to 24 hours for steel grades with SMYS of 355MPa or lower, and for steel grades with SMYS of 420MPa or lower for plate thicknesses below 40 mm, provided delayed cracking have not been observed for the materials and welding consumables in question. When PWHT is performed, the final NDT shall be carried out when all heat treatment have been completed.

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Prior to fabrication start-up, contractor shall implement a system for recording of weld defect rates. If this system shall be used as basis for a reduction of NDT extent according to table 10.1, the system must ensure that a correct rate identification is prepared for each weld method, each NDT method and each production area. The defect rate is defined as:

Note 1: "Tested part of welds" means the part that is tested with the same NDT method. NDT after repair shall not be included when calculating the defect rate.

10.2 Qualification of inspectors and NDT-operators

The NDT operators shall be qualified according to EN 473 level 2. Level 2 operators may when relevant be assisted by level 1 operators. Ultrasonic operators used in testing of tubular joints shall satisfy the requirements in API RP 2X, para 2.3. (NOTE: UT operators with EN 473 Level 2 qualifications who are testing tubular joints according to the requirements of API RP 2X, requires no further qualification tests, but shall be conversent with the content of the API RP 2X standard.) Personnel qualified according to EN 473 Level 3 shall be responsible for all NDT activities. Personnel responsible for visual inspection shall be qualified in accordance with NS 477 or an equivalent scheme.

10.3 Extent of visual examination and NDT

The required minimum extent of examination is given in table 10.1. Ultrasonic testing to reveal the presence of possible weld metal transverse cracking shall be included for butt welds with thickness more than 25 mm. The examination shall be performed on minimum 5% of welds in inspection category A and B for SAW and FCAW.

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Table 10.1 Minimum extent (in %) of non-destructive examination for structural welds.

Inspection category

Type of connection Buttw. T-conn. Fillet/partial Buttw. T-conn. Fillet/partial Buttw. T-conn. Fillet/partial All conn. All conn.

Visual examination 100 100 100 100 100 100 100 100 100 100 100

Extent of testing RT 10 Spot UT 100 100 50 1) 50 1) 20 1) 20 1) MT 100 100 100 100 1) 100 1) 100 1) 20 1) 20 1) 20 1) spot -

C D E

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

Note: 1. The extent may be reduced to 50% of the specified extent, based on experience and documented records with similar joints, provided the defect rate (see clause 10.1 and 11.1) for UT/RT is <2.0% and for MT is <0.2% during the last 100m of weld. The last 100m shall be continuosly updated every week. If the defect rate exceeds the limits given above, the normal extent of NDT shall apply again. A possible reduction in the extent of NDT shall be considered separately for each welding method and each production area.

When partial testing is defined for welds in an area, the testing 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. The specified percentage to be tested in table 10.1 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 10.1. This extent shall be maintained for a weld and test length sufficient to conclude that the weld repair percentage is at a reasonable level.

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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 or other significant weld defects are revealed. Corrective actions shall be taken to ensure that all similar defects will be detected. In addition to what is listed in table 10.1, the following shall apply for inspection category A and B: a) One film at each end for longitudinal welds of tubulars (including tubulars for nodes and stubs). b) Where radiographic testing is required, intersection welds, and those locations where presence of defects is deemed to be most harmful, shall be tested. c) Ultrasonic and radiographic testing shall not overlap, except when 100% UT is specified. However, ambiguous imperfections revealed by UT shall in addition be tested by RT. d) Ultrasonic testing is normally not applicable for thicknesses less than 10mm. For such thicknesses, UT may be replaced with RT. In general, RT should be considered if UT is not possible. Radiographic testing is normally not applicable for thicknesses above 40mm. e) MT shall be performed on both external and internal surface as accessible.

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; or EN 444. Suspect planar indications discovered by RT shall be type determined, located and sized by UT. 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 in plate and tubular butt welds shall be performed in accordance with ASME V Article 5, T-542.7. Ultrasonic testing of tubular joints (nodes) shall be performed in accordance with API RP 2X. DAC reference curves shall be produced from reference block of thicknesses, and containing sidedrilled holes with diameters, in accordance with table 10.2. DAC curves shall be produced in accordance with ASME V Article 4, Appendix B-20 and C-20.

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The effective test range of a DAC curve shall be determined by the point at which the curve has fallen to 25% FSH, when it will be necessary to raise the curve using reflectors at increased depth. The reference block shall be from a steel type that is representative for the steel to be inspected. Where ultrasonic testing is to be performed on steel produced by controlled rolling or thermomechanical treatment, blocks shall be produced both perpendicular to, and parallel to, the direction of rolling. The rolling direction shall be clearly identified. The actual refracted angle for each probe measured from the reference block or as measured on the actual object being examined, shall be used when plotting indications. A transfer correction between the reference block and the test surface shall be performed. Ultrasonic examination procedures shall be sufficiently detailed to ensure 100% of the weld body and heat affected zones are examined for longitudinal defects in accordance with ASME V, Article 5, T-542.7.2.3. All indications exceeding 20% DAC shall be investigated to the extent that they can be evaluated in terms of the acceptance criteria. All indications exceeding 50% DAC and having any dimension exceeding 5mm shall be reported, unless more stringent requirements are given in table 10.5. The examination record shall include the position, the echo height, length, depth and type of indication.

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 General All welds shall comply with the requirements given below, in 10.8.2 - 10.8.5. 10.8.2 Visual examination All welds shall show evidence of good workmanship. The quality shall comply with the requirements of table 10.3. 10.8.3 Radiographs The soundness of the welded joint shall comply with the requirements of table 10. 4.

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10.8.4 Ultrasonic testing acceptance criteria The acceptance criteria for welds shall comply with table 10.5, except that the acceptance criteria for tubular joints shall comply with API RP 2X level C, unless more stringent requirements are specified by the designer. Table 10.2 Calibration reference block requirements Thickness of material to be examined (mm) 10 < t < 50 50 < t < 100 100 < t < 150 150 < t < 200 200 < t < 250 t > 250 Thickness of block 40 or t 75 or t 125 or t 175 or t 225 or t 275 or t 6mm +/0.2mm Diameter of hole 3mm +/0.2mm t/2 and t/4. Additional holes areallowed and recommended Distance of hole from one surface

Table 10.3 Visual acceptance criteria for structural steel welds Welding Type of defect Cracks Lack of penetration or lack of fusion Acceptance criteria Insp. cat. A, B Not acceptable Not acceptable Max depth 0.5mm Continuous undercut is not permitted Inspection category C, D, E Not acceptable Single - side weld: Length < t/2, max 10mm Defects shall be regarded as a continuous defect if the distance between them is <t. Maximum depth 0.75mm Continuous undercut is not permitted Not acceptable. However,the following defects may be acceptable if it does not conflict with surface treatment requirements: Accumulated pore diameters in any area of 10 x 150mm is not to exceed 15mm. Max. size of a single pore is t/4 or 4mm, whichever is the smaller.

Undercut

Surface porosity Exposed slag

Not acceptable

Concave root Excessive pen. 1)

Max. concavity 0.5 mm if the transition is smoothly formed. Max. 3mm

"U" shall be less than 2.5mm. Weld surface shall be smooth, without Roughness of weld (fig. 1) sharp transitions. The bottom of roughness in butt welds shall not be below the base material surface. M-CR-101, Rev. 2, January 1996 page 20

Misalignment of butt welds (fig. 2) Reinforcement of butt welds (fig. 3) 1)

Max. misalignment (M), 0.15 x t or max. 4mm, whichever is the smaller. "t" less or equal to 10 "t" greater than 10, up to 25 "t" greater than 25, up to 50 "t" greater than 50 "a" less or equal to 10 "a" greater than 10, up to 15 "a" greater than 15, up to 25 "a" greater than 25 "a" less or equal to 6 "a" greater than 6, up to 13 "a" greater than 13 Max reinforcement "C" 2mm Max reinforcement "C" 3mm Max reinforcement "C" 3mm Max reinforcement "C" 5mm Max reinforcement "C" 2mm Max reinforcement "C" 3mm Max reinforcement "C" 4mm Max reinforcement "C" 5mm Max difference, b - h: 3mm Max difference, b - h: 5mm Max difference, b - h: 8mm

Reinforcement of fillet/partial pen. welds (fig.4) 1)

Symmetry of fillet welds (fig. 5) Grinding arc strikes etc. Removal of temporary attachments 2) Sharp edges Notes:

Grinding of base material shall not exceed 7% of the wall thickness or max. 3mm. Repair welding and inspection shall be performed if removal of the base metal exceeds the specified requirements. Minimum 2 mm radius (Ref. 7.5)

1. Localised reinforcements exceeding the above requirements are acceptable. 2. Temporary attachments shall be flame cut min. 3mm from the base metal and ground smooth. The ground area shall be visually inspected and MT shall be performed in accordance with the inspection category in question. 3. When required (ref. 7.12), grinding of the surface shall be specified. Typical examples of grinding requirements are given in annex A.

Figure 1 Roughness of weld

Figure 2 Misaligment of butt weld

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Figure 3 Reinforcement of butt weld

Figure 4a Reinforcement of fillet weld

Figure 4b Reinforcement of partial pen weld Figure 5 Symmetri of fillet weld Table 10.4 Structural steel welds, Radiographic acceptance criteria Type of defect Internal porosity (Note 1) Isolated: Pore diameter Cluster: Pore diameter Piping porosity: Length of projected area Scattered: Accumulated pore diameters in any 10x150mm area of weld Slag inclusions (Note 2) Width max t/4,but max.6mm max.3mm max.25mm max.20mm t/4, max .6mm 2t, max 50mm max t/3, but max.6mm max .4mm max. 30mm max. 25mm t/3, max. 6mm 4t, max. 100mm Inspection category A, B C, D, E

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Length Lack of penetration Length (Note 2) Lack of fusion Length (Note 2) Cracks Notes: 1. If more than one pore is located inside a circle of diameter 3 times the pore diameter, the pores are to be considered as a cluster. 2. Defects in a line where the distance between the defect is shorter than the longest defect shall be regarded as one continuous defect. t, max. 25 mm Not acceptable Not acceptable 2t,max 50 mm 2t, max.50mm Not acceptable

Table 10.5 Ultrasonic acceptance criteria for weld defects Description General Inspection category A+B Inspection category C, D, E Notes 1 2 3 4 1 2 3 4 5

If the type of defect can not be ascertained with certainty the defect shall be repaired when the length exceeds 10mm and the echo height exceeds the reference curve. Unambiguous cracks are unacceptable regardless of size or amplitude. Internal defects : I: The echo height exceeds the reference curve: Max length t, max 25mm Max length 2t, max 50mm

Cracks Lack of fusion or incomplete penetration

II: The echo height is between 50 and 100% of the reference curve: Max length 2t, Max length 4t, max 50mm max 100mm Surface defects are not acceptable except: For root defects in single sided welds , the max length for which the echo height exceeds the reference curve shall be: Max length t, Max length 2t, max 25mm max 50mm

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Slag inclusions

When echo height exceeds the reference curve: Max length 2t, Max length 4t, max 50mm max 100mm Repair is required if porosity may mask for other defects.

1 2 1

Porosity Notes:

1. Type of defect shall be decided by: I: Supplementary non-destructive testing. II: The ultrasonic operator's assessment of the defect, using his knowledge of the welding process, signal geometry, defect position etc. 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. Defect length shall be determined by the 6dB drop method from the end of the defect (for defects larger than the beam) or by the maximum amplitude technique (for defects smaller than the beam). 4. With UT performed from only one side of the weld with only one surface accessible, the acceptable echo heights are reduced from 100% to 50% and from 50% to 20%, respectively. 5. With "internal defects" it is meant defects which are located more than 6mm from the nearest surface. A defect is classified as a "surface defect" if any part of the defect is located less than 6 mm or t/4, whichever is smaller, from the nearest surface.

10.8.5 Magnetic particle testing Linear indications (i.e. indications with a length/width ratio above 3 and length above 1.5mm) are not acceptable. Any linear indications shall be ground and re-examined. Rounded indications shall be evaluated in accordance with the requirements of table 10.3. 10.8.6 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. M-CR-101, Rev. 2, January 1996 page 24

Weld defect: Discontinuity with a size and/or density that exceeds 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. 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 50mm long, measured at defect depth even if the defect itself is smaller. Defects spaced less than 100mm shall be repaired as one continuous defect. After repair welding the complete weld (i.e. the repaired area plus at least 100mm on each side) 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.

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

ANNEX A TYPICAL PERFORMANCE FOR GRINDING OF WELDS (INFORMATIVE)

TYPICAL GRINDING DETAILS FOR HIGH FATIGUE UTILISATION

TYPICAL TUBULAR JOINT GRINDING DETAIL

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TYPICAL BUTT WELD JOINT GRINDING DETAIL

Notes to figures: 1. For removal of undercuts the toe of the weld should be blended in a smooth transition and extended below the plate surface in order to remove the toe defects. 2. Grinding should extend below plate surface to a minimum of 0.5mm below the bottom of any visible undercut and ensuring that no exposed defects remain, using a rotary burr grinder. Grinding marks should run at right angels to weld axis and under no circumstances parallel to it. 3. Minimum radii of weld profiles after blending should not be less than 10 mm. 4. Upon completion of blending of toe the whole of the ground surface should be inspected with 100% visual examination and 100% MP1. 5. Ground surface shall be free of any cracks or cracklike indications, and there shall be no evidence of undercut or overlap.

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ANNEX B CORRELATION BETWEEN STEEL QUALITY LEVEL, MDS NUMBER AND STEEL GRADE/DESIGNATIONS (NORMATIVE)

Steel quality level

NORSOK MDS No.1)

Reference standard

Product type Plates Rolled sections Seamless tubulars Plates Rolled sections Seamless tubulars Plates Rolled sections Seamless tubulars Plates Rolled sections Seamless tubulars Plates Rolled sections Seamless tubulars Plates Rolled sections Seamless tubulars Plates Rolled sections Seamless tubulars Plates Rolled sections Seamless tubulars Plates Rolled sections Seamless tubulars

Steel grade

Y20 Y21 Y22 Y30 Y31 Y32 Y40 Y41 Y42 Y50 Y51 Y52

prEN 10225

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

II

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

prEN 10225

S355NLO3 S355NLO3 S355NLO3 S420QLO2 S420QLO2 S420QLO2 S460QLO2 S460QLO2 S460QLO2 S500QLO2 S500QLO2 S500QLO2

III

Y03

EN 10025 EN 10025 prEN 10225

S355J2G3 S355J2G3 NO1

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Y01 IV Y02

EN 10025

Plates Rolled sections Seamless tubulars Plates Rolled sections Seamless tubulars

S235JRG2

EN 10025

S275JR

NORSOK Material data sheets are in NORSOK standard M-CR-120.

ANNEX C QUALIFICATION OF WELDING CONSUMABLES BY DATA SHEETS (NORMATIVE)

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. The data sheet shall give guaranteed limits and/or minimum values for composition and mechanical properties, determined under defined reference conditions. If the consumable shall be used for welds in PWHT condition, then the properties shall also be documented in PWHT condition in addition to the as-welded condition.

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Specifically this shall include, as applicable:

Chemical analysis limits for solid wires and metal powders. For information also typical weld metal analysis, using a relevant shielding gas or flux. Chemical analysis limits of weld metal from coated electrodes and cored wires, deposited according to EN 26847. For information also specified limits for S, P and N in the core wire or strip.

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.

Mechanical properties (range or/and guaranteed minimum) of the weld, deposited and tested according to prEN 1597 part 1 and including tensile strength, yield strength elongation, notch toughness Charpy-V at -40C. For information also typical properties of a relevant butt weld should be added. Diffusible hydrogen content HDM max., including any information on drying, restricted welding parameters etc. required to ensure this value in practice. When relevant for the product, basic information about CTOD properties, to be supported by separate test reports as required and agreed.

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.

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ANNEX D WELDING CONSUMABLE DOCUMENTED BY BATCH TESTING (NORMATIVE)

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. 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:

All elements specified in the relevant classification standard and /or intentionally added. The main impurities S, P and N.

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:

Tensile strength, yield strength and elongation. Impact strength Charpy-V, at temperatures -40C, or as specified by purchaser.

The need for other types of tests shall be evaluated for the application in question, such as:

Mechanical properties based on a defined butt weld rather than all weld metal test. Mechanical properties in the PWHT condition. CTOD testing. Testing of hydrogen level.

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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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