Structural Steel Fabrication Norsk Standard

NORSOK STANDARD
STRUCTURAL STEEL FABRICATION

M-101
Rev.4. Dec. 2000
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 Center
Oscarsgt. 20, Postbox 7072 Majorstua
N-0306 Oslo, NORWAY
Telephone: + 47 22 59 01 00 Fax: + 47 22 59 01 29
Email: norsok@nts.no Website: http://www.nts.no/norsok
Copyrights reserved
Structural steel fabrication M-101
Rev. 4, Dec. 2000
NORSOK standard Page 1 of 36
CONTENTS
FOREWORD 3
INTRODUCTION 3
1 SCOPE 4
2 NORMATIVE REFERENCES 4
3 DEFINITIONS AND ABBREVIATIONS 5
3.1 Definitions 5
3.2 Abbreviations 5
4 SELECTION OF STEELS 6
4.1 Design classes 6
4.2 Selection of steel quality level 6
5 QUALIFICATION OF WELDING PROCEDURES AND WELDERS 6
5.1 Welding procedure specification (WPS) 6
5.2 Qualification of welding procedures 6
5.3 Welding procedure approval record (WPAR) - Range of approval 7
5.4 Examination of the test weld 8
5.5 Welder and welding operators qualifications 11
6 FABRICATION AND WELDING REQUIREMENTS 11
6.1 General 11
6.2 Forming 11
6.3 Assembly 12
6.4 Preparation for coatings 13
6.5 Preparation and fit-up of weld bevels 13
6.6 Welding processes 13
6.7 Welding consumables 14
6.8 Preheat and interpass temperature 14
6.9 Production welding 15
6.10 Post weld heat treatment (PWHT) 16
6.11 Grinding 16
6.12 Peening 16
7 PRODUCTION TESTS 17
8 FABRICATION TOLERANCES 17
9 NON-DESTRUCTIVE TESTING (NDT) 17
9.1 General 17
9.2 Qualification of inspectors and NDT-operators 18
9.3 Extent of visual examination and NDT 19
9.4 Visual examination and finish of welds 21
9.5 Radiographic testing 21
9.6 Ultrasonic testing 21
9.7 Magnetic particle and Penetrant testing 22
9.8 Acceptance criteria 22
10 REPAIR 28
Rev. 4, Dec. 2000
10.1 Definitions 28
10.2 Correction of welds containing defects 28
10.3 Repair by welding 28
10.4 Repair welding procedure 29
10.5 Correction of distortion 29
ANNEX A 1 - TYPICAL GRINDING DETAILS FOR HIGH FATIGUE UTILISATION
(INFORMATIVE) 30
ANNEX A 2 - TYPICAL PEENING DETAILS FOR HIGH FATIGUE UTILISATION
(INFORMATIVE) 31
ANNEX B - CORRELATION BETWEEN STEEL QUALITY LEVEL, MDS NUMBER AND
STEEL GRADE/DESIGNATIONS (NORMATIVE) 33
ANNEX C - QUALIFICATION OF WELDING CONSUMABLES BY DATA SHEETS
(NORMATIVE) 34
ANNEX D - WELDING CONSUMABLE DOCUMENTED BY BATCH TESTING
(NORMATIVE) 36
ANNEX E FABRICATION TOLERANCES (NORMATIVE) 37
Rev. 4, Dec. 2000
FOREWORD
NORSOK (The competitive standing of the Norwegian offshore sector) is the industry initiative to
add value, reduce cost and lead time and eliminate 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 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 Center).
The purpose of NORSOK standards is to contribute to meet the NORSOK goals, e.g. to develop
standards that ensure adequate safety, value adding and cost effectiveness and thus are used in
existing and future petroleum industry developments.
The NORSOK standards make extensive references to international standards. Where relevant, the
contents of a NORSOK standard will be used to provide input to the international standardisation
process. Subject to implementation into international standards, the NORSOK standard will be
withdrawn.
Annex A is informative. Annexes B, C, D and E are normative.
INTRODUCTION
Revision 4 of this standard has been necessary due to regulations in new design standard N 004 and
new designation of steel grades. In addition a steel grade with SMYS 690 is introduced with
additional requirements to fabrication.
Rev. 4, Dec. 2000
1 SCOPE
This standard covers the requirements for fabrication and inspection of offshore steel structures with
SMYS < 500 MPa and with a minimum design temperature down to -14C. For special application
steels with SMYS up to 690 MPa may be used.
Note: For highly fatigue utilized structures, more severe requirements may apply, and these will be
shown on the design drawings.
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 recognized standards may be used provided it can be shown that they meet or exceed
the requirements of the standards referenced below.
API 2B Specification for fabricated structural steel pipe.
API RP 2X Ultrasonic examination of offshore structural fabrications.
ASME, Section V Non-destructive testing.
BS 7448, Part 1 Fracture mechanics toughness tests.
BS 7910 Guide on methods for assessing the acceptability of flaws in fusion
welded structures.
DNV RP D404 Unstable fracture.
EN 287-1 Approval testing of welders - Fusion welding.
EN 288-series 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-series NDT - Image quality of radiographs.
EN 473 Qualification and certification of NDT personnel - General principles.
EN 719 Welding coordination - Tasks and responsibilities.
EN 729-series 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.
EN 970 Welding - Visual examination of fusion welded joints.
EN 1011-series Welding - Recommendation for welding of metallic materials, relevant
parts.
EN 1289 Non destructive examination of welds - Penetrant testing of welds -
Acceptance levels.
EN 1290 NDT of welds - Magnetic particle examination of welds - .
Rev. 4, Dec. 2000
EN 1291 NDT of welds - Magnetic particle examination of welds - Acceptance
levels.
EN 1418 Welding personnel - Approval testing for fully mechanised and automatic
welding.
EN 1435 Non destructive examination of welds - Radiographic examination of
welded joints.
EN 1597-1 Welding consumables - Test methods - Part 1: Test piece for all weld
metal test specimens in steel, nickel and nickel alloys.
EN 1714 Non destructive examination of welds - Ultrasonic examination of
welded joints.
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 indeposited 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.
NORSOK M-001 Material selection
NORSOK M-120 Material data sheets for structural steel
NORSOK N-001 Structural design
NORSOK N-004 Design of steel structures
NS 477 Welding. Rules for approval of welding inspectors.
3 DEFINITIONS AND ABBREVIATIONS
3.1 Definitions
Normative references Shall mean normative in the application of NORSOK standards.
Informative references Shall mean informative in the application of NORSOK standards.
Shall Shall is an absolute requirement which shall be followed strictly in order
to conform with the standard.
Should Should is a recommendation. Alternative solutions having the same
functionality and quality are acceptable.
May May indicates a course of action that is permissible within the limits of
the standard (a permission).
Can Can is conditional and indicates a possibility open to the user of the
standard.
3.2 Abbreviations
AWS American Welding Society
BS British Standard
CE Carbon Equivalent equation
CTOD Crack Tip Opening Displacement
DAC Distance Amplitude Curve
DC Design Class
DIN Deutsche Institut fr Normung
Rev. 4, Dec. 2000
DNV Det Norske Veritas
EN (pr EN) European Standard (proposal for EN)
FCAW Flux Cored Arc Welding
FSH Full Screen Height
HAZ Heat Affected Zone
H
DM
Hydrogen content, deposit metal
IIW International Institute of Welding
ISO International Organization for Standardization
NDT Non Destructive Testing
MDS Material Data Sheet
MSF Module Support Frame
P
cm
Carbon equivalent (Parameter for crack, modified)
PWHT Post Weld Heat Treatment
SAW Submerged Arc Welding
SMYS Specified Minimum Yield Strength
SQL Steel Quality Level
WPS Welding Procedure Specification
WPAR Welding Procedure Approval Record
4 SELECTION OF STEELS
4.1 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-004.
4.2 Selection of steel quality level
The steel quality level will be decided by the designer in compliance with N-004.
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-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.
5 QUALIFICATION OF WELDING PROCEDURES AND WELDERS
5.1 Welding procedure specification (WPS)
WPS shall be established in accordance with EN 288 part 2.
5.2 Qualification of welding procedures
Welding procedures used for structures requiring steel quality level I and II for all strength levels
and steel quality level III for SMYS 355 MPa 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.
Rev. 4, Dec. 2000
5.3 Welding procedure approval record (WPAR) - Range of approval
5.3.1 For welding of steels with SMYS 500 MPa
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 P
cm
0.21, or a carbon content C 0.13%, then an increase
of more than 0.02 P
cm
units or 0.03 carbon equivalent units (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.
d) A change in delivery condition (normalised, thermomechanically controlled processed or
quenched and tempered).
e) A change in microalloying element or manufacturing technique for steel with SMYS 400
MPa.
f) A change in groove angle more than +20 deg./-10 deg.
g) A qualification of fillet welds carried out on plate thickness equal to or greater than 30 mm,
applies for all plate and throat thicknesses. Single layer fillet welds qualifies multi-layer, but not
the converse.
h) CTOD testing shall be included in the qualification of welding procedures for weldments with a
plate thickness above 50 mm for all strength levels for steel quality level I and II and for SMYS
>400 MPa for steel quality level III. CTOD testing shall be included in the qualification of
welding procedures for weldments with a plate thickness below and equal 50 mm if requested
by the designer for the specified steel quality level.
Testing shall be executed from as welded and PWHT weld assemblies as applicable, covering the
following combined conditions:
Full penetration buttweld with K-, or half V -groove as deemed most representative for the
actual fabrication. V and X groove are acceptable for weld metal test..
A welding procedure representing the maximum heat input to be used in fabrication.
Maximum joint thickness (within 10%).
Assemblies shall be made and tested for the actual combination of steel manufacturer, welding
process and welding consumable (brand) used, except welding consumables used for root passes
only, provided these are removed completely by gouging and grinding.
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 manufacturer for relevant thicknesses
and heat input ranges. If sufficient documentation from the steel manufacturer 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.
Rev. 4, Dec. 2000
5.3.2 For welding of steels with SMYS > >> >500MPa
In addition to the requirements given in 5.3.1 the following additional requirements apply for
welding of steels with SMYS >500 MPa
a) A change in steel manufacturer.
b) CTOD testing as described in 5.3.1 h) shall be executed for thicknesses above 30 mm
c) Stress relieving if required/specified by designer
d) When the steel to be welded has a Pcm 0,21 or a carbon content 0,13, then an increase of
more than 0,03 Pcm or 0,04 carbon equivalent units (IIW formula) over the value of the
approval test shall require a new qualification test.
5.4 Examination of the test weld
5.4.1 General
The type and number of tests shall be in accordance with table 5.1. 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 9.
Rev. 4, Dec. 2000
Table 5.1 Type and number of tests
Mechanical testing
Joint
configuration
Joint
thickness
(mm)
Tensile
test
Bend
tests
1)
Charpy
V-notch
tests
Hardness
and
macro
5)
CTOD
Buttwelds
(Tubulars and
plates)
t<50
t50
2
2
2
2
4 sets
6 sets
1
1
Ref. 5.3.1h
and 5.4.4
T-joints
(plates)
4)
t<50
t50
3)
3)
4 sets
2)
6 sets
2
2
Tubular joints
4)
t<50
t50
3)
3)
4 sets
2)
6 sets
2
2
Fillet welds All 2
Notes:
1. Bend tests shall consist of 1 face and 1 root bend specimen for t < 20 mm and 2 side
bend specimens for t 20 mm
2. 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.
3. It shall be documented on a butt weld test that the welding consumable used will have
sufficient tensile strength.
4. T-joints on plates qualify for tubular joints, and vice versa.
5. For welds on submerged structures with cathodic protection, the hardness limits in
NORSOK M-001 (i.e. max 350 HV10) shall apply in addition to the requirements of
EN 288. For SMYS 690 MPa max 400 HV10 shall apply.
5.4.2 Charpy V-notch testing
Sampling of Charpy V-notch impact tests shall be carried out in accordance with EN 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 EN 875).
Notch in centre of weld (VWT 0/2)
Notch in fusion line (VHT 0/2)
Notch in HAZ, 2 mm from fusion line (VHT 2/2)
Notch in HAZ, 5 mm from fusion line (VHT 5/2)
For welds with a joint thickness of 50 mm 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/b)
Notch in fusion line (VHT 0/b)
The test temperature and energy requirements shall comply with table 5.2.
Rev. 4, Dec. 2000
Table 5.2 Charpy impact test temperatures and energy requirements for welding
procedure qualifications.
Material Steel quality level
thickness I II III
mm SMYS
400
400<
SMYS
500
SMYS
>500
SMYS
400
400<
SMYS
500
SMYS
>500
355
SMYS
500
SMYS
>500
t 12 0C -20C -20C 0C -0C -20C -0C 0C
12 < t 25 -20C -40C -40C 0C -20C -40C 0C -20C
25 < t 50 -40C -40C -40C -20C -40C -40C -20C -40C
t > 50 -40C -40C -40C -40C -40C -40C -40C -40C
Energy
Requirement
1)
36J 42J 60J 27J 42J 60J 27J 42J
Note:
1. The minimum average value is given in the table. No individual value shall be less than 70% of
the minimum average value. Reduction factors of energy requirements for subsize specimens
shall be: 7,5 mm - 5/6 and 5 mm - 2/3.
5.4.3 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/HAZ).
5.4.4 CTOD testing
The CTOD- technique with the Bx2B through-thickness notched type specimen according to BS
7448 Part 1 should be used. Three valid test specimens shall be obtained for each test position.
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, determination of the actual
location of the fatigue crack tip shall be performed after testing. Ref. is made to prEN 10225.
Note: Test assemblies may be given hydrogen diffusion treatment prior to testing, and specimens
may be precompressed.
If not specified otherwise, the test temperature for design temperature down to -14 C shall be:
-10 C for splash zone or above.
0 C for submerged parts.
Other test temperature may be prescribed by the designer.
Three (3) valid test specimens shall be obtained for each notch location.
The requirement for minimum CTOD value shall be prescribed by the designer. If not specified, the
requirement for minimum CTOD value shall be as for the steel purchase order.
CTOD-testing of HAZ can be omitted if relevant CTOD properties in HAZ have been documented
previously in accordance with requirements in this standard, provided the requirements for the
essential variables are met.
Rev. 4, Dec. 2000
CTOD-testing of weld metal can be omitted if relevant CTOD properties in WM have been
documented previously in accordance with requirements in this standard, provided the requirements
for the essential variables are met.
The required fracture toughness level shall be decided in design for joints when steel quality level I
and II are required. Testing is normally not requested for structures with plate thickness below 40
mm for SMYS500 MPa or for structures with plate thicknes below 25 mm for SMYS>500 MPa.
5.5 Welder and welding operators qualifications
The welders, welding operators and tack welders shall be qualified in accordance with EN 287, EN
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 joint, representing the minimum angle to be used in production.
For welding of joints where steel quality level IV is selected, a certificate for welding of plates in
position PE is sufficient for welding all product forms.
6 FABRICATION AND WELDING REQUIREMENTS
6.1 General
All welding work shall be according to recommendations given in relevant part of EN 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.
6.2 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.
Rev. 4, Dec. 2000
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:
100% x
diameter thickness mid Forming
thickness Wall
strain Percent =
6.3 Assembly
6.3.1 General
In tubular joints, circumferential and longitudinal weld joints should not be placed in the shaded
areas shown in fig. 6.1, unless otherwise shown on design drawings.
W1
W1
W1
W1
W2
W
3
D
W2
W2
W2
Longitudinal welds Circumferential welds
W1 = 75 mm or min. 2 times chord thickness
W2 = 150 mm or min. D/4
W3 = 600 mm or min. D
Fig. 6.1 Prohibited location of welds in tubular joints. Longitudinal respectively circumferential
welds shall not be located in shaded area.
6.3.2 Splices
Splices shall not be located in areas, noted as restricted on design drawings.
6.3.3 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.
Rev. 4, Dec. 2000
6.3.4 Bolting connection
Bolting material shall comply with requirements in NORSOK standard M-001, Material selection.
Holes shall be made by machine drilling.
6.3.5 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 3 mm. Where steel items
shall be hot dip galvanised, hollow sections shall be ventilated.
6.3.6 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 100 mm. 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.
6.3.7 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 600C.
6.3.8 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.
6.4 Preparation for coatings
Edges of plates and structural shapes which are intended to be coated shall be rounded to
approximately 2 mm radius, unless otherwise indicated on design drawings.
6.5 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. Buttering in excess of 20 mm
shall be avoided.
6.6 Welding processes
The welding processes listed in EN 288-3 are acceptable.
Rev. 4, Dec. 2000
6.7 Welding consumables
The manufacturers shall ensure that welding consumables applied for joints where steel quality level
I, II and III 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.
For steels with SMYS 500 MPa Annex D is mandatory
Except for solid wires such consumables shall be classified by the supplier as extra low hydrogen,
i.e. H
DM
5ml/100g weld metal. For self shielded flux cored wire H
DM
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.
For all steels with SMYS 500 MPa special precautions shall be taken to verify that selected
consumables comply with hydrogen requirements. Stricter requirements than given above may be
relevant. Prequalification with mock-up structures shall apply if there is a risk for high restraint in
welding or erection.
Consumables for joints in steel quality level III (with SMYS <355MPa) 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 10204 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 10204 type 2.2), declaring conformity with the approved product type.
6.8 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 250C 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.
Rev. 4, Dec. 2000
Note: Production welding of high strength steels with SMYS>500 MPa is normally more sensitive
to hydrogen cracking than experienced during welding for qualification. Special precautions,
including preheating temperature, minimum holding temperature and extended post weld holding
temperature for 24 hours or more, shall be taken into consideration.
6.9 Production welding
6.9.1 General
Welding shall be carried out in accordance with the WPS and applicable drawings.
Butt welds in joints where steel quality level I and II for all strength levels, or steel quality level III
for SMYS > 400 MPa 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 10
O
, unless it is documented that possible defects can be detected by the
UT technique used

. (For K-grooves, the 10
O
should be machined from the root to each plate
surface.)
Any occurrence of cracking during production welding shall be investigated. Welding should be
suspended until the cause of cracks and defects has been identified and measures taken to prevent
their reoccurrence. Cracks or other persistent weld defects may lead to revision and requalification
of the WPS.
6.9.2 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 cut minimum 3 mm from the base metal and ground. The
ground area shall be visually examined and magnetic particle/penetrant tested (as relevant) in
accordance with the inspection category in question.
6.9.3 Stainless steel components
Permanent or temporary structural elements, attachments or penetration sleeves in stainless steel
materials may be selected for various purposes.
Requirements for welding and testing of stainless outfitting structures shall follow similar
classification principles as for other structural steel elements. All welding and testing of welds to
carbon steel structures shall as a minimum comply with the requirements for the structure to which
they are attached.
Unless other requirements apply higher alloyed consumables than given for the relevant stainless
component shall be selected for tacking and final welding.
Rev. 4, Dec. 2000
6.10 Post weld heat treatment (PWHT)
PWHT shall be required for structural welds in steel quality level I or II, or quality level III with
Re>400MPa, when the nominal thickness (as defined in EN 288-3, section 8.3.2.1) exceeds 50 mm,
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 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 time and temperature shall be as recommended by the steel manufacturer
The temperature difference between different parts of the structure during soaking time shall not
exceed 30C 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.
6.11 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.
6.12 Peening
Weld improvement by peening shall be performed in accordance with detailed procedures.
Normally pregrinding of a groove will be required to assure correct location of peening area. Tools
for grinding and peening, surface roughness and profile of grinding as well as peening shall be
specified. Tools for check and measurements shall be described and shall be available during
operations. Documentation of correct performance shall include macrophotography. Typical
examples of requirements for peening of joints are given in Annex A.
Rev. 4, Dec. 2000
7 PRODUCTION TESTS
Production tests shall be selected on weldments in critical regions to verify that the specified
requirements have been meet. 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.
8 FABRICATION TOLERANCES
Fabrication tolerances shall be in accordance with Annex E, unless otherwise specified on drawings.
9 NON-DESTRUCTIVE TESTING (NDT)
9.1 General
The inspection category shall be decided by the designer in accordance with NORSOK N-004, 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/or welding consumables in question.
When PWHT is performed, the final NDT shall be carried out when all heat treatment have been
completed.
Prior to fabrication start-up, contractor shall implement a system for recording of weld defect rates.
The defect rates shall be recorded on a weekly basis from each production area (geographically split
in production areas at the same yard) and shall be reported together with the accumulated defect
rate. The defect rate statistics shall be used as a tool in weld quality control. Causes for defects shall
immediately be investigated and corrective actions shall be taken to prevent further occurrence.
Cracks detected with any NDT method shall require documented investigation/action by the
responsible welding engineer.
At a weekly high defect rate or at repeated occurrence of planar defects, two trigger levels apply for
extended NDT for welds in inspection category B, C and D. Two steps of actions apply within
trigger level 2.
Rev. 4, Dec. 2000
Trigger level 1
If a defect rate for any method exceed 10 % for a single week the extent shall be increased to 100 %
for all welds in question irrelevant of the required inspection category for the welds.
Trigger level 2
If a defect rate for any method of 5 - 10 % for a single week is observed the following two steps of
extended NDT shall apply:
Step 1.
A defect rate for any NDT method exceeding 5 % (1% for MT) for a single week require doubling
of the extent of NDT according to the inspection category. Spot extent shall be increased to 20 %.
Step 2.
If the defect rate for the weld length where the extended NDT is taken in accordance with Step 1
above exceed 5 %, the extent shall be increased to 100 % for all welds in question irrelevant of the
required inspection category for the welds.
The increased NDT extent shall cover welds of the same inspection categories, welded in the same
period of time when the high defect rate was produced, to assure that the weld quality is maintained
also with the lower extent of NDT. Unless the causes for defects found leads to immediate and
documented preventive actions, the higher level of extent of NDT shall be maintained until the
weekly defect rate is well below 5 %.
Generally, if the defect rate approaches 10 % during any stage in production welding, further
welding should be held until investigations are completed and corrective actions implemented.
A low defect rate may be used as basis for a reduction in the extent of NDT for inspection
categories B, C and D, provided that a correct defect rate identification is prepared for each weld
method, each NDT method and each production area. See Note 2 in Table 9.1.
1)
welds) of parts tested of (Length
100%) length x (Defect
: as defined is rate defect The
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.
9.2 Qualification of inspectors and NDT-operators
Personnel responsible for welding inspection - welding inspectors - shall be qualified in accordance
with NS 477 or equivalent scheme.
Personnel performing visual inspections of welded joints shall be qualified in accordance with
relevant part of EN 473/NORDTEST.
Personnel responsible for all NDT activities shall be qualified according to EN 473/NORDTEST
Level 3 or equivalent.
The NDT operators shall be qualified according to EN 473/NORDTEST Level 2 or equivalent.
Rev. 4, Dec. 2000
Operators simply producing radiographs and not performing evaluation, do not require level 2, but
shall have sufficient training.
In undertaking testing of castings or forgings the NDT operator should also document experience
with forged and cast products.
9.3 Extent of visual examination and NDT
The required minimum extent of examination/testing is given in table 9.1. Design drawings may
show areas of welds where testing is mandatory.
Testing performed shall be representative for the weld quality. Partial NDT shall normally be planed
for on all shop drawings.
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 testing shall be performed on
minimum 5% of welds in inspection category A and B for SAW (12) and FCAW (131 and 136)
Rev. 4, Dec. 2000
Table 9.1 Minimum extent (in %) of non-destructive testing for structural welds.
Inspection
category
Type of
connection
Visual
examination
Extent of testing
RT UT MT
A Buttw.
T-conn.
Fillet/partial
100
100
100
10
-
-
100
100
-
100
100
100
B
1)
Buttw.
T-conn.
Fillet/partial
100
100
100
Spot
-
-
50
2)
50
2)
-
100
2)
100
2)
100
2)
C
1)
Buttw.
T-conn.
Fillet/partial
100
100
100
-
-
-
20
2)
20
2)
-
20
2)
20
2)
20
2)
D
1)
All conn. 100 - - spot
E All conn. 100 - - -
Legend -
RT = Radiographic testing
UT = Ultrasonic testing
MT = Magnetic particle testing
Spot means 2 - 5%.
Note:
1. The extent of NDT shall be increased for Inspection categories B, C and D if repeated
occurrence of planar defects are revealed or if the weekly defect rate for any NDT
method, including all types of defects, are as given for the limits below.
Trigger level 1 - Defect rate exceeding 10 %:
The extent shall be increased to 100 % irrelevant of inspection category.
Trigger level 2 - Defect rate of 10 % and below calls for stepwise increase in extent:
Step 1 - Defect rate exceeding 5 % ( MT exceeding 1%): The original extent shall be
doubled. Spot extent shall be increased to 20 %.
Step 2 - Defect rate for the extended testing under Step 1 exceed 5 %: The extent shall
be increased to 100 % of the weld lengths in question for all inspection categories.
The required level of increased extent shall be maintained until a defect
rate below 5 % is re-established and documented.
2. 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 continuously
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.
Rev. 4, Dec. 2000
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 9.1 refers to the total length of welds in each
inspection category.
All WPS's used and welds representing all 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 9.1. This extent shall be maintained for a
weld and test length sufficient to conclude that the weld repair percentage is at a reasonable level.
The increased initial testing may be accounted for in the overall extent provided the initial testing
confirms consistent good workmanship.
In addition to what is listed in table 9.1, 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 10 mm. 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 40 mm.
e) MT shall be performed on both external and internal surface as accessible or as required by the
designer.
9.4 Visual examination and finish of welds
The visual examination shall be carried out in accordance with EN 970.
9.5 Radiographic testing
Radiographic testing shall be carried out in accordance with EN 1435, Class A.
Suspect planar indications discovered by RT shall be type determined, located and sized by UT.
Penetrameters of wire type (according to EN 462-1 or equivalent) 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.
9.6 Ultrasonic testing
Ultrasonic testing of welds in plate and tubular butt welds and double side welded tubular joints
shall be performed in accordance with EN 1714, examination level C.
Reference blocks shall be made with thickness and side-drilled holes in accordance with table 9.2.
DAC reference curves shall be established.
Rev. 4, Dec. 2000
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, reference 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.
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 acceptance criteria shall be reported, unless more stringent requirements
are given in table 9.5.
The examination record shall include the position, the echo height, length, depth and type of
indication.
9.7 Magnetic particle and Penetrant 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.
For non-magnetic materials penetrant testing in accordance with EN 1289 should be used.
9.8 Acceptance criteria
9.8.1 General
All welds shall comply with the requirements given below, in 9.8.2 - 9.8.5.
9.8.2 Visual examination
All welds shall show evidence of good workmanship. The quality shall comply with the
requirements of table 9.3.
9.8.3 Radiographs
The soundness of the welded joint shall comply with the requirements of table 9.4.
9.8.4 Ultrasonic testing acceptance criteria
The acceptance criteria for welds shall comply with table 9.5 unless more stringent requirements are
specified by the designer.
Rev. 4, Dec. 2000
9.8.5 Magnetic particle testing
Linear indications (i.e. indications with a length/width ratio above 3 and length above 1.5 mm ) are
not acceptable. Any linear indications shall be ground and re-examined. Rounded indications shall
be evaluated in accordance with the requirements of table 9.3.
The same acceptance criteria applies for penetrant testing.
9.8.6 All methods
All defects shall be repaired according to clause 10.
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 BS 7910 , DNV RP D404 or other recognised methods.
Table 9.2 Calibration reference block requirements
Thickness of
material to be
examined (mm)
Thickness of block Diameter of hole Distance of hole
from one surface
10 < t < 50 40 or t 3 mm +/-0.2 mm
50 < t < 100 75 or t t/2 and t/4.
100 < t < 150 125 or t 6 mm +/-0.2 mm Additional holes are
150 < t < 200 175 or t allowed and
200 < t < 250 225 or t recommended
t > 250 275 or t
Rev. 4, Dec. 2000
Table 9.3 Structural steel welds. Visual and MT-acceptance criteria for structural steel
welds
Welding Acceptance criteria
Type of defect Insp. cat. A, B Inspection category C, D, E
Cracks Not acceptable Not acceptable
Incomplete
penetration or lack
of fusion
Not acceptable Single - side weld:
Length < t/2, max 10 mm
Defects shall be regarded as a continuous
defect if the distance between them is < t.
Undercut Max depth 0.5 mm
Continuous
undercut is not
permitted
Maximum depth 0.75 mm
Continuous undercut is not permitted
Surface porosity
Exposed slag
Not acceptable 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 150 mm is not to exceed 15 mm. Max. size
of a single pore is t/4 or 4 mm, whichever is
the smaller.
Concave root Max. concavity 0.5 mm if the transition is smoothly formed.
Excessive pen.
1)
Max. 3 mm
Roughness of weld
(fig. 1)
U shall be less than 2.5 mm. Weld surface shall be smooth,
without sharp transitions. The bottom of roughness in butt welds
shall not be below the base material surface.
Misalignment of
butt welds (fig. 2)
Max. misalignment (M), 0.15 x t or max. 4 mm,
whichever is the smaller.
Reinforcement of
butt welds (fig. 3)
1)
t less or equal to 10 Max reinforcement C 2 mm
t greater than 10, up to 25 Max reinforcement C 3 mm
t greater than 25, up to 50 Max reinforcement C 4 mm
t greater than 50 Max reinforcement C 5 mm
Reinforcement of
fillet/partial pen.
welds (fig.4)
1)
a less or equal to 10 Max reinforcement C 2 mm
a greater than 10, up to 15 Max reinforcement C 3 mm
a greater than 15, up to 25 Max reinforcement C 4 mm
a greater than 25 Max reinforcement C 5 mm
Symmetry of fillet
welds (fig. 5)
a less or equal to 6 Max difference, b - h: 3 mm
a greater than 6, up to 13 Max difference, b - h: 5 mm
a greater than 13 Max difference, b - h: 8 mm
Grinding arc strikes
etc. Removal of
temporary
attachments
2)
Grinding of base material shall not exceed 7% of the wall thickness
or max. 3 mm. Repair welding and inspection shall be performed if
removal of the base metal exceeds the specified requirements.
Sharp edges Minimum 2 mm radius (Ref. 6.4)
Rev. 4, Dec. 2000
Notes:
1) Localised reinforcements exceeding the above requirements are acceptable.
2) Temporary attachments shall be cut min. 3 mm 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. 6.11), grinding of the surface shall be specified. Typical examples of
grinding requirements are given in annex A.
U
U
Fig. 1 Roughness of weld
c
t
M
t
Fig. 2 Misalignment of butt weld Fig.3 Reinforcement of butt weld
c
a
c
a a
b
h
Fig. 4a Fig. 4b Fig. 5
Reinforcement of fillet weld Reinforcement of partial pen. weld Symmetry of fillet weld
Rev. 4, Dec. 2000
Table 9.4 Structural steel welds, RT acceptance criteria
Type of defect Inspection category
A, B C, D, E
Internal porosity (Note 1)
Isolated:
Pore diameter max t/4, but max.6
mm
max t/3, but max. 6 mm
Cluster:
Pore diameter max. 3 mm max. 4 mm
Scattered:
Accumulated pore diameters in any
10x150 mm area of weld
max. 20 mm max. 25 mm
Slag inclusions, or piping porosity (Note 2)
Width t/4, max .6 mm t/3, max. 6 mm
Length (Note 3) 2t, max 50 mm 4t, max. 100 mm
Incomplete penetration, lack of fusion
Length (Note 2) t, max. 25 mm 2t, max 50 mm
Cracks Not acceptable Not acceptable
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.
3) No length limitation for width 2 mm for t 20 mm and for width 1 mm for t <20 mm.
Rev. 4, Dec. 2000
Table 9.5 Structural steel welds. UT acceptance criteria.
Description Inspection category
A + B
Inspection category
C, D, E
Notes
General If the type of defect can not be ascertained with certainty the
defect shall be repaired when the length exceeds 10 mm and the
echo height exceeds the reference curve.
1
2
3
4
Cracks Unambiguous cracks are unacceptable regardless of size or
amplitude.
Lack of
fusion or
incomplete
penetration
Internal defects :
I: The echo height exceeds the reference curve:
Max length t, Max length 2t,
max 25 mm max 50 mm
II: The echo height is between 50 and 100% of the reference
curve:
Max length 2t, Max length 4t,
max 50 mm max 100 mm
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 25 mm max 50 mm
1
2
3
4
5
Slag
inclusions
When echo height exceeds the reference curve:
Max length 2t, Max length 4t,
max 50 mm max 100 mm
1
2
Porosity Repair is required if porosity may mask for other defects. 1
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 6 mm 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.
Rev. 4, Dec. 2000
10 REPAIR
10.1 Definitions
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 9 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.
Weld defect: Discontinuity with a size and/or density that exceeds the acceptance criteria defined in
clause 9.
10.2 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.
10.3 Repair by welding
10.3.1 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 50 mm long, measured at defect depth even if the defect
itself is smaller. Defects spaced less than 100 mm shall be repaired as one continuous defect.
After repair welding the complete weld (i.e. the repaired area plus at least 100 mm 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.
Rev. 4, Dec. 2000
10.3.2 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.
10.4 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.
For repairs using a different process, and/or consumable, a separate WPS shall be qualified if
required by 5.2. Mechanical testing may be limited to HAZ Charpy V-notch testing in the original
weld, provided the process/consumable is backed up by other WPARs.
10.5 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 6.
Rev. 4, Dec. 2000
ANNEX A 1 - TYPICAL GRINDING DETAILS FOR HIGH FATIGUE
UTILISATION (INFORMATIVE)
TYP. TUBULAR JONT GRNDNG DETAL
TYPCAL GRNDNG DETALS
FOR HGH FATGUE UTLSATON
T4= 2mm or 0,05 x T3 max.
(wichever is less)
Remove
sharp edges
O
U
T
S
D
E
B
R
A
C
E
W
A
L
L
T
4
T
3
T2 = 2mm or 0, 05 x T1 max.
(wichever is less)
T
1
Remove
sharp edges
Weld rad.
Rotary burr grinder
chord wall
Remove overlap flush
with plate surface
Blend out to remove edge on undercut
Maximum depth below plate
surface for blend is not to exceed
1,5mm
Grinding direct ion
TYP. BUTT WELD JONT GRNDNG DETAL
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 0.5 mm 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 shall be inspected with
100% visual examination and 100% MT.
5. Ground surface shall be free of any cracks or cracklike indications, and there shall be no
evidence of undercut or overlap.
Rev. 4, Dec. 2000
ANNEX A 2 - TYPICAL PEENING DETAILS FOR HIGH FATIGUE
UTILISATION (INFORMATIVE)
A.2.1 General
Peening of local area as weld toe or weld trasition is an acceptable method to improve fatigue life of
structures. Peening is applied together with grinding where grinding serves the purposes to remove
stress risers such as surface defects and to define a steering grove for the tool in the area to be
peened. Both grinding and peening require skills and preparations not normally available in
fabrication yards. Due to the dependancy of correct performance specific precautions shall be taken
when peening is planned for.
A.2.2 Requirements for application
When peening is planned for the following preparations are required :
Nomination of responsible engineer for preparations, performance and documentation
A complete responsibility and personnel matrix
Statement on expected or required improvements
Detailed work instructions
Documentation on operators experience, skill or training
Selection of peening methods to be applied
Detailed mark up drawings showing all areas of application
Detailed stepwise procedure for the work, including:
grinding details as tools, radius, depth and direction
tools to be used for peening
method, intensity and extent of peening
quality control measures
documentation of performance and results
Verification of performance such as experiments, tests or other relevant information
As built record index for the final DFI resume
As preparation for peening the surface shall be dressed in a way that makes lack of coverage
detectable, preferably by stone grinding. Applicable tool for grinding is normally a rotary burr or
stone of 6 to 8 mm diameter when a single tool hammer is used and 10 to 12 mm when a needle
hammer is used. The depth of the groove is approximately 0.5 mm below the original surface.
All surface defects shall be removed by grinding prior to peening.
Applicable tool for peening is normally pneumatic hammers. A needle hammer is normally used
when a wider area shall be covered. For local toe peening a single tool hammer is recommended.
Correct tool is essential to maintain correct peening in compliance with requirements.
Special tools with adjusted curvature shall be prepared in accordance with weld geometry.
Needle peening shall be applied with a coverage of minimum 200 %. Single hammer peening shall
result in a fully covered hammered groove where the surface is smooth with uniform indentation.
All traces from previous grinding shall be completely removed.
Rev. 4, Dec. 2000
Devices for quality control and documentation shall be thoroughly selected. Groove depth
measuring tools and macro photo is normally applied. Reference specimens shall be prepared for
comparison between ground and final peened surfaces.
Rev. 4, Dec. 2000
ANNEX B - CORRELATION BETWEEN STEEL QUALITY LEVEL, MDS
NUMBER AND STEEL GRADE/DESIGNATIONS (NORMATIVE)
Steel
quality
level
NORSOK
MDS No.
Note 1
Rev.
No.
Reference
standard
Product type Steel grade Former Steel
grade
Y20 3 Plates S355G10+N/G10+M S355N4z/M4z
Y21 3 Rolled sections S355G12+N/G12+M S355N3z/M3z
Y22 3 Seamless tubulars S355G15+Q/G15+N S355Q3z/N3z
Y30 3 Plates S420G2+Q/G2+M S420Q3z/M3z
Y31 3 Rolled sections S420G4+M S420M3z
Y32 3 prEN 10225 Seamless tubulars S420G6+Q(mod) S420Q3 (z mod)
I Y40 3 Plates S460G2+Q/G2+M S460Q3zM3z
Y42 3 Seamless tubulars S460G6+Q(mod) S460Q3(z-mod)
Y50 3 Plates S500G2+Q/G2+M S500Q3z/M3z
Y52 3 Seamless tubulars S500G6+Q(mod) S500Q3(z-mod)
Y70 Plates S690+Q
Y25 3 Plates S355G9+N/G9+M S355N4/M4
Y26 3 Rolled sections S355G11+N/G11+M S355N3/M3
Y27 3 Seamless tubulars S355G14+Q/G14+N S355Q3/N3
Y28 Welded tubulars S355G13+N
Y35 3 Plates S420G1+Q/G1+M S420Q3/M3
Y36 3 Rolled sections S420G3+M S420M3
Y37 3 Seamless tubulars S420G6+Q S420Q3
II Y46 3 prEN 10225 Rolled sections S460G3+M S460M3
Y56 3 Rolled sections S500G3+M S500M3
Y70 Plates S690+Q
Y05 EN 10113 Plates and sections S355NL/ML
Y06 prEN 10225 Tubulars S355G1+N
III Y07 EN 10210 Hot finished tubulars S355NH
Y08 EN 10219 Cold formed tubulars S355MLH
Y15 En 10113 Plates and sections S420NL/ML
Y16 EN 10219 Cold formed tubulars S420MLH
S235JRG2
EN 10025 Plates and sections S275JR
S355J0
S235JRH
IV Y01 3 EN 10210 Hot finished tubulars S275J0H
S355J0H
S235JRH
EN 10219 Cold formed tubulars S275J0H
S355J2H
Note 1 NORSOK Material data sheets are published in NORSOK standard M-120.
Rev. 4, Dec. 2000
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.
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.
Rev. 4, Dec. 2000
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 H
DM
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 non-
specific 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.
Rev. 4, Dec. 2000
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.
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.
Rev. 4, Nov. 2000
ANNEX E - FABRICATION TOLERANCES (NORMATIVE)
CONTENTS
E.1 SCOPE AND OBJECTIVES 38
E.2 CODES, STANDARDS AND SPECIFICATIONS 38
E.3 DEFINITIONS 38
E.4 GENERAL REQUIREMENTS 39
E.4.1 Implementation policy of requirements 39
E.4.2 Procedures and documents 40
E.4.3 Qualification of inspectors 40
E.4.4 Instrument reliability 40
E.4.5 Reference temperature 40
E.4.6 Control methods 41
E.4.7 Interface criterias 43
E.4.8 Alignment Requirement 43
E.5 FABRICATION TOLERANCES FOR STRUCTURAL COMPONENTS 44
E.5.1 I / H- Girders 44
E.5.2 Box Girders 45
E.5.3 Tubulars 46
E.5.4 Panels 49
E.5.5 Girder Nodes 50
E.5.6 Box Nodes 52
E.5.7 Tubular Nodes 53
E.5.8 Cast and Forged Elements 55
E.5.9 Curved and cylindrical shell 56
E.5.10 Conical transitions 56
E.6 ASSEMBLY TOLERANCES 57
E.6.1 Topsides and modules 57
E.6.2 Jacket and other tubular frame structures 58
E.6.3 Floating production units 63
E.6.4 Subsea structures 64
E.7 FABRICATION TOLERANCES FOR SPECIAL ITEMS 65
E.7.1 Crane Pedestal 65
E.7.2 Skid Beams 65
E.7.3 Outfitting Structure 65
E.7.4 Installation Aids 65
E.7.5 Grillages 65
E.7.6 Cranes 65
Rev. 4, Nov. 2000
E.1 SCOPE AND OBJECTIVES
This annex defines the maximum allowable dimensional tolerances for offshore steel items and
structures.
The Designer may, however, specify stricter tolerances and additional tolerances. These will, in case
take presedence over this annex.
Note: It should be observed that the requirement to fabrication tolerances in this annex may be more
strict than the manufacturing tolerances for steel products according to M-120.
The intention of this annex is to give dimensional tolerances which will ascertain that:
The calculated strength and fatigue resistance is present in the structures
Items and structures can be assembled without dimensional rework
All parts of the structures are suitable for their intended use
The structures are thrustworthy relative to measurements given on the structural drawings
The relevant components tolerances are achieved and maintained after the components final
incorporation in the completed structure(s)
E.2 CODES, STANDARDS AND SPECIFICATIONS
Reference standards for this annex are:
ISO-8062 Castings - System of dimensional tolerances and machining
ENV 1090-1 1995 for Cranes. Execution of steel structures - Part 1: General
E.3 DEFINITIONS
Terminology used in conjunction with this annex:
AFC drawing:
Engineering drawings formally approved for construction.
Centreline:
A real or imaginary line that is equidistant from the surface or sides of the (measured) object.
Deflection:
Load imposed curves, bends, angles or irregularities from an unloaded structure. Note: Opposed to
straightness deviation.
Flatness:
Flatness is here defined as vertical offset at any point from a plane parallel with the surveyed object.
Rev. 4, Nov. 2000
Grid System:
The grid system is defined as the design reference system for all parts, components and elements of
a completed structure.
The grid system defines the 3D position of any item within a completed structure.
The grid system is normally denoted in one of the following manners:
x, y and z coordinates,
North, east and height coordinates
Longitudinal, transversal and elevation coordinates.
The grid system defines the design origo (location and elevation datum) for a structure.
Position Deviation:
The specified point's actual position relative to it's nominal position.
(Measured value minus nominal value equals deviation).
Reference Lines:
Reference lines are marked lines on construction parts and assemblies. The reference lines shall be
parallel to, and in determined distances from grid lines.
Straightness Deviation:
Curves, bends, angles or irregularities from a straight generator.
Note: Straightness deviation is regarded to be fabrication imposed irregularities and not caused by
elastic deformation.
Survey Reference System
A reference system constituting of fixed and coordinate determined points, from where surveys can
be performed, and where the location and elevation of the fixed points are identifiable relative to the
grid system.
Work Point:
A marked or imaginary point on a member or structure from which dimensions shall be related.
E.4 GENERAL REQUIREMENTS
E.4.1 Implementation policy of requirements
The tolerances given in this annex shall be applied for completed structures.
For single elements to be parts of complex structures, specification of detailed and more stringent
tolerances for each fabrication and erection sequence may be necessary in order to meet the
requirements of this annex in the completed structure. Such tolerances shall be presented in the
plan/scope of work for fabrication.
Specification of detailed and more stringent tolerances for intermediate and final interfaces may also
be necessary in order to meet the requirements of this annex in the completed structure.
The allowable tolerances given for individual members shall not cumulate to give unacceptable
deviation for the finished section or complete structure.
Rev. 4, Nov. 2000
If tolerances given for individual sections and components are conflicting, those tolerances
representing the stricter values shall be governing.
If no appropriate tolerance is stated in this document, the tolerance requirements shall be agreed.
All tolerance requirements are based on nominal values on unloaded structure.
E.4.2 Procedures and documents
The following procedures and documents shall be prepared:
Plan for fabrication and erection including methods, techniques and dimensional control to assure
that all structures can be fabricated and assembled to dimensions within the specified tolerances.
The plan shall assure that all allowable tolerances for individual elements are not cumulative to the
extent of exceeding the allowable tolerance for the complete structure.
Dimensional inspection procedures relevant for the structures and any additional specifications
needed to those included in this document, subject drawings or other regulations/guidelines for the
structural fabrication.
The following documents shall be prepared prior to start of fabrication:
Plan for dimensional assurance/inspection
Dimensional inspection procedures
During fabrication and erection deviations outside the specified tolerances shall be identified and
informed of in advance of the formal handling of deviations.
The detailed deviation reports shall be available at all stages in fabrication, and shall be submitted
on request.
Final documentation shall be prepared in correspondence with the requirements for as built
documentation and fabrication record.
E.4.3 Qualification of inspectors
Personnel responsible for dimensional control activities shall have a minimum background of at
least 5 years relevant experience in industrial surveying.
Personnel monitoring dimensions and tolerances shall have relevant training in use and
understanding of instruments, and subsequent calculations, enabling them to perform all necessary
controls of own work performance.
E.4.4 Instrument reliability
All instruments used shall be in accurate permanent adjustment, have current valid control
certificates and be subject to a programme of periodic checking.
E.4.5 Reference temperature
Reference temperature for survey activities should be +20 deg. C.
Rev. 4, Nov. 2000
The field work temperature shall as a minimum be noted on all dimensional reports, when this is
necessary for future use of the report and the component surveyed. For components to be assembled,
built under significantly different temperature conditions, dimensions shall be computed to the
reference temperature and this shall be annotated on any subsequently produced document or report.
E.4.6 Control methods
E.4.6.1 Reference System
Prior to fabrication a survey reference system related to the grid system, shall be established. The
survey reference system shall use the same numerical values, and the same orientation directions of
the system axis as the grid system.
The system's north axis shall be positive toward platform north (or bow, if ship).
The system's east axis shall be positive toward east (or starboard, if ship).
The system's elevation shall be positive upward.
The numerical value should be the same for all disciplines and packages.
For special structures such as jackets being built laying down, the reference system must be adjusted
to this fabrication situation, but the final as built survey shall be related to the platform grid system.
The survey reference system should be established within the following tolerances:
Sections/complete structures: 3 mm
Stricter survey reference system tolerances shall be used on components where the requirements of
the final product are more stringent than the above tolerance. For components where the tolerance of
the product are less than 2 mm, the proposed survey methods shall be described.
At all stages during fabrication and erection, the Contractor shall ensure that the survey reference
system and the fabricated item shall be in correct position relative to each other.
Permanent survey stations shall be properly constructed and be protected from disturbance.
The permanent survey stations shall be rechecked periodically, or whenever additional permanent
survey stations are established. All additional or rechecked surveys shall be properly documented.
Rev. 4, Nov. 2000
Fig. E.4.6-1 Principal reference system
Figure E.4.6.1, indicates sample of applicable and practical reference systems.
The layout of the reference system may be specially designed to suit the task at hand and the
methods chosen for controls.
E.4.6.2 Marking criterias
During layout and assembly of each structural item all work points and centrelines, which are
relevant for the remaining steps of the construction, shall be marked and identified.
Location of hidden stiffeners, bulkheads etc. shall be marked on the outside of the structure to
ensure a correct assembly, if relevant for the remaining steps of the construction.
All primary datum work points on the structure shall be set out using accepted engineering
surveying techniques consistent with the tolerances required by this annex. All girders, boxes, nodes
and other structures shall be properly and clearly marked relative to the grid system at all interfaces,
if relevant for the remaining steps of the construction.
E.4.6.3 Accuracy
Surveys shall be performed using survey techniques and technology which enables the achievement
of a survey accuracy better than the specified tolerances.
The methods and equipment used must enable verification of the survey accuracy.
Rev. 4, Nov. 2000
All activities related to measurement and inspection of dimensions and tolerances shall take into
account the effects of self weight while the structure is under fabrication.
E.4.7 Interface criterias
All non-adjustable interfaces and interfaces deemed critical prior to erection shall be surveyed and
documented. A comparison of the interface results prior to erection shall be performed and
necessary actions in order to meet the global requirements shall be carried out.
E.4.8 Alignment Requirement
Requirements to alignments with regard to eccentricity of butt joints and cruciform joints are as
follows:
a) Butt-joints
Reference is made to table 9.3.
b) Cruciform Joints
Eccentricity of non-continuous plating in cruciform joints shall not exceed the following
requirements, (ref. figure 4.8-1)
e t
1
/2 (mm), maximum 5 mm, for t
2
20 mm
e t
1
/2 (mm), maximum 8 mm, for t
2
> 20 mm
t
1
= smaller thickness in mm of non-continuous plate
t
2
= thickness in mm of continuous plate
t
3
= larger thickness in mm of non-continuous plate
e = 2m + t
3
- t
1
2
m = misalignment
e = eccentricity
Fig. E.4.8-1 Cruciform joints
Rev. 4, Nov. 2000
E.5 FABRICATION TOLERANCES FOR STRUCTURAL COMPONENTS
E.5.1 I / H- Girders
Type of deviation Figure Nota-
tion
Ref.
Length
Allow % of
ref. length
Max.
Deviation mm
Lateral or vertical
deflection
5.1-1A f L 0.15 10
Length 5.1-1A L L 0.25 3
Height 5.1-1B H H 0.3 3
Width 5.1-1B B B 3
Inclination of web 5.1-1B V H 0.8 10
Eccentricity of web
on flange
5.1-1B V
1
H 1.0 3
Buckling of web 5.1-1B V
3
H 0.75 10
Curvature/rotation
flange
5.1-1B V
2
B/2 2.5 3
Twisting of section 5.1-1C d
5
L 0.10 10
Fig. E.5.1-1 I-/H-Girders tolerance references
Rev. 4, Nov. 2000
E.5.2 Box Girders
Type of deviation Figure Notation Ref. Length Allow % of
ref. Length
Max Dev.
mm
Position deviation at
end/interface section
5.2-1A d1 Ref. Centre
Lines
- 3
Length 5.1-1A L L 0.25 3
Height 5.1-1B H H 0.3 3
Width 5.1-1B B B 3
Out of straightness 5.2-1B d2 L 0.15 10
Buckling of plates 5.2-1C d3 H, W 0.5 10
Pos. deviation of load
bearing stiffeners
inclusive inclination
5.2-1D d4 Ref. Centre
Lines
- 5
Twisting 5.2-1E d5 H 0,5 6
Fig. E.5.2-1 Box Girders tolerance references
Rev. 4, Nov. 2000
E.5.3 Tubulars
The allowable tolerance given for individual tubular segments shall not be cumulative for the
finished tubular.
a) Circumference:
The external circumference shall not depart from the nominal external circumference by more than
the following (Ref. Figure 5.3-1):
Measured at joints or within 610 mm from the joint (Zone A in Figure 5.3-1):
of the nominal wall thickness or 10 mm whichever is the smallest.
The tolerances in (i) may be increased by 50% for the remaining length of the tubular (Zone B in
Figure 5.3-1).
b) Out-of Roundness (Ovality):
Ovality is defined as the difference between the measured maximum and minimum internal (or
external) diameters and shall not be more than 1% of the nominal OD (OD
n
) or 8 mm, whichever is
the least. (Ref. Figure 5.3-2)
c) Out of circularity:
Circularity is defined as the difference between the actual and the average radius, both beeing
determined from the optimum centre of the tubular. Maximum difference is not to be more than
0.25% of OD
n
.
d) Straightness:
The maximum allowable deviation from straightness in any 3 m increment of length shall be 3 mm.
The straightness deviation over tube length (L), shall not exceed 0.001 x L, with maximum 10 mm
deviation for lengths up to 12 m. Above 12 m length max. allowable deviation is 12 mm. Out of
straightness shall be checked on two longitudinal planes separated by 90.
e) Length:
Unless otherwise noted, the tubular shall be delivered within following tolerances:
Unbevelled ends: L
a
L
n
+25 mm
Bevelled ends: L
a
= L
n
5 mm
f) Tube ends:
The tube ends shall be perpendicular to the longitudinal axis within the following tolerances:
Unbevelled ends: 5 mm
Bevelled ends: 3 mm
Rev. 4, Nov. 2000
g) Local out-of roundness:
The local out-of roundness shall not deviate from the theoretical curvature by more than e=0.002 x
OD
n
(ref. fig. 5.3-3). The local out-of roundness shall be measured inside or outside over 20 of the
circumference.
h) Local Out-Of Straightness:
Local straightness is defined as the deviation of the shell plate from a straight generator of length
(L) parallel to the true centre line of the tubular. This tolerance shall not exceed 20% of the wall
thickness. Local straightness shall be checked on the inside or outside of tubulars with a nominal
external diameter greater than 2000 mm or with a nominal external diameter to nominal wall
thickness ratio greater than 65. These checks shall be carried out at 45 intervals of arc with L= 3 m.
Above tubular tolerances apply to welded and not seamless tubulars.
Fig. E.5.3-1 Tubulars - Circumfential tolerance
Fig. E.5.3-2 Tubulars - Ovality tolerance
Rev. 4, Nov. 2000
Fig. E.5.3-3 Tubulars - Local out-of roundness references
Rev. 4, Nov. 2000
E.5.4 Panels
Type of deviation Figure Notation Ref. Allow. % Max. dev. mm
PANEL SHEET:
Out of plane straightness,
sagging/hogging, between
girders
5.4-1 p1 W 0.15 15
Local buckles between
stiffeners 5.4-1 p2 W1 0,5 5
GIRDERS/ STIFFENERS:
Out of straightness
in X and Y direction 5.4-1 g
1
W 0.15% 10
Position deviation 5.4-1 g2 Grid
system 10
Inclination 5.4-1 g3 Hg 0.8 10
Out of straightness of web
normal to web
(web buckles) 5.4-1 g4 Hg , W1 0.75 10
Fig. E.5.4-1 Deck panels tolerance references
Rev. 4, Nov. 2000
E.5.5 Girder Nodes
Type of deviation Figure Notation Ref. length Allow % of
ref. length
Max. deviation
mm
Position deviation of
interfaces
5.5-1B,
5.5-1C
d1 Ref. Centre
Line
- 5
Lateral and vertical
straightness of node
5.5-1A f L 0.15 5
Lateral and vertical
straightness of stiffeners
5.5-1A f1 L,H 0.1 5
Height of node 5.5-1B s - - 5
Pos. deviation stiffeners
inclusive inclination
5.5-1B,
5.5-1C
d2 Ref. Centre
Line
- 5
Position deviation
column interfaces
5.5-1C d3 Ref.Centre
Line
- 5
Baseplate flatness
/rotation rel.to Z axis
5.5-1A,
5.5-1B
b1 Ref. Centre
Line
- 2
Pos.deviation baseplate
relative to Z axis
5.5-1B d4 Ref.Centre
Line
- 3
Fig. E.5.5-1 Girder nodes tolerance references
Rev. 4, Nov. 2000
Fig. E.5.5-1 Girder nodes tolerances
Rev. 4, Nov. 2000
E.5.6 Box Nodes
Type of deviation Figure Notation Ref. Length Allow of
ref. length
Max. deviation
mm
Position deviation of main box
interface
5.6-1A d1 Ref. Centre
Line
- 3
Out of straightness 5.6-1B d2 L 0,10% 10
Buckling of plates 5.6-1C d3 H, W 0,5% 10
Radial and tangential stub end
deviation
5.6-1C,
5.6-1E
d4 Ref. Centre
Line
- 5
Pos. deviation of load bearing
stiffeners incl. inclination
5.6-1D d5 Ref. Centre
line
- 5
Offset of centrelines at centre
of node
5.6-1E,
5.6-1F
d6 Ref. Centre
Line
- 5
Fig. E.5.6.1 Box nodes tolerance references
Rev. 4, Nov. 2000
E.5.7 Tubular Nodes
Type of deviation Figure Notation Ref. length Allow of
ref. length
Max.
deviation
mm
Overlength of stub 5.7-1A l2 L2 +25
-0
Overlength of node can barrel 5.7-1A l1 L1 +10
-0
Stub ends perpendicularity 5.7-1A p - 3
Radial and tangential stub end/
node cans position
5.7-2 V Grid
system
0.2 of arc 6
Position of intersection point
node can / stub
5.7-2 E Grid
system
6
Internal stiffeners
-Position
-Inclination of web
-Flange width
-Bow of web
-Rotation of flange
-Eccentricity of flange
on web
-Height of stiffeners
5.7-1A
5.7-1B
5.7-1B
5.7-1C
5.7-1B
5.7-1B
5.7-1B
P
M
B
N
Lx
h
b
1,0%
1,5%
1,0%
5
5
3
6
6
6
+10/-3
Local straightness of
stubs/barrel
5.7-1A Wall
thickness
25% 8
Straightness of barrel 5.7-1A L 1/1200 10
The centre line of stub shall be within 0.2 from the stub angle specified on the design drawings.
Maximum position deviation measured at the intersection of stub end / node can shall be 6 mm.
For stubs longer than 1 stub diameter, the position deviation between can and stub may be taken at
the 1 diameter location.
Tolerance for:
Circumference
Out-of Roundness (Ovality)
Local out-of roundness
Out-of circularity
are defined in Section E.5.3
Rev. 4, Nov. 2000
Fig. A
Fig. B (tolerance references)
Fig. C (tolerance references - internal stiffeners)
Fig. E.5.7-1 Tubular nodes
Rev. 4, Nov. 2000
Fig. E.5.7-2 Node stub location
E.5.8 Cast and Forged Elements
All relevant tolerances regarding these elements geometry i.e. hole positions, flatness, web and rib
positions shall be specified on the design drawings.
The nominal axes, work points, rib centrelines etc. shall be properly marked on each element
interface(s) to adjacent main steel.
Rev. 4, Nov. 2000
During installation of cast and forged items, special care shall be taken that the parent plate edges
are located within prepared face of casting / forging.
See also ISO-8062 standard for tolerances.
E.5.9 Curved and cylindrical shell
For elements including curved shells (such as semi submersibles pontoons) special dimensional
procedures shall be implemented for measurement and computing.
Sylindrical shells.
The maximum deviation from the nominal radius, measured at ringstiffeners or at bulkheads shall
not exceed the value:
= | r
a
- r| <= 0,005 r
r
a
= actual distance from the cylinder axis to the shell wall
r = nominal radius of the shell
Components defined as Cylindrical Shell to be specified on design drawings.
E.5.10 Conical transitions
At both ends of a cone, the maximum deviation from the nominal radius shall not exceed the value:
=| r
a
- r| <= 0,005 r
where r
a
= Actual distance from the cylinder axis to the cone wall
r = Nominal radius at cone end
Requirements for internal stiffeners shall be in accordance with table 5.7.
Rev. 4, Nov. 2000
E.6 ASSEMBLY TOLERANCES
E.6.1 Topsides and modules
Type of deviation Figure Notation Ref. Allowable
% of ref.
length
Max.
deviation
mm
Position of any point of main
steel
6.1-1 X1,Y1 Grid system 10
Position of support node 2) 6.1-1 X2, Y2,
Z2
Grid system 6
Position of lifting node 6.1-1 X2, Y2,
Z2
Grid system 10
Elevation of decks and mezz.
decks sag./hog.
6.1-1 H1, H2,
H3
Grid system 10
Footings deviation from
elevation reference 1)
6.1-1 H Grid system 5
For truss frames without any defined support points the elevation reference should be based on a
mean of all levelled points on main steel.
NOTES:
1) Maximum allowable deviation shall also apply to mating surface level at stab-in onto
jacket legs.
2) Includes Main Support Frame (MSF) stab-in nodes and module footing nodes.
Fig. E.6.1-1 Topside and module tolerance references
Rev. 4, Nov. 2000
E.6.2 Jacket and other tubular frame structures
E.6.2.1 Assembly tolerances
Type of deviation Figure Notation Ref. Max. dev. mm
Position deviation
of centre of nodes 6.2.1-A
x, y Grid system 12
Rotation of node 6.2.1-A S 6
Distance deviation
between two nodes
6.2.1-A 20
Diagonal distance
between coloumn
in each hor. plane
12
Position of leg
ring stiffeners and
diaphragms 6
Inclination of
ringstiffeners 6
Straightness of
legs / chords 6.2.1-B/C f L X10
Straightness of
braces 6.2.1-C f L XL/1000
Position of
intersecting braces Grid system 15
NOTE: Local tolerances for sliding and pivoting ends shall be specified on the structural drawings.
Rev. 4, Nov. 2000
Fig. E.6.2-1 Jacket and tubular frame structures - assembly tolerances
Rev. 4, Nov. 2000
E.6.2.2 Final Tolerances for Jacket, Interface Jacket/MSF
Type of deviation Figure Notation Reference Max. dev.
mm
Horizontal position
deviation of centre of
stab-in cans
6.2.2 Vx, Vy
V =
(Vx+Vy)
Grid system
1)
6
8
Jacket:
Distance between centre
of column to centre of
any column at stab-in
cans
6.2.2 F L 12
Jacket:
Mating surface level at
stab-in
Grid system
2)
3
MSF:
Distance between centre
of column to centre of
any column at stab-in
cans
6.2.2 F L 6
Ovality of stab-in can As in section
E.5.3b
Horizontal position
deviation of caissons,
risers, J-tube
Grid system 6
NOTES:
1) The position of the stab-in cans shall, if the situation allowes, be related to the top-
side stab-in cones with the tolerances stated above.
2) The jacket legs shall by preference be cut within above tolerances after grout is cured.
If survey of the deck footings show out-of acceptable elevation/flatness tolerances, ref. Section
E.6.1, the measured deviations shall be considered incorporated when cutting the legs in order to
minimise loads due to differential settlements in footings.
Rev. 4, Nov. 2000
Fig. E.6.2-2 Final tolerance jacket interface jacket/MSF
E.6.2.3 Guides, Sleeves, Piles and clamps
The position deviation of the centre of pile guides/sleeves shall be 25 mm related to the
coordinate system.
Local alignment of sleeves 20 mm.
Radius of spacer plates 5 mm.
Rev. 4, Nov. 2000
E.6.2.4 Piles
Type of deviation Figure Notation Ref. Max. dev.
mm.
Length 100
Diameter between
spacerplates
6.2.4 d1 As specified on
drawing
Diameter in driving
head
6.2.4 d2 As specified on
drawing
End perpendicularity
in driving head
6.2.4 P As specified on
drawing
Pile markings 50
For general tolerances, see E.5.3 Tubulars.
Fig. E.6.2-4 Piles tolerance references
E.6.2.5 Conductor Guides
The position deviation of the centre of the conductor guides shall be 10 mm related to the
coordinate system for top el. and 15 mm for the other elevations related to the same coordinate
system.
The maximum deviation of any conductor guide from the optimised centreline through all conductor
guides, shall not vary more than 15 mm.
Rev. 4, Nov. 2000
E.6.2.6 Appurtenances
Caissons, J-tubes and risers.
Type of deviation Figure Notation Ref. Max.dev. mm
Length - - - 25
E.6.3 Floating production units
E.6.3.1 Semi submersibles and tension leg platforms
Overall hull / substructure tolerances:
Type of deviation Figure Ref. Max. dev. mm
Global position of column top /
bottom
6.3.1-1
6.3.1-2
Global
grid system 15
Distance between top / bottom
of two columns
6.3.1-1
6.3.1-2
30
Local position of column top /
bottom 6.3.1-3
Local
grid system 5
Fig. E.6.3.1-1 Semi submerisibles / tension leg platforms. Global tolerance
Rev. 4, Nov. 2000
Fig. E.6.3.1-2 Semi submerisibles / tension leg platforms. Global tolerance
Fig. E.6.3.1-3 Semi submerisibles / tension leg platforms. Local tolerance
E.6.3.2 Ship
Ships should be fabricated using a grid system with origo in the aft perpendicular, and in accordance
with section E.3 of this annex. Based on the grid system a reference system according to section
E.4.6.1 should be permanently marked onboard the ship.
E.6.4 Subsea structures
Subsea structures should be fabricated according to tolerances given on drawings.
Rev. 4, Nov. 2000
E.7 FABRICATION TOLERANCES FOR SPECIAL ITEMS
E.7.1 Crane Pedestal
Crane pedestal tolerances shall be specified in a separate document to be prepared by the designer,
taking into account the structural aspects as well as the mechanical functional tolerances and
equipment interface tolerances.
E.7.2 Skid Beams
Skid beam tolerances shall be specified in a separate document to be prepared by the designer,
taking into account the structural aspects as well as the mechanical functional tolerances and
equipment interface tolerances.
E.7.3 Outfitting Structure
This section covers all primary and secondary outfitting structures.
The difference in elevation of deck plates and/or grating at joints shall not exceed 2 mm.
Plates and gratings shall be without visible warping.
Landing and stairway locations shall not deviate more than 25 mm from the dimensions shown
on the AFC drawings.
Fabrication of handrails shall be performed to such a degree of accuracy that when erected, the
toprail shall be continuous, straight, have smooth transitions and be level to the eye.
Members in the vertical plane shall not be out of plumb by more than 6 mm on each 3000 mm
section and not more than 26 mm over the total height of the structure.
Wherever tolerances are not shown on the drawings, or specified elsewhere, fabrication work
shall be accurate to within 10 mm of all nominal dimensions.
Matching holes for bolted connections shall not exceed 2 mm difference in location.
E.7.4 Installation Aids
Installation aid structures such as primary and secondary guides and bumpers shall be fabricated and
installed in accordance with acceptable tolerances for relevant elements/structures defined in this
document.
Specific tolerance requirements are shown on respective drawings, and shall be mandatory.
E.7.5 Grillages
Load out grillage, barge grillage and seafastening shall be fabricated and installed in accordance
with acceptable tolerances for relevant structures/elements defined in this document.
(Ref. section E.4.8)
Specific tolerance requirements shall be shown on respective drawings and shall be mandatory.
E.7.6 Cranes
Reference standard: ENV 1090-1 applies.

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