Norsok Standard M-122: Rev. 1, June 2003
Norsok Standard M-122: Rev. 1, June 2003
Norsok Standard M-122: Rev. 1, June 2003
This NORSOK standard is developed by NTS with broad industry participation. Please note that whilst every effort
has been made to ensure the accuracy of this standard, neither OLF nor TBL or any of their members will assume
liability for any use thereof. NTS is responsible for the administration and publication of this standard.
Norwegian Technology Centre Telephone: + 47 22 59 01 00
Oscarsgt. 20, Postbox 7072 Majorstua Fax: + 47 22 59 01 29
N-0306 Oslo Email: norsok@nts.no
NORWAY Website: www.nts.no/norsok
Copyrights reserved
NORSOK standard M-122 Rev. 1, June 2003
Foreword 2
Introduction 2
1 Scope 3
2 Normative references 3
3 Abbreviations 3
4 Qualification 4
4.1 General 4
4.2 Qualification based upon a test program 5
5 Requirement to cast structural steel 7
5.1 Steel making process 7
5.2 Heat treatment 7
5.3 Chemical composition 7
5.4 Mechanical testing 8
5.5 Retesting and criteria for rejection 9
6 Non – destructive testing 9
6.1 General 9
6.2 Surface requirements 9
6.3 Qualification of NDT personnel 10
6.4 Extent of testing 10
6.5 Test methods 11
6.6 Acceptance criteria 12
7 Repair 13
7.1 Repair by grinding 13
7.2 Repair by welding 13
8 Dimensions/tolerances 14
9 Surface protection 14
10 Marking 14
11 Certificate 15
Foreword
The NORSOK standards are developed by the Norwegian petroleum industry to ensure adequate safety,
value adding and cost effectiveness for existing and future petroleum industry developments.
The NORSOK standards are prepared to complement available international standards and fill the broad
needs of the Norwegian petroleum industry. Where relevant NORSOK standards will be used to provide the
Norwegian industry input to the international standardisation process. Subject to development and
publication of international standards, the relevant NORSOK standard will be withdrawn.
These standards are developed according to the consensus principle generally applicable for most
standards work and according to established procedures defined in NORSOK A-001
The preparation and publication of the NORSOK standards is supported by OLF (The Norwegian Oil
Industry Association) and TBL (Federation of Norwegian Manufacturing Industries). NORSOK standards are
administered and issued by NTS (Norwegian Technology Centre).
Introduction
This standard is based on former company specifications and experience from deliveries and operation.
1 Scope
This 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 references
The following standards include provisions which, through reference in this text, constitute provisions of this
NORSOK standard. Latest issue of the references shall be used unless otherwise agreed. Other recognised
standards may be used provided it can be shown that they meet or exceed the requirements of the
standards referenced below.
3 Abbreviations
AOD Argon Oxygen Decarburisation
CTOD Crack Tip Opening Displacement
FATT Fracture Appearance Transition Temperatures
NDT Non Destructive Testing
PWHT Post Weld Heat Treatment
VODC Vacuum Oxygen Decarburisation Converter
VAD Vacuum Argon Decarburisation
4 Qualification
The purchaser may accept the foundry’s qualification based on general information described in 4.1
combined with a verification or audit at the foundry.
However, depending on the criticality and complexity of the casting and the experience of the foundry, the
purchaser may require the foundry to perform a qualification as described in 4.2.
4.1 General
• 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 fulfil the requirements related to product realization in ISO
9001 or equivalent.
• Results of testing in compliance with this standard.
Prior to qualification a complete report, with information and results of testing as required by this standard
shall be available for review.
Experience should be supported by statistical data or relevant test records for the size range to be qualified.
The steel shall have been produced to manufacturing procedures and with equipment intended used for the
actual manufacturing.
Facilities and equipment shall be fit for purpose, regularly maintained and calibrated as required. The
assessment shall concentrate on facilities and equipment for moulding, melting, refining, welding, heat
treatment, etc.
Foundries shall have heat treatment facilities on their own premises or such facilities shall be located in their
close vicinity.
If parts of the production is carried out at a sub-supplier, the manufacturer is responsible for ensuring that
the sub-supplier meets the requirements of this standard for the manufacturing steps that he is performing.
4.1.3 Manufacturing
The manufacturer shall have a Manufacturing Summary for each production route. The Manufacturing
Summary shall describe, step by step in a logical and correct sequence all important manufacturing activities
with reference to detailed procedures. A short description and the main parameters for each activity shall be
included. The production route shall be illustrated with a flow chart. The scope of the manufacturing
summary shall be clearly defined:
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 is subcontracted, this
shall be identified in the documentation.
Whenever a change is made in the equipment or procedures, the documentation shall be updated
accordingly.
a) Demonstrate that the proposed manufacturing route and production parameters results in products
meeting specified requirements.
b) Verify that the proposed production test sampling gives results which are representative of the properties
in the actual components which they represent.
If production is carried out at different plants/locations, a separate qualification is required for each plant.
This applies also for change of subcontractors for essential operations as e.g. heat treatment, etc.
• The chemical composition and mechanical properties shall be within the guaranteed limits
• The steel making process, casting methods and heat treatment condition shall be equal to that proposed
for the actual delivery
The tested section thickness shall be representative for the thinnest and thickest portion in the casting for the
actual delivery.
Both the energy absorption (J) and the FATT (Fracture Appearance Transition Temperatures), defined as
50% crystallinity, shall be reported.
4.2.6 Weldability
Weldability data are required for castings with a weld bevel thickness above 25 mm. The thickness to be
used for the weldability test shall be agreed, but is not to be more than 10% below the weld bevel thicknes to
be delivered The documentation of the weldability shall be in accordance with EN 10225 (Aug 2001), Annex
E. The heat input shall be 3.5 +/- 0.2 kJ/mm (EN 10225, Table E.3).
For weld bevel thicknesses above 50 mm the testing shall be carried out both in the as welded and PWHT
condition.
CTOD testing is required for weld bevel thickness above 50 mm and shall meet a requirement of minimum
0.25 mm (as-welded) and 0.20 mm (PWHT), at – 10°C unless a lower value has been accepted by the
purchaser. CTOD testing is limited to only grain-coarsened HAZ.
5.2.1 General
All castings shall be delivered in homogenised, normalised and stress relieved condition, or in homogenised,
quenched and tempered condition, also including any post weld heat treatment after repair welding.
The heat treatment variables shall be selected to promote uniform microstructure, correct mechanical
properties for the different section thicknesses and to reduce residual stresses. Heat treatment temperatures
shall be measured and recorded by means of thermocouples attached to the castings.
The temperature in the furnace at the time of loading the castings shall not exceed 200°C. The heating and
cooling rates for temperatures above 300°C shall not exceed 70°C and 50°C per hour respectively except for
quenching. Below 300°C the castings may be cooled in still air.
All values are maximum values unless a range is given, all in weight percent.
a)
Si Mn + Cu + Cr Ni Mo V
Pcm = C + + + + + + 5B
30 20 60 15 10
Mn Cr + Mo + V Ni + Cu
CE = C + + +
6 5 15
b)
Nb + V < 0,05%
5.4.1 General
All mechanical testing for certification shall be performed by an accredited laboratory or a laboratory
accepted by the purchaser
The thickness of the integral test sample shall represent the maximum weld member end thickness and/or
critical thickness to ensure representative microstructure and mechanical properties.
The purchaser shall approve the location (sketch) and size of the integral test sample(s) prior to start of
production. If there are more than one test sample on a casting, the samples shall be located as far away
from each other as possible.
Two separately cast test samples shall be cast per heat/heat treatment batch with equivalent thickness to
the maximum casting section in the heat treatment batch (up to a limit of 500 mm).
The Charpy V-notch testing shall be carried out according to ISO 148 or equivalent. The longitudinal axis of
the specimen shall be parallel to the cast surface with the notch perpendicular to the same.
Steel grade Yield Tensile Elongation Reduction IMpact test KV test Ratio
strength strength A5 min of area KV min temp. oC Re/ Rm
Re min* Rm min % Z min J aver./single max
MPa MPa %
310 310 450 20 50 36/27 -40 0,85
420 420 540 20 40 42/35 -40 0,90
460 460 560 18 40 42/35 -40 0,90
For section thicknesses above 100 mm, lower values for Re and Rm may be agreed
* Re = ReH or Rp 0,2
6.1 General
All NDT shall be carried out in accordance with the established procedures.
The NDT reports shall show examined areas, size and nature of defects and reportable indications.
The surface of the castings shall be examined visually and shall be free of adhering sand, scale, cracks and
hot tears.
Other surface discontinuities shall meet the requirements specified for MT.
Surface roughness shall as a minimum be as follows, ref. Recommendation Technique No. 359-01 du
Bureau de Normalisation des Industries de la Fonderie (BNIF):
- 4S1 on surfaces subject to UT with normal probes
- 3S2 on surfaces subject to UT with angle probes
- 3S2 on transition zones/fillets surfaces subject to MT
- 4S1 on general surfaces subject to MT and Visual inspection.
- 3S1 on surfaces subject to RT only
When surfaces are machined the roughness shall as a minimum be as follows, ref. ISO 2632/III:
- N 10 (Ra ≤ 12 µm) on surfaces subject UT with normal probes
- N 9 (Ra ≤ 6 µm) on surfaces subject UT with angel probes
- N 10 (Ra ≤ 12 µm) on general surfaces subject to MT and Visual inspection
Personnel qualified to level III, shall be responsible for all NDT activities.
ASNT-TC-1A level III personnel shall hold valid ASNT-TC-1A level III Certificate (i.e. Management appointed
level III is not accepted).
Contractor shall keep an updated list of all NDT personnel engaged in the work, with reference to possessed
certificates and expiry dates. This list shall be made available to Purchaser on request.
- shooting sketches as specified in SE – 1030, Appendix XI, Radiographic Standard Shooting Sketch
(RSS)
- location for IQI
- acceptance criteria.
6.5.3.1 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
6.5.3.2 Probes
The probes for ultrasonic testing shall be selected in accordance with Table 4.
Notes:
- Crystal size shall be selected to give optimum coverage and coupling to test surface.
- Twin crystal probes shall be used for evaluation of indications close to the surface.
- All available probes shall be used for assessment of indications.
One additional reference block is required having metal distance equal to 10 mm for assessment of
indications close to the surface.
6.6.1 General
Contractor shall review the defined acceptance criteria in clause 6.6.2, 6.6.3 and 6.6.4 and secure that these
meet the design requirements for the cast steel materials. Purchaser shall be informed if more stringent
acceptance criteria have to be applied. Revised acceptance criteria shall be implemented on drawings, NDT
procedures and NDT reports.
The castings are devided in Zone 1, 2 and 3 as follows, unnless otherwise shown on drawings:
Zone 1: 0-30 mm from all finished surfaces and all critical zones independent of thickness
Zone 2: Depths greater than 30 mm from all finished surfaces.
Zone 3: Weld end zones: Full thickness of end (preparation) for a distance of 3T or minimum 100 mm
from the (preparation) end.
Zone 1 ASTM A 609 Table 2 - Level 1 Linear indications are not acceptable.
Zone 2 ASTM A 609 Table 2 - Level 3 Linear indications are not acceptable.
Zone 3 Indications shall meet the requirements of NORSOK M 101 - Inspection category A + B Table
9.5.
7 Repair
The maximum extent of repair welding shall not exceed 20% of the total surface area unless otherwise
agreed with the purchaser.
The excavations shall be suitably shaped to allow good access for welding. The groove shall be ground
smooth and be free from dirt, grease, oil, etc.
Welding consumable of low hydrogen content (max. 5 ml/HDM 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 qualified according to NS-EN 288, ASME IX or equivalent with the
following additional requirements:
• Charpy V-notch impact tests with notch locations in weld metal, fusion line and heat affected zone + 2
mm and + 5 mm from fusion line, respectively. Test results shall meet the requirements specified for the
parent metal.
• Macrosection.
• Hardness values shall not exceed 350 HV10.
Castings repaired by welding shall be post weld heat treated at a temperature at least 15 °C below the
tempering temperature. On completion of heat treatment the weld repairs and adjacent material shall be
ground smooth. All weld repairs shall be magnetic particle tested and major repairs shall additionally be
ultrasonic (or radiographic) tested. Weld repairs shall meet the quality level designated for that particular
area of the casting.
The foundry shall maintain records of repair welding, subsequent heat treatment and inspections traceable
to each casting repaired.
8 Dimensions/tolerances
Dimensions and required tolerances shall be as given on the relevant drawing of the casting or other
information supplied. If nothing is specified, ISO 8062 Grade CT 13 shall apply.
9 Surface protection
Castings shall before delivery, be degreased, shot blasted to bright metal and protected by a shop primer
with a dry film thickness of approximately 20 µm. All sharp edges shall be rounded and smoothed by
grinding to a minimum radius of 2 mm to assure full film thickness on all edges.
Machined surfaces shall be protected by a rust protection coating (water soluble tectyl or equivalent).
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 EN 10204 3.1b is required.
The certificate shall contain all relevant information including, but not restricted to the following: