Structural Steel Fabrication Norsok Standard M101

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 eIIort has been made to ensure the accuracy oI this standard, neither OLF nor TBL or
any oI their members will assume liability Ior any use thereoI. NTS is responsible Ior the
administration and publication oI 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: norsoknts.no Website: http://www.nts.no/norsok
Copyrights reserved
Structural steel Iabrication M-101
Rev. 4, Dec. 2000
NORSOK standard Page 1 oI 36
CONTENTS
FOREWORD 3
INTRODUCTION 3
1 SCOPE 4
2 NORMATIVE REFERENCES 4
3 DEFINITIONS AND ABBREVIATIONS 5
3.1 DeIinitions 5
3.2 Abbreviations 5
4 SELECTION OF STEELS 6
4.1 Design classes 6
4.2 Selection oI steel quality level 6
5 QUALIFICATION OF WELDING PROCEDURES AND WELDERS 6
5.1 Welding procedure speciIication (WPS) 6
5.2 QualiIication oI welding procedures 6
5.3 Welding procedure approval record (WPAR) - Range oI approval 7
5.4 Examination oI the test weld 8
5.5 Welder and welding operators qualiIications 11
6 FABRICATION AND WELDING REQUIREMENTS 11
6.1 General 11
6.2 Forming 11
6.3 Assembly 12
6.4 Preparation Ior coatings 13
6.5 Preparation and Iit-up oI 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 QualiIication oI inspectors and NDT-operators 18
9.3 Extent oI visual examination and NDT 19
9.4 Visual examination and Iinish oI 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 DeIinitions 28
10.2 Correction oI welds containing deIects 28
10.3 Repair by welding 28
10.4 Repair welding procedure 29
10.5 Correction oI 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 oI the Norwegian oIIshore sector) is the industry initiative to
add value, reduce cost and lead time and eliminate unnecessary activities in oIIshore Iield
developments and operations.
The NORSOK standards are developed by the Norwegian petroleum industry as a part oI the
NORSOK initiative and supported by OLF (The Norwegian Oil Industry Association) and TBL
(Federation oI Norwegian ManuIacturing Industries). NORSOK standards are administered and
issued by NTS (Norwegian Technology Center).
The purpose oI NORSOK standards is to contribute to meet the NORSOK goals, e.g. to develop
standards that ensure adequate saIety, value adding and cost eIIectiveness and thus are used in
existing and Iuture petroleum industry developments.
The NORSOK standards make extensive reIerences to international standards. Where relevant, the
contents oI 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 inIormative. Annexes B, C, D and E are normative.
INTRODUCTION
Revision 4 oI this standard has been necessary due to regulations in new design standard N 004 and
new designation oI steel grades. In addition a steel grade with SMYS 690 is introduced with
additional requirements to Iabrication.
Rev. 4, Dec. 2000
1 SCOPE
This standard covers the requirements Ior Iabrication and inspection oI oIIshore steel structures with
SMYS 500 MPa and with a minimum design temperature down to -14!C. For special application
steels with SMYS up to 690 MPa may be used.
Note: For highly Iatigue utilized structures, more severe requirements may apply, and these will be
shown on the design drawings.
2 NORMATIVE REFERENCES
The Iollowing standards include provisions which, through reIerence in this text, constitute
provisions oI this NORSOK standard. Latest issue oI the reIerences shall be used unless otherwise
agreed. Other recognized standards may be used provided it can be shown that they meet or exceed
the requirements oI the standards reIerenced below.
API 2B SpeciIication Ior Iabricated structural steel pipe.
API RP 2X Ultrasonic examination oI oIIshore structural Iabrications.
ASME, Section V Non-destructive testing.
BS 7448, Part 1 Fracture mechanics toughness tests.
BS 7910 Guide on methods Ior assessing the acceptability oI Ilaws in Iusion
welded structures.
DNV RP D404 Unstable Iracture.
EN 287-1 Approval testing oI welders - Fusion welding.
EN 288-series SpeciIication and qualiIication oI welding procedures Ior metallic
materials.
EN 444 NDT - General principles Ior radiographic examination oI metallic
materials by X-rays and gamma rays.
EN 462-series NDT - Image quality oI radiographs.
EN 473 QualiIication and certiIication oI NDT personnel - General principles.
EN 719 Welding coordination - Tasks and responsibilities.
EN 729-series Quality requirements Ior welding - Fusion welding oI metallic materials.
EN 875 Welding - Welded joints in metallic materials - Specimen location and
notch orientation Ior impact tests.
EN 970 Welding - Visual examination oI Iusion welded joints.
EN 1011-series Welding - Recommendation Ior welding oI metallic materials, relevant
parts.
EN 1289 Non destructive examination oI welds - Penetrant testing oI welds -
Acceptance levels.
EN 1290 NDT oI welds - Magnetic particle examination oI welds - .
Rev. 4, Dec. 2000
EN 1291 NDT oI welds - Magnetic particle examination oI welds - Acceptance
levels.
EN 1418 Welding personnel - Approval testing Ior Iully mechanised and automatic
welding.
EN 1435 Non destructive examination oI welds - Radiographic examination oI
welded joints.
EN 1597-1 Welding consumables - Test methods - Part 1: Test piece Ior all weld
metal test specimens in steel, nickel and nickel alloys.
EN 1714 Non destructive examination oI welds - Ultrasonic examination oI
welded joints.
EN 10204 Metallic products - Types oI inspection documents.
prEN 10225 Weldable structural steels Ior Iixed oIIshore structures.
EN 26847 Covered electrodes Ior manual metal arc welding.
Deposition oI a weld pad Ior chemical analysis.
ISO 3690 Welding - Determination oI hydrogen indeposited weld metal arising
Irom the use oI covered electrodes Ior welding mild and low alloy steels.
ISO 5817 (EN 25817) Arc welded joints in steel - Guidance on quality levels Ior imperIections.
NORSOK M-001 Material selection
NORSOK M-120 Material data sheets Ior structural steel
NORSOK N-001 Structural design
NORSOK N-004 Design oI steel structures
NS 477 Welding. Rules Ior approval oI welding inspectors.
3 DEFINITIONS AND ABBREVIATIONS
3.1 Definitions
Normative reIerences Shall mean normative in the application oI NORSOK standards.
InIormative reIerences Shall mean inIormative in the application oI NORSOK standards.
Shall Shall is an absolute requirement which shall be Iollowed strictly in order
to conIorm with the standard.
Should Should is a recommendation. Alternative solutions having the same
Iunctionality and quality are acceptable.
May May indicates a course oI action that is permissible within the limits oI
the standard (a permission).
Can Can is conditional and indicates a possibility open to the user oI 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 Ir Normung
Rev. 4, Dec. 2000
DNV Det Norske Veritas
EN (pr EN) European Standard (proposal Ior EN)
FCAW Flux Cored Arc Welding
FSH Full Screen Height
HAZ Heat AIIected Zone
H
DM
Hydrogen content, deposit metal
IIW International Institute oI Welding
ISO International Organization Ior Standardization
NDT Non Destructive Testing
MDS Material Data Sheet
MSF Module Support Frame
P
cm
Carbon equivalent (Parameter Ior crack, modiIied)
PWHT Post Weld Heat Treatment
SAW Submerged Arc Welding
SMYS SpeciIied Minimum Yield Strength
SQL Steel Quality Level
WPS Welding Procedure SpeciIication
WPAR Welding Procedure Approval Record
4 SELECTION OF STEELS
4.1 Design classes
The design classes will be decided by the designer and shall Iorm the basis Ior selection oI steel
quality level (SQL). ReIerence 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 oI a better steel quality level in Iabrication than the minimum required by the designer
shall not lead to more stringent requirements in Iabrication.
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 Ior structures requiring steel quality level I and II Ior all strength levels
and steel quality level III Ior SMYS " 355 MPa shall be qualiIied in accordance with EN 288 part 3
and the additional requirements in this standard.
The qualiIication is primarily valid Ior the workshop perIorming the welding tests, and other
workshops under the same technical and quality management. It may also be transIerred to and used
by a subcontractor, provided the principles oI 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 speciIied in EN 288 part 3, with the Iollowing
clariIications and modiIications:
a) Control oI heat input according to EN 288 part 3, section 8.4.7, shall apply. II an approval
testing have been perIormed at both a high and a low heat input level (with all speciIied
mechanical testing), then all intermediate heat inputs are also qualiIied.
b) When the steel to be welded has a P
cm
" 0.21, or a carbon content C " 0.13, then an increase
oI more than 0.02 P
cm
units or 0.03 carbon equivalent units (IIW Iormula) over the value on the
approval test shall require a new qualiIication test.
c) A change Irom wrought (rolled, Iorged) 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 manuIacturing technique Ior steel with SMYS " 400
MPa.
I) A change in groove angle more than 20 deg./-10 deg.
g) A qualiIication oI Iillet welds carried out on plate thickness equal to or greater than 30 mm,
applies Ior all plate and throat thicknesses. Single layer Iillet welds qualiIies multi-layer, but not
the converse.
h) CTOD testing shall be included in the qualiIication oI welding procedures Ior weldments with a
plate thickness above 50 mm Ior all strength levels Ior steel quality level I and II and Ior SMYS
~400 MPa Ior steel quality level III. CTOD testing shall be included in the qualiIication oI
welding procedures Ior weldments with a plate thickness below and equal 50 mm iI requested
by the designer Ior the speciIied steel quality level.
Testing shall be executed Irom as welded and PWHT weld assemblies as applicable, covering the
Iollowing combined conditions:
$ Full penetration buttweld with K-, or halI V -groove as deemed most representative Ior the
actual Iabrication. V and X groove are acceptable Ior weld metal test..
$ A welding procedure representing the maximum heat input to be used in Iabrication.
$ Maximum joint thickness (within 10).
Assemblies shall be made and tested Ior the actual combination oI steel manuIacturer, welding
process and welding consumable (brand) used, except welding consumables used Ior root passes
only, provided these are removed completely by gouging and grinding.
Note: The changes speciIied in d) and e) need not require re-qualiIication iI HAZ properties Ior the
material to be welded have been documented Irom the steel manuIacturer Ior relevant thicknesses
and heat input ranges. II suIIicient documentation Irom the steel manuIacturer is not available, a
change oI material shall require re-qualiIication oI a reduced number oI procedures. The number oI
procedures to be re-qualiIied shall be suIIicient to veriIy that the HAZ properties oI the new
material is comparable with that used Ior the previous qualiIications.
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 Iollowing additional requirements apply Ior
welding oI steels with SMYS ~500 MPa
a) A change in steel manuIacturer.
b) CTOD testing as described in 5.3.1 h) shall be executed Ior thicknesses above 30 mm
c) Stress relieving iI required/speciIied by designer
d) When the steel to be welded has a Pcm " 0,21 or a carbon content " 0,13, then an increase oI
more than 0,03 Pcm or 0,04 carbon equivalent units (IIW Iormula) over the value oI the
approval test shall require a new qualiIication test.
5.4 Examination of the test weld
5.4.1 General
The type and number oI tests shall be in accordance with table 5.1. Testing shall be perIormed in
accordance with EN 288 and the additional requirements given below.
The test weld shall be 100 examined Ior both surIace and volumetric deIects with the relevant
NDT-methods. The soundness oI the weld shall comply with clause 9.
Rev. 4, Dec. 2000
Table 5.1 Type and number of tests
Mechanical testing
1oint
configuration
1oint
thickness
(mm)
Tensile
test
Bend
tests
1)
Charpy
V-notch
tests
Hardness
and
macro
5)
CTOD
Buttwelds
(Tubulars and
plates)
t50
t"50
2
2
2
2
4 sets
6 sets
1
1
ReI. 5.3.1h
and 5.4.4
T-joints
(plates)
4)
t50
t"50
3)
3)
4 sets
2)
6 sets
2
2
Tubular joints
4)
t50
t"50
3)
3)
4 sets
2)
6 sets
2
2
Fillet welds All 2
Notes:
1. Bend tests shall consist oI 1 Iace and 1 root bend specimen Ior t 20 mm and 2 side
bend specimens Ior t " 20 mm
2. II the dimensions oI 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 qualiIied Ior the joint.
3. It shall be documented on a butt weld test that the welding consumable used will have
suIIicient tensile strength.
4. T-joints on plates qualiIy Ior 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 oI
EN 288. For SMYS 690 MPa max 400 HV10 shall apply.
5.4.2 Charpy V-notch testing
Sampling oI 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 surIace oI the material.) (Designation in parenthesis reIers to EN 875).
$ Notch in centre oI weld (VWT 0/2)
$ Notch in Iusion line (VHT 0/2)
$ Notch in HAZ, 2 mm Irom Iusion line (VHT 2/2)
$ Notch in HAZ, 5 mm Irom Iusion line (VHT 5/2)
For welds with a joint thickness oI 50 mm or more, two additional sets oI Charpy V-notch tests
shall be taken Irom the root area, with the notch in the Iollowing positions:
$ Notch in centre oI weld (VWT 0/b)
$ Notch in Iusion 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 0!C -20!C -20!C 0!C -0!C -20!C -0!C 0!C
12 t # 25 -20!C -40!C -40!C 0!C -20!C -40!C 0!C -20!C
25 t # 50 -40!C -40!C -40!C -20!C -40!C -40!C -20!C -40!C
t ~ 50 -40!C -40!C -40!C -40!C -40!C -40!C -40!C -40!C
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 oI
the minimum average value. Reduction Iactors oI energy requirements Ior 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 Iracture shall be located outside the
weld metal (i.e. max. 20 oI the Iracture surIace shall consist oI 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 Ior each test position.
CTOD-testing oI welds shall be carried out with the Iatigue notch tip positioned in the coarse
grained region oI the heat aIIected zone and in the weld metal. For HAZ, determination oI the actual
location oI the Iatigue crack tip shall be perIormed aIter testing. ReI. is made to prEN 10225.
Note: Test assemblies may be given hydrogen diIIusion treatment prior to testing, and specimens
may be precompressed.
II not speciIied otherwise, the test temperature Ior design temperature down to -14 C shall be:
-10 C Ior splash zone or above.
0 C Ior submerged parts.
Other test temperature may be prescribed by the designer.
Three (3) valid test specimens shall be obtained Ior each notch location.
The requirement Ior minimum CTOD value shall be prescribed by the designer. II not speciIied, the
requirement Ior minimum CTOD value shall be as Ior the steel purchase order.
CTOD-testing oI HAZ can be omitted iI relevant CTOD properties in HAZ have been documented
previously in accordance with requirements in this standard, provided the requirements Ior the
essential variables are met.
Rev. 4, Dec. 2000
CTOD-testing oI weld metal can be omitted iI relevant CTOD properties in WM have been
documented previously in accordance with requirements in this standard, provided the requirements
Ior the essential variables are met.
The required Iracture toughness level shall be decided in design Ior joints when steel quality level I
and II are required. Testing is normally not requested Ior structures with plate thickness below 40
mm Ior SMYS#500 MPa or Ior structures with plate thicknes below 25 mm Ior SMYS~500 MPa.
5.5 Welder and welding operators qualifications
The welders, welding operators and tack welders shall be qualiIied in accordance with EN 287, EN
1418 or equivalent. For tack welders, an internal test may be used.
For welding oI single sided acute angled tubular joints with & 70, welders shall be qualiIied with
a realistic joint, representing the minimum angle & to be used in production.
For welding oI joints where steel quality level IV is selected, a certiIicate Ior welding oI plates in
position PE is suIIicient Ior welding all product Iorms.
6 FABRICATION AND WELDING REQUIREMENTS
6.1 General
All welding work shall be according to recommendations given in relevant part oI EN 1011. The
manuIacturer shall have a quality system, which IulIil the relevant part oI EN 729 and the applicable
level oI EN 719.
The Iabricator shall apply a weld numbering system Ior identiIication on all shop drawings and as
reIerence in all documentation.
6.2 Forming
Cold Iorming oI steel (i.e. Iorming below 250!C) shall be carried out within the deIormation range
recommended by the steel manuIacturer. For steel quality level I and II, the deIormation limit
without documentation oI mechanical properties is 5.
II the deIormation is more than the above given limits, either heat treatment shall be perIormed, or
strain ageing tests shall be carried out according to the Iollowing procedure:
$ The material shall be permanently strained locally to the actual deIormation.
$ The material shall be artiIicially aged at 250!C Ior 1 hour.
$ One set oI 3 impact test specimens shall be tested Irom the base material in the strained plus
artiIicially aged condition. The notch shall be located within the plastically strained portion oI the
material, in the part oI the cross section which have received the highest strain.
$ The impact testing temperature shall be as speciIied Ior the actual steel grade in question.
$ The Charpy-V impact value shall comply with the minimum requirements Ior the steel grade and
shall not be more than 25 lower than the impact value Ior the material beIore deIormation and
strain ageing.
Rev. 4, Dec. 2000
II Iorming is perIormed at temperature above 250!C, it shall be documented that the base material
properties, weldability, weldmetal and HAZ properties satisIy the actual MDS and this standard.
The percentage strain due to Iorming is deIined as Iollows:
100 x
diameter thickness mid Forming
thickness Wall
strain Percent '
6.3 Assembly
6.3.1 General
In tubular joints, circumIerential and longitudinal weld joints should not be placed in the shaded
areas shown in Iig. 6.1, unless otherwise shown on design drawings.
W 1
W 1
W 1
W 1
W 2
D
W 2
W 2
W 2
Longitudinal welds CircumIerential 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 oI welds in tubular joints. Longitudinal respectively circumIerential
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. II no
other requirements are speciIied, a tapering oI 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 aIter Iabrication or assembly shall be sealed oII Irom
the outside atmosphere. Seal welds shall have a throat thickness oI 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
reIitting 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 satisIy the speciIied requirements aIter straightening.
Maximum temperature Ior straightening shall not exceed the temperature limit recommended by the
steel manuIacturer, but it shall in no case be higher than 600!C.
6.3.8 Doubler plates
All temporary attachments which shall be Ilame 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 oI 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 oI 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 manuIacturers shall ensure that welding consumables applied Ior joints where steel quality level
I, II and III are required, meet the requirements Ior mechanical properties as speciIied Ior the
welding procedure qualiIication, 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 oI batch certiIication against accepted supplier data sheets,
see annex C.
$ For steels with SMYS " 500 MPa Annex D is mandatory
Except Ior solid wires such consumables shall be classiIied by the supplier as extra low hydrogen,
i.e. H
DM
# 5ml/100g weld metal. For selI shielded Ilux 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 veriIy that selected
consumables comply with hydrogen requirements. Stricter requirements than given above may be
relevant. PrequaliIication with mock-up structures shall apply iI there is a risk Ior high restraint in
welding or erection.
Consumables Ior joints in steel quality level III (with SMYS 355MPa) and IV and Ior joining
stainless to carbon steel shall be selected with due consideration oI base material properties,
thickness and weldability, to ensure suIIicient weld strength, toughness and homogenity.Such
consumables shall be delivered with EN 10204 type 2.2 certiIicate, as a minimum.
All welding consumables shall be individually marked.
When certiIication according to Annex C is used, welding consumables (except welding Iluxes)
shall be supplied with an inspection certiIicate (type 3.1B) in accordance with EN 10204, including
a statement oI compliance with the Welding Consumable Data Sheet and the chemical composition
oI the weld deposit (elements oI the data sheet). Welding Iluxes shall be supplied with a test report
(EN 10204 type 2.2), declaring conIormity 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 Ior preheating.
The minimum interpass temperature shall not drop below the minimum required preheat
temperature. II not otherwise stated in the WPS, and qualiIied by the WPAR, the maximum
interpass temperature shall not exceed 250!C measured at the edge oI the groove. For C- and C/Mn-
steels, a maximum interpass temperature oI 250C may be used, even iI a lower temperature was
recorded on the WPAR.
The preheat temperatures used during repair welding should be minimum 50!C higher than the
preheat used Ior the original weld.
Rev. 4, Dec. 2000
Note: Production welding oI high strength steels with SMYS~500 MPa is normally more sensitive
to hydrogen cracking than experienced during welding Ior qualiIication. Special precautions,
including preheating temperature, minimum holding temperature and extended post weld holding
temperature Ior 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 Ior all strength levels, or steel quality level III
Ior SMYS ~ 400 MPa are required shall, whenever possible, be welded Irom both sides.
II any welding is conducted aIter PWHT, the PWHT shall be repeated.
For joints in inspection category A, the straight edges oI K- and
1
/
2
V-butt weld grooves shall have
a groove angle oI at least 10
O
, unless it is documented that possible deIects can be detected by the
UT technique used . (For K-grooves, the 10
O
should be machined Irom the root to each plate
surIace.)
Any occurrence oI cracking during production welding shall be investigated. Welding should be
suspended until the cause oI cracks and deIects has been identiIied and measures taken to prevent
their reoccurrence. Cracks or other persistent weld deIects may lead to revision and requaliIication
oI the WPS.
6.9.2 Attachments
Temporary attachments as liIting lugs, lugs Ior scaIIolding and assembly, supports Ior cables,
equipment, ladders or other Iabrication and erection aids should be removed. II indicated on design
drawings that removal (Iull or partial) is not required, the temporary attachments may be leIt as is,
or removed only partially.
All welding oI attachments shall comply with the requirements Ior the structure to which they are
attached. Temporary attachments shall be cut minimum 3 mm Irom 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 Ior various purposes.
Requirements Ior welding and testing oI stainless outIitting structures shall Iollow similar
classiIication principles as Ior other structural steel elements. All welding and testing oI welds to
carbon steel structures shall as a minimum comply with the requirements Ior the structure to which
they are attached.
Unless other requirements apply higher alloyed consumables than given Ior the relevant stainless
component shall be selected Ior tacking and Iinal welding.
Rev. 4, Dec. 2000
6.10 Post weld heat treatment (PWHT)
PWHT shall be required Ior structural welds in steel quality level I or II, or quality level III with
Re~400MPa, when the nominal thickness (as deIined in EN 288-3, section 8.3.2.1) exceeds 50 mm,
unless adequate Iracture toughness can be documented in the as welded conditions. For restrained
joints oI complicated design, PWHT may be required Ior smaller thicknesses, independent oI 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 Iacilities.
$ Insulation.
$ Control devices.
$ Recording equipment.
$ ConIiguration oI structure to be PWHT or details iI local PWHT shall be carried out.
$ Number and location oI thermocouples to be used during PWHT.
The holding time and temperature shall be as recommended by the steel manuIacturer
The temperature diIIerence between diIIerent parts oI the structure during soaking time shall not
exceed 30!C within the heated area. Double sided heating shall be used as Iar as possible.
The temperatures shall be continuously and automatically recorded on a chart.
6.11 Grinding
When grinding is speciIied on design drawings or is instructed as a corrective action, the grinding
shall be perIormed according to a detailed procedure. Grinding tools, direction, surIace roughness
and Iinal proIile shall be speciIied. ReIerence samples Ior typical joints and sections may be
prepared and used Ior acceptance oI treated welds. Typical examples Ior requirements Ior grinding
oI joints are given in Annex A.
6.12 Peening
Weld improvement by peening shall be perIormed in accordance with detailed procedures.
Normally pregrinding oI a groove will be required to assure correct location oI peening area. Tools
Ior grinding and peening, surIace roughness and proIile oI grinding as well as peening shall be
speciIied. Tools Ior check and measurements shall be described and shall be available during
operations. Documentation oI correct perIormance shall include macrophotography. Typical
examples oI requirements Ior peening oI joints are given in Annex A.
Rev. 4, Dec. 2000
7 PRODUCTION TESTS
Production tests shall be selected on weldments in critical regions to veriIy that the speciIied
requirements have been meet. Minimum one test coupon is required Irom each applied welding
process.
Test coupons shall be welded in a manner which realistically simulates the actual production
welding, normally as extension oI the production weld, and meet the requirements Ior welding
procedure approval tests.
CTOD testing is not required Ior production testing.
II a production test Iails, the reason Ior the Iailure shall be determined and remedial action
implemented.
8 FABRICATION TOLERANCES
Fabrication tolerances shall be in accordance with Annex E, unless otherwise speciIied 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 speciIied on the design drawings.
Final inspection and NDT oI structural steel welds shall not be carried out beIore 48 hours aIter
completion except where PWHT is required. The time delay may be reduced to 24 hours Ior steel
grades with SMYS oI 355MPa or lower, and Ior steel grades with SMYS oI 420MPa or lower Ior
plate thicknesses below 40 mm, provided delayed cracking have not been observed Ior the materials
and/or welding consumables in question.
When PWHT is perIormed, the Iinal NDT shall be carried out when all heat treatment have been
completed.
Prior to Iabrication start-up, contractor shall implement a system Ior recording oI weld deIect rates.
The deIect rates shall be recorded on a weekly basis Irom each production area (geographically split
in production areas at the same yard) and shall be reported together with the accumulated deIect
rate. The deIect rate statistics shall be used as a tool in weld quality control. Causes Ior deIects shall
immediately be investigated and corrective actions shall be taken to prevent Iurther occurrence.
Cracks detected with any NDT method shall require documented investigation/action by the
responsible welding engineer.
At a weekly high deIect rate or at repeated occurrence oI planar deIects, two trigger levels apply Ior
extended NDT Ior welds in inspection category B, C and D. Two steps oI actions apply within
trigger level 2.
Rev. 4, Dec. 2000
Trigger level 1
II a deIect rate Ior any method exceed 10 Ior a single week the extent shall be increased to 100
Ior all welds in question irrelevant oI the required inspection category Ior the welds.
Trigger level 2
II a deIect rate Ior any method oI 5 - 10 Ior a single week is observed the Iollowing two steps oI
extended NDT shall apply:
Step 1.
A deIect rate Ior any NDT method exceeding 5 (1 Ior MT) Ior a single week require doubling
oI the extent oI NDT according to the inspection category. Spot extent shall be increased to 20 .
Step 2.
II the deIect rate Ior the weld length where the extended NDT is taken in accordance with Step 1
above exceed 5 , the extent shall be increased to 100 Ior all welds in question irrelevant oI the
required inspection category Ior the welds.
The increased NDT extent shall cover welds oI the same inspection categories, welded in the same
period oI time when the high deIect rate was produced, to assure that the weld quality is maintained
also with the lower extent oI NDT. Unless the causes Ior deIects Iound leads to immediate and
documented preventive actions, the higher level oI extent oI NDT shall be maintained until the
weekly deIect rate is well below 5 .
Generally, iI the deIect rate approaches 10 during any stage in production welding, Iurther
welding should be held until investigations are completed and corrective actions implemented.
A low deIect rate may be used as basis Ior a reduction in the extent oI NDT Ior inspection
categories B, C and D, provided that a correct deIect rate identiIication is prepared Ior each weld
method, each NDT method and each production area. See Note 2 in Table 9.1.
1)
welds) oI parts tested oI (Length
100) length x (DeIect
: as deIined is rate deIect The
Note 1: 'Tested part oI welds means the part that is tested with the same NDT method.
NDT aIter repair shall not be included when calculating the deIect rate.
9.2 Qualification of inspectors and NDT-operators
Personnel responsible Ior welding inspection - welding inspectors - shall be qualiIied in accordance
with NS 477 or equivalent scheme.
Personnel perIorming visual inspections oI welded joints shall be qualiIied in accordance with
relevant part oI EN 473/NORDTEST.
Personnel responsible Ior all NDT activities shall be qualiIied according to EN 473/NORDTEST
Level 3 or equivalent.
The NDT operators shall be qualiIied according to EN 473/NORDTEST Level 2 or equivalent.
Rev. 4, Dec. 2000
Operators simply producing radiographs and not perIorming evaluation, do not require level 2, but
shall have suIIicient training.
In undertaking testing oI castings or Iorgings the NDT operator should also document experience
with Iorged and cast products.
9.3 Extent of visual examination and NDT
The required minimum extent oI examination/testing is given in table 9.1. Design drawings may
show areas oI welds where testing is mandatory.
Testing perIormed shall be representative Ior the weld quality. Partial NDT shall normally be planed
Ior on all shop drawings.
Ultrasonic testing to reveal the presence oI possible weld metal transverse cracking shall be
included Ior butt welds with thickness more than 25 mm. The testing shall be perIormed on
minimum 5 oI welds in inspection category A and B Ior 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 oI
connection
Visual
examination
Extent oI 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 oI NDT shall be increased Ior Inspection categories B, C and D iI repeated
occurrence oI planar deIects are revealed or iI the weekly deIect rate Ior any NDT
method, including all types oI deIects, are as given Ior the limits below.
Trigger level 1 - DeIect rate exceeding 10 :
The extent shall be increased to 100 irrelevant oI inspection category.
Trigger level 2 - DeIect rate oI 10 and below calls Ior stepwise increase in extent:
Step 1 - DeIect rate exceeding 5 ( MT exceeding 1): The original extent shall be
doubled. Spot extent shall be increased to 20 .
Step 2 - DeIect rate Ior the extended testing under Step 1 exceed 5 : The extent shall
be increased to 100 oI the weld lengths in question Ior 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 oI the speciIied extent, based on experience and documented
records with similar joints, provided the deIect rate (see clause 10.1 and 11.1) Ior UT/RT is
2.0 and Ior MT is 0.2 during the last 100m oI weld. The last 100m shall be continuously
updated every week. II the deIect rate exceeds the limits given above, the normal extent oI NDT
shall apply again.
A possible reduction in the extent oI NDT shall be considered separately Ior each welding
method and each production area.
Rev. 4, Dec. 2000
When partial testing is deIined Ior 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 oI welds most
susceptible to weld deIects are covered.
The speciIied percentage to be tested in table 9.1 reIers to the total length oI welds in each
inspection category.
All WPS's used and welds representing all welding personnel involved in the Iabrication shall be
subject to NDT.
During the initial Iabrication the extent oI UT and MT oI inspection category B and C welds shall
be intensiIied, normally to twice the level given in table 9.1. This extent shall be maintained Ior a
weld and test length suIIicient to conclude that the weld repair percentage is at a reasonable level.
The increased initial testing may be accounted Ior in the overall extent provided the initial testing
conIirms consistent good workmanship.
In addition to what is listed in table 9.1, the Iollowing shall apply Ior inspection category A and B:
a) One Iilm at each end Ior longitudinal welds oI tubulars (including tubulars Ior nodes and stubs).
b) Where radiographic testing is required, intersection welds, and those locations where presence
oI deIects is deemed to be most harmIul, shall be tested.
c) Ultrasonic and radiographic testing shall not overlap, except when 100 UT is speciIied.
However, ambiguous imperIections revealed by UT shall in addition be tested by RT.
d) Ultrasonic testing is normally not applicable Ior thicknesses less than 10 mm. For such
thicknesses, UT may be replaced with RT. In general, RT should be considered iI UT is not
possible. Radiographic testing is normally not applicable Ior thicknesses above 40 mm.
e) MT shall be perIormed on both external and internal surIace 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 oI 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, iI gamma ray sources are used, the
sensitivity shall be 2 or better.
9.6 Ultrasonic testing
Ultrasonic testing oI welds in plate and tubular butt welds and double side welded tubular joints
shall be perIormed in accordance with EN 1714, examination level C.
ReIerence blocks shall be made with thickness and side-drilled holes in accordance with table 9.2.
DAC reIerence curves shall be established.
Rev. 4, Dec. 2000
The eIIective test range oI a DAC curve shall be determined by the point at which the curve has
Iallen to 25 FSH, when it will be necessary to raise the curve using reIlectors at increased depth.
The reIerence block shall be Irom a steel type that is representative Ior the steel to be inspected.
Where ultrasonic testing is to be perIormed on steel produced by controlled rolling or
thermomechanical treatment, reIerence blocks shall be produced both perpendicular to, and parallel
to, the direction oI rolling. The rolling direction shall be clearly identiIied.
The actual reIracted angle Ior each probe measured Irom the reIerence block or as measured on the
actual object being examined, shall be used when plotting indications.
A transIer correction between the reIerence block and the test surIace shall be perIormed.
Ultrasonic examination procedures shall be suIIiciently detailed to ensure 100 oI the weld body
and heat aIIected zones are examined Ior longitudinal deIects.
All indications exceeding 20 DAC shall be investigated to the extent that they can be evaluated in
terms oI 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 oI
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 oI the welded joint
prevents the use oI 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 oI good workmanship. The quality shall comply with the
requirements oI table 9.3.
9.8.3 Radiographs
The soundness oI the welded joint shall comply with the requirements oI table 9#4.
9.8.4 Ultrasonic testing acceptance criteria
The acceptance criteria Ior welds shall comply with table 9.5 unless more stringent requirements are
speciIied 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 oI table 9.3.
The same acceptance criteria applies Ior penetrant testing.
9.8.6 All methods
All deIects shall be repaired according to clause 10.
DeIects may be accepted by the relevant parties when repair work is considered detrimental to the
total integrity oI the weld. Such acceptance shall be based on a Iitness Ior purpose evaluation in
accordance with BS 7910 , DNV RP D404 or other recognised methods.
Table 9.2 Calibration reference block requirements
Thickness oI
material to be
examined (mm)
Thickness oI block Diameter oI hole Distance oI hole
Irom one surIace
10 t 50 40 or t O 3 mm /-0.2 mm
50 t 100 75 or t t/2 and t/4.
100 t 150 125 or t O 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 oI deIect Insp. cat. A, B Inspection category C, D, E
Cracks Not acceptable Not acceptable
Incomplete
penetration or lack
oI Iusion
Not acceptable Single - side weld:
Length t/2, max 10 mm
DeIects shall be regarded as a continuous
deIect iI 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
SurIace porosity
Exposed slag
Not acceptable Not acceptable. However, the Iollowing
deIects may be acceptable iI it does not
conIlict with surIace treatment requirements:
Accumulated pore diameters in any area oI 10
x 150 mm is not to exceed 15 mm. Max. size
oI a single pore is t/4 or 4 mm, whichever is
the smaller.
Concave root Max. concavity 0.5 mm iI the transition is smoothly Iormed.
Excessive pen.
1)
Max. 3 mm
Roughness oI weld
(Iig. 1)
'U shall be less than 2.5 mm. Weld surIace shall be smooth,
without sharp transitions. The bottom oI roughness in butt welds
shall not be below the base material surIace.
Misalignment oI
butt welds (Iig. 2)
Max. misalignment (M), 0.15 x t or max. 4 mm,
whichever is the smaller.
ReinIorcement oI
butt welds (Iig. 3)
1)
't less or equal to 10 Max reinIorcement 'C 2 mm
't greater than 10, up to 25 Max reinIorcement 'C 3 mm
't greater than 25, up to 50 Max reinIorcement 'C 4 mm
't greater than 50 Max reinIorcement 'C 5 mm
ReinIorcement oI
Iillet/partial pen.
welds (Iig.4)
1)
'a less or equal to 10 Max reinIorcement 'C 2 mm
'a greater than 10, up to 15 Max reinIorcement 'C 3 mm
'a greater than 15, up to 25 Max reinIorcement 'C 4 mm
'a greater than 25 Max reinIorcement 'C 5 mm
Symmetry oI Iillet
welds (Iig. 5)
'a less or equal to 6 Max diIIerence, b - h: 3 mm
'a greater than 6, up to 13 Max diIIerence, b - h: 5 mm
'a greater than 13 Max diIIerence, b - h: 8 mm
Grinding arc strikes
etc. Removal oI
temporary
attachments
2)
Grinding oI base material shall not exceed 7 oI the wall thickness
or max. 3 mm. Repair welding and inspection shall be perIormed iI
removal oI the base metal exceeds the speciIied requirements.
Sharp edges Minimum 2 mm radius (ReI. 6.4)
Rev. 4, Dec. 2000
Notes:
1) Localised reinIorcements exceeding the above requirements are acceptable.
2) Temporary attachments shall be cut min. 3 mm Irom the base metal and ground smooth.
The ground area shall be visually inspected and MT shall be perIormed in accordance
with the inspection category in question.
3) When required (reI. 6.11), grinding oI the surIace shall be speciIied. Typical examples oI
grinding requirements are given in annex A.
U
Fig. 1 Roughness oI weld
c
t
M
t
Fig. 2 Misalignment oI butt weld Fig.3 ReinIorcement oI butt weld
b
h
Fig. 4a Fig. 4b Fig. 5
ReinIorcement oI Iillet weld ReinIorcement oI partial pen. weld Symmetry oI Iillet weld
Rev. 4, Dec. 2000
Table 9.4 Structural steel welds, RT acceptance criteria
Type oI deIect 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 oI 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 oI Iusion
Length (Note 2) t, max. 25 mm 2t, max 50 mm
Cracks Not acceptable Not acceptable
Notes:
1) II more than one pore is located inside a circle oI diameter 3 times the pore diameter, the
pores are to be considered as a cluster.
2) DeIects in a line where the distance between the deIect is shorter than the longest deIect
shall be regarded as one continuous deIect.
3) No length limitation Ior width #2 mm Ior t "20 mm and Ior width #1 mm Ior 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 II the type oI deIect can not be ascertained with certainty the
deIect shall be repaired when the length exceeds 10 mm and the
echo height exceeds the reIerence curve.
1
2
3
4
Cracks Unambiguous cracks are unacceptable regardless oI size or
amplitude.
Lack oI
Iusion or
incomplete
penetration
Internal deIects :
I: The echo height exceeds the reIerence curve:
Max length t, Max length 2t,
max 25 mm max 50 mm
II: The echo height is between 50 and 100 oI the reIerence
curve:
Max length 2t, Max length 4t,
max 50 mm max 100 mm
SurIace deIects are not acceptable except:
For root deIects in single sided welds , the max length Ior which
the echo height exceeds the reIerence 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 reIerence curve:
Max length 2t" Max length 4t"
max 50 mm max 100 mm
1
2
Porosity Repair is required iI porosity may mask Ior other deIects. 1
Notes:
1. Type oI deIect shall be decided by:
I: Supplementary non-destructive testing.
II: The ultrasonic operator's assessment oI the deIect, using his knowledge oI the
welding process, signal geometry, deIect position etc.
2. II elongated deIects are situated on line and the distance between them is less than the
length oI the longest indication, the deIects shall be evaluated as one continuous deIect.
3. DeIect length shall be determined by the 6dB drop method Irom the end oI the deIect
(Ior deIects larger than the beam) or by the maximum amplitude technique (Ior deIects
smaller than the beam).
4. With UT perIormed Irom only one side oI the weld with only one surIace accessible, the
acceptable echo heights are reduced Irom 100 to 50 and Irom 50 to 20,
respectively.
5. With 'internal deIects it is meant deIects which are located more than 6 mm Irom the
nearest surIace. A deIect is classiIied as a 'surIace deIect iI any part oI the deIect is
located less than 6 mm or t/4, whichever is smaller, Irom the nearest surIace.
Rev. 4, Dec. 2000
10 REPAIR
10.1 Definitions
Weld discontinuities: Irregularities in the body oI the weld or on the weld surIace classiIied as either
weld imperIection or as weld deIect.
Weld imperIection: Discontinuities that are within the acceptance criteria deIined in clause 9 and
are considered to have no practical limitations on the intended use oI the product. Weld
imperIections may be leIt without remedial work. Cosmetic grinding may be perIormed at the
discretion oI the Iabricator.
Weld deIect: Discontinuity with a size and/or density that exceeds the acceptance criteria deIined 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 Ior the cracking has been determined.
II necessary, the deIective part oI the weld shall be cut out Ior Iurther examination. Crater cracks
may be repaired by grinding Iollowed by NDT and subsequent repair welding according to an
accepted repair welding procedure.
Other deIects shall be corrected by grinding, repair welding or re-welding.
When weld deIects are removed by grinding only, the Iinal weld surIace and the transition to the
base material shall be smooth. Removal oI deIects shall be veriIied by local visual inspection, aided
by applicable NDT methods. II applicable, the remaining thickness in the ground area shall be
measured. Repair welding is required iI the remaining thickness is less than that speciIied.
10.3 Repair by welding
10.3.1 Repair and re-repair welding
BeIore repair welding, the deIect shall be completely removed.
The excavated area shall have smooth transitions to the metal surIace and allow good access Ior
both NDT aIter excavation and subsequent repair welding. AIter excavation, complete removal oI
the deIect shall be conIirmed by MT or PT. PWHT shall be perIormed aIter repair iI speciIied Ior
the original weld.
The excavated groove shall be minimum 50 mm long, measured at deIect depth even iI the deIect
itselI is smaller. DeIects spaced less than 100 mm shall be repaired as one continuous deIect.
AIter 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 speciIied Ior 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 perIormed in accordance with the procedures and WPS utilised Ior the original
weld, and includes complete removal oI the original weld and HAZ.
10.4 Repair welding procedure
Repair and re-re-repair welding may be perIormed using the same WPS as Ior the original weld, or a
separately qualiIied procedure.
For repairs using a diIIerent process, and/or consumable, a separate WPS shall be qualiIied iI
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 WPAR`s.
10.5 Correction of distortion
Improperly Iitted parts should be cut apart and re-welded in accordance with the applicable qualiIied
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 JOlNT GRlNDlNG DETAlL
TYPlCAL GRlNDlNG DETAlLS
FOR HlGH FATlGUE UTlLlSATlON
T4= 2mm or 0,05 x T3 max.
(wichever is less)
Remove
sharp edges
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 JOlNT GRlNDlNG DETAlL
Notes to Iigures:
1. For removal oI undercuts the toe oI the weld should be blended in a smooth transition and
extended below the plate surIace in order to remove the toe deIects.
2. Grinding should extend below plate surIace to a minimum oI 0.5 mm below the bottom oI any
visible undercut and ensuring that no exposed deIects 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 oI weld proIiles aIter blending should not be less than 10 mm.
4. Upon completion oI blending oI toe the whole oI the ground surIace shall be inspected with
100 visual examination and 100 MT.
5. Ground surIace shall be Iree oI any cracks or cracklike indications, and there shall be no
evidence oI undercut or overlap.
Rev. 4, Dec. 2000
ANNEX A 2 - TYPICAL PEENING DETAILS FOR HIGH FATIGUE
UTILISATION (INFORMATIVE)
A.2.1 General
Peening oI local area as weld toe or weld trasition is an acceptable method to improve Iatigue liIe oI
structures. Peening is applied together with grinding where grinding serves the purposes to remove
stress risers such as surIace deIects and to deIine a steering grove Ior the tool in the area to be
peened. Both grinding and peening require skills and preparations not normally available in
Iabrication yards. Due to the dependancy oI correct perIormance speciIic precautions shall be taken
when peening is planned Ior.
A.2.2 Requirements for application
When peening is planned Ior the Iollowing preparations are required :
$ Nomination oI responsible engineer Ior preparations, perIormance 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 oI peening methods to be applied
$ Detailed mark up drawings showing all areas oI application
$ Detailed stepwise procedure Ior the work, including:
grinding details as tools, radius, depth and direction
tools to be used Ior peening
method, intensity and extent oI peening
quality control measures
documentation oI perIormance and results
$ VeriIication oI perIormance such as experiments, tests or other relevant inIormation
$ As built record index Ior the Iinal DFI resume
As preparation Ior peening the surIace shall be dressed in a way that makes lack oI coverage
detectable, preIerably by stone grinding. Applicable tool Ior grinding is normally a rotary burr or
stone oI 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 oI the groove is approximately 0.5 mm below the original surIace.
All surIace deIects shall be removed by grinding prior to peening.
Applicable tool Ior 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 oI minimum 200 . Single hammer peening shall
result in a Iully covered hammered groove where the surIace is smooth with uniIorm indentation.
All traces Irom previous grinding shall be completely removed.
Rev. 4, Dec. 2000
Devices Ior quality control and documentation shall be thoroughly selected. Groove depth
measuring tools and macro photo is normally applied. ReIerence specimens shall be prepared Ior
comparison between ground and Iinal peened surIaces.
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.
ReIerence
standard
Product type Steel grade Former Steel
grade
Y20 3 Plates S355G10N/G10M S355N4z/M4z
Y21 3 Rolled sections S355G12N/G12M S355N3z/M3z
Y22 3 Seamless tubulars S355G15Q/G15N S355Q3z/N3z
Y30 3 Plates S420G2Q/G2M S420Q3z/M3z
Y31 3 Rolled sections S420G4M S420M3z
Y32 3 prEN 10225 Seamless tubulars S420G6Q(mod) S420Q3 (z mod)
I Y40 3 Plates S460G2Q/G2M S460Q3zM3z
Y42 3 Seamless tubulars S460G6Q(mod) S460Q3(z-mod)
Y50 3 Plates S500G2Q/G2M S500Q3z/M3z
Y52 3 Seamless tubulars S500G6Q(mod) S500Q3(z-mod)
Y70 Plates S690Q
Y25 3 Plates S355G9N/G9M S355N4/M4
Y26 3 Rolled sections S355G11N/G11M S355N3/M3
Y27 3 Seamless tubulars S355G14Q/G14N S355Q3/N3
Y28 Welded tubulars S355G13N
Y35 3 Plates S420G1Q/G1M S420Q3/M3
Y36 3 Rolled sections S420G3M S420M3
Y37 3 Seamless tubulars S420G6Q S420Q3
II Y46 3 prEN 10225 Rolled sections S460G3M S460M3
Y56 3 Rolled sections S500G3M S500M3
Y70 Plates S690Q
Y05 EN 10113 Plates and sections S355NL/ML
Y06 prEN 10225 Tubulars S355G1N
III Y07 EN 10210 Hot Iinished tubulars S355NH
Y08 EN 10219 Cold Iormed tubulars S355MLH
Y15 En 10113 Plates and sections S420NL/ML
Y16 EN 10219 Cold Iormed tubulars S420MLH
S235JRG2
EN 10025 Plates and sections S275JR
S355J0
S235JRH
IV Y01 3 EN 10210 Hot Iinished tubulars S275J0H
S355J0H
S235JRH
EN 10219 Cold Iormed 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 oI certiIication is to veriIy that each batch oI consumables has a chemical composition
within limits as speciIied by the supplier in conIormance with a recognised classiIication standard.
By controlled and certiIied chemistry the supplier also conIirms that mechanical properties oI the
weld metal IulIil the minimum requirements speciIied Ior the product.
For this speciIication a batch (or lot) is deIined as the volume oI product identiIied by the supplier
under one unique batch/lot number, manuIactured in one continuous run Irom batch controlled raw
materials.
Each individual consumable (brand name and dimension) shall be certiIied per batch, except Ior
solid wire (GTAW, GMAW, SAW), originating Irom the same heat, where one diameter may
represent all.
C.2 DATA SHEET
Each welding consumable or combination oI 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 oI consumables upon reviewed and accepted data sheets.
The data sheet shall give guaranteed limits and/or minimum values Ior composition and mechanical
properties, determined under deIined reIerence conditions.
II the consumable shall be used Ior welds in PWHT condition, then the properties shall also be
documented in PWHT condition in addition to the as-welded condition.
SpeciIically this shall include, as applicable:
$ Chemical analysis limits Ior solid wires and metal powders. For inIormation also typical weld
metal analysis, using a relevant shielding gas or Ilux.
$ Chemical analysis limits oI weld metal Irom coated electrodes and cored wires, deposited
according to EN 26847. For inIormation also speciIied limits Ior S, P and N in the core wire or
strip.
The analysis shall include limits Ior all elements speciIied in the relevant classiIication standard
and/or intentionally added and Ior residual elements known to inIluence weld metal quality.
Minimum:
C, Si, Mn, S, P, Cu, Ni, Cr, Mo, V, Nb.
For SAW Iluxes the analysis shall be given as ranges Ior all main ingredient and Ilux basicity.
Rev. 4, Dec. 2000
$ Mechanical properties (range or/and guaranteed minimum) oI 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 inIormation also typical properties oI a relevant butt weld
should be added.
$ DiIIusible hydrogen content H
DM
max., including any inIormation on drying, restricted welding
parameters etc. required to ensure this value in practice.
$ When relevant Ior the product, basic inIormation about CTOD properties, to be supported by
separate test reports as required and agreed.
Data sheets shall also contain product classiIication according to recognised standards, relevant
approvals and inIormation on packing, storage etc. as required Ior correct application and use oI the
product.
C.3 CERTIFICATE
Every batch oI consumables shall be supplied with an inspection certiIicate 3.1.B, containing as a
minimum the speciIic tested chemical composition oI the wire or weld metal, as applicable. The
chemical elements shall conIorm to those oI the data sheets, with a statement 'below speciIied
maximum acceptable Ior residual elements.
The supplier may optionally add inIormation about mechanical properties, based on speciIic or non-
speciIic type oI control. (ReI. EN 10204). Other tests may also be agreed between supplier and
purchaser.
CertiIicates shall be actively used by the purchaser to control received consumables against the
accepted data sheet. Full conIormance oI chemical composition shall be required to release each
batch Ior Iabrication welding.
Rev. 4, Dec. 2000
ANNEX D - WELDING CONSUMABLE DOCUMENTED BY BATCH
TESTING (NORMATIVE)
D.1 SCOPE
The purpose oI the batch testing is to veriIy that the consumables remains nominally equivalent to
that used Ior welding procedure qualiIication, with respect to chemistry and mechanical properties.
For this speciIication a batch (or lot) is deIined as the volume oI product identiIied by the supplier
under one unique batch/lot number, manuIactured in one continuous run Irom batch controlled raw
materials.
Each individual product (brand name and dimensions) shall be tested once per batch, except Ior
solid wire originating Irom the same heat, where one diameter may represent all. SAW Iluxes do not
require individual testing, while SAW wires shall be tested in combination with a selected, nominal
batch oI Ilux.
Chemical Analysis
For solid wires and metal powders the analysis shall represent the product itselI.
For coated electrodes and cored wires the analysis shall represent the weld metal, deposited
according to EN 26847.
The analysis shall include:
$ All elements speciIied in the relevant classiIication standard and /or intentionally added.
$ The main impurities S, P and N.
D.2 MECHANICAL PROPERTIES
Unless otherwise speciIied 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 speciIied by purchaser.
The need Ior other types oI tests shall be evaluated Ior the application in question, such as:
$ Mechanical properties based on a deIined butt weld rather than all weld metal test.
$ Mechanical properties in the PWHT condition.
$ CTOD testing.
$ Testing oI hydrogen level.
D.3 DOCUMENTATION
Batch tests shall be documented by an inspection certiIicate 3.1B to EN 10204, with reIerence to a
recognised product classiIication standard and containing all speciIied test results.
Rev. 4, Nov. 2000
ANNEX E - FABRICATION TOLERANCES (NORMATIVE)
CONTENTS
E.1 SCOPE AND OB1ECTIVES 38
E.2 CODES, STANDARDS AND SPECIFICATIONS 38
E.3 DEFINITIONS 38
E.4 GENERAL REQUIREMENTS 39
E.4.1 Implementation policy oI requirements 39
E.4.2 Procedures and documents 40
E.4.3 QualiIication oI inspectors 40
E.4.4 Instrument reliability 40
E.4.5 ReIerence temperature 40
E.4.6 Control methods 41
E.4.7 InterIace criteria`s 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 Irame 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 OutIitting 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 OB1ECTIVES
This annex deIines the maximum allowable dimensional tolerances Ior oIIshore steel items and
structures.
The Designer may, however, speciIy stricter tolerances and additional tolerances. These will, in case
take presedence over this annex.
Note: It should be observed that the requirement to Iabrication tolerances in this annex may be more
strict than the manuIacturing tolerances Ior steel products according to M-120.
The intention oI this annex is to give dimensional tolerances which will ascertain that:
! The calculated strength and Iatigue resistance is present in the structures
! Items and structures can be assembled without dimensional rework
! All parts oI the structures are suitable Ior their intended use
! The structures are thrustworthy relative to measurements given on the structural drawings
! The relevant components tolerances are achieved and maintained aIter the components Iinal
incorporation in the completed structure(s)
E.2 CODES, STANDARDS AND SPECIFICATIONS
ReIerence standards Ior this annex are:
ISO-8062 Castings - System oI dimensional tolerances and machining
ENV 1090-1 1995 Ior Cranes. Execution oI steel structures - Part 1: General
E.3 DEFINITIONS
Terminology used in conjunction with this annex:
AFC drawing:
Engineering drawings Iormally approved Ior construction.
Centreline:
A real or imaginary line that is equidistant Irom the surIace or sides oI the (measured) object.
Deflection:
Load imposed curves, bends, angles or irregularities Irom an unloaded structure. Note: Opposed to
straightness deviation.
Flatness:
Flatness is here deIined as vertical oIIset at any point Irom a plane parallel with the surveyed object.
Rev. 4, Nov. 2000
Grid System:
The grid system is deIined as the design reIerence system Ior all parts, components and elements oI
a completed structure.
The grid system deIines the 3D position oI any item within a completed structure.
The grid system is normally denoted in one oI the Iollowing manners:
! x, y and z coordinates,
! North, east and height coordinates
! Longitudinal, transversal and elevation coordinates.
The grid system deIines the design origo (location and elevation datum) Ior a structure.
Position Deviation:
The speciIied point's actual position relative to it's nominal position.
(Measured value minus nominal value equals deviation).
Reference Lines:
ReIerence lines are marked lines on construction parts and assemblies. The reIerence lines shall be
parallel to, and in determined distances Irom grid lines.
Straightness Deviation:
Curves, bends, angles or irregularities Irom a straight generator.
Note: Straightness deviation is regarded to be Iabrication imposed irregularities and not caused by
elastic deIormation.
Survey Reference System
A reIerence system constituting oI Iixed and coordinate determined points, Irom where surveys can
be perIormed, and where the location and elevation oI the Iixed points are identiIiable relative to the
grid system.
Work Point:
A marked or imaginary point on a member or structure Irom 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 Ior completed structures.
For single elements to be parts oI complex structures, speciIication oI detailed and more stringent
tolerances Ior each Iabrication and erection sequence may be necessary in order to meet the
requirements oI this annex in the completed structure. Such tolerances shall be presented in the
plan/scope oI work Ior Iabrication.
SpeciIication oI detailed and more stringent tolerances Ior intermediate and Iinal interIaces may also
be necessary in order to meet the requirements oI this annex in the completed structure.
The allowable tolerances given Ior individual members shall not cumulate to give unacceptable
deviation Ior the Iinished section or complete structure.
Rev. 4, Nov. 2000
II tolerances given Ior individual sections and components are conIlicting, those tolerances
representing the stricter values shall be governing.
II 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 Iollowing procedures and documents shall be prepared:
Plan Ior Iabrication and erection including methods, techniques and dimensional control to assure
that all structures can be Iabricated and assembled to dimensions within the speciIied tolerances.
The plan shall assure that all allowable tolerances Ior individual elements are not cumulative to the
extent oI exceeding the allowable tolerance Ior the complete structure.
Dimensional inspection procedures relevant Ior the structures and any additional speciIications
needed to those included in this document, subject drawings or other regulations/guidelines Ior the
structural Iabrication.
The Iollowing documents shall be prepared prior to start oI Iabrication:
! Plan Ior dimensional assurance/inspection
! Dimensional inspection procedures
During Iabrication and erection deviations outside the speciIied tolerances shall be identiIied and
inIormed oI in advance oI the Iormal handling oI deviations.
The detailed deviation reports shall be available at all stages in Iabrication, and shall be submitted
on request.
Final documentation shall be prepared in correspondence with the requirements Ior as built
documentation and Iabrication record.
E.4.3 Qualification of inspectors
Personnel responsible Ior dimensional control activities shall have a minimum background oI at
least 5 years relevant experience in industrial surveying.
Personnel monitoring dimensions and tolerances shall have relevant training in use and
understanding oI instruments, and subsequent calculations, enabling them to perIorm all necessary
controls oI own work perIormance.
E.4.4 Instrument reliability
All instruments used shall be in accurate permanent adjustment, have current valid control
certiIicates and be subject to a programme oI periodic checking.
E.4.5 Reference temperature
ReIerence temperature Ior survey activities should be 20 deg. C.
Rev. 4, Nov. 2000
The Iield work temperature shall as a minimum be noted on all dimensional reports, when this is
necessary Ior Iuture use oI the report and the component surveyed. For components to be assembled,
built under signiIicantly diIIerent temperature conditions, dimensions shall be computed to the
reIerence 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 Iabrication a survey reIerence system related to the grid system, shall be established. The
survey reIerence system shall use the same numerical values, and the same orientation directions oI
the system axis as the grid system.
The system's north axis shall be positive toward platIorm north (or bow, iI ship).
The system's east axis shall be positive toward east (or starboard, iI ship).
The system's elevation shall be positive upward.
The numerical value should be the same Ior all disciplines and packages.
For special structures such as jackets being built laying down, the reIerence system must be adjusted
to this Iabrication situation, but the Iinal as built survey shall be related to the platIorm grid system.
The survey reIerence system should be established within the Iollowing tolerances:
Sections/complete structures: "3 mm
Stricter survey reIerence system tolerances shall be used on components where the requirements oI
the Iinal product are more stringent than the above tolerance. For components where the tolerance oI
the product are less than "2 mm, the proposed survey methods shall be described.
At all stages during Iabrication and erection, the Contractor shall ensure that the survey reIerence
system and the Iabricated item shall be in correct position relative to each other.
Permanent survey stations shall be properly constructed and be protected Irom 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 oI applicable and practical reIerence systems.
The layout oI the reIerence system may be specially designed to suit the task at hand and the
methods chosen Ior controls.
E.4.6.2 Marking criteria`s
During layout and assembly oI each structural item all work points and centrelines, which are
relevant Ior the remaining steps oI the construction, shall be marked and identiIied.
Location oI hidden stiIIeners, bulkheads etc. shall be marked on the outside oI the structure to
ensure a correct assembly, iI relevant Ior the remaining steps oI 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 interIaces,
iI relevant Ior the remaining steps oI the construction.
E.4.6.3 Accuracy
Surveys shall be perIormed using survey techniques and technology which enables the achievement
oI a survey accuracy better than the speciIied tolerances.
The methods and equipment used must enable veriIication oI the survey accuracy.
Rev. 4, Nov. 2000
All activities related to measurement and inspection oI dimensions and tolerances shall take into
account the eIIects oI selI weight while the structure is under Iabrication.
E.4.7 Interface criteria`s
All non-adjustable interIaces and interIaces deemed critical prior to erection shall be surveyed and
documented. A comparison oI the interIace results prior to erection shall be perIormed 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 oI butt joints and cruciIorm joints are as
Iollows:
a) Butt-joints
ReIerence is made to table 9.3.
b) CruciIorm Joints
Eccentricity oI non-continuous plating in cruciIorm joints shall not exceed the Iollowing
requirements, (reI. Iigure 4.8-1)
e # t
1
/2 (mm), maximum 5 mm, Ior t
2
# 20 mm
e # t
1
/2 (mm), maximum 8 mm, Ior t
2
~ 20 mm
t
1
smaller thickness in mm oI non-continuous plate
t
2
thickness in mm oI continuous plate
t
3
larger thickness in mm oI 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 oI deviation Figure Nota-
tion
ReI.
Length
Allow oI
reI. length
Max.
Deviation mm
Lateral or vertical
deIlection
5.1-1A I 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 oI web 5.1-1B V H +0.8 +10
Eccentricity oI web
on Ilange
5.1-1B V
1
H +1.0 +3
Buckling oI web 5.1-1B V
3
H +0.75 +10
Curvature/rotation
Ilange
5.1-1B V
2
B/2 +2.5 +3
Twisting oI 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 oI deviation Figure Notation ReI. Length Allow oI
reI. Length
Max Dev.
mm
Position deviation at
end/interIace section
5.2-1A d1 ReI. 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 oI straightness 5.2-1B d2 L +0.15 +10
Buckling oI plates 5.2-1C d3 H, W +0.5 +10
Pos. deviation oI load
bearing stiIIeners
inclusive inclination
5.2-1D d4 ReI. 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 Ior individual tubular segments shall not be cumulative Ior the
Iinished tubular.
a) CircumIerence:
The external circumIerence shall not depart Irom the nominal external circumIerence by more than
the Iollowing (ReI. Figure 5.3-1):
! Measured at joints or within +610 mm Irom the joint (Zone A in Figure 5.3-1):
oI the nominal wall thickness or +10 mm whichever is the smallest.
! The tolerances in (i) may be increased by 50 Ior the remaining length oI the tubular (Zone B in
Figure 5.3-1).
b) Out-oI Roundness (Ovality):
Ovality is deIined as the diIIerence between the measured maximum and minimum internal (or
external) diameters and shall not be more than 1 oI the nominal OD (OD
n
) or 8 mm, whichever is
the least. (ReI. Figure 5.3-2)
c) Out oI circularity:
Circularity is deIined as the diIIerence between the actual and the average radius, both beeing
determined Irom the optimum centre oI the tubular. Maximum diIIerence is not to be more than
0.25 oI OD
n
.
d) Straightness:
The maximum allowable deviation Irom straightness in any 3 m increment oI length shall be 3 mm.
The straightness deviation over tube length (L), shall not exceed 0.001 x L, with maximum 10 mm
deviation Ior lengths up to 12 m. Above 12 m length max. allowable deviation is 12 mm. Out oI
straightness shall be checked on two longitudinal planes separated by 90$.
e) Length:
Unless otherwise noted, the tubular shall be delivered within Iollowing tolerances:
! Unbevelled ends: L
a
% L
n
25 mm
! Bevelled ends: L
a
L
n
" 5 mm
I) Tube ends:
The tube ends shall be perpendicular to the longitudinal axis within the Iollowing tolerances:
! Unbevelled ends: 5 mm
! Bevelled ends: 3 mm
Rev. 4, Nov. 2000
g) Local out-oI roundness:
The local out-oI roundness shall not deviate Irom the theoretical curvature by more than e0.002 x
OD
n
(reI. Iig. 5.3-3). The local out-oI roundness shall be measured inside or outside over 20$ oI the
circumIerence.
h) Local Out-OI Straightness:
Local straightness is deIined as the deviation oI the shell plate Irom a straight generator oI length
(L) parallel to the true centre line oI the tubular. This tolerance shall not exceed 20 oI the wall
thickness. Local straightness shall be checked on the inside or outside oI 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 oI 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 oI deviation Figure Notation ReI. Allow. Max. dev. mm
PANEL SHEET:
Out oI plane straightness,
sagging/hogging, between
girders
5.4-1 p1 W "0.15 "15
Local buckles between
stiIIeners 5.4-1 p2 W1 "0,5 "5
GIRDERS/ STIFFENERS:
Out oI 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 oI straightness oI 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 oI deviation Figure Notation ReI. length Allow oI
reI. length
Max. deviation
mm
Position deviation oI
interIaces
5.5-1B,
5.5-1C
d1 ReI. Centre
Line
- "5
Lateral and vertical
straightness oI node
5.5-1A I L "0.15 "!
Lateral and vertical
straightness oI stiIIeners
5.5-1A I1 L,H "0.1 "5
Height oI node 5.5-1B s - - "!
Pos. deviation stiIIeners
inclusive inclination
5.5-1B,
5.5-1C
d2 ReI. Centre
Line
- "5
Position deviation
column interIaces
5.5-1C d3 ReI.Centre
Line
- "5
Baseplate Ilatness
/rotation rel.to Z axis
5.5-1A,
5.5-1B
b1 ReI. Centre
Line
- "2
Pos.deviation baseplate
relative to Z axis
5.5-1B d4 ReI.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 oI deviation Figure Notation ReI. Length Allow oI
reI. length
Max. deviation
mm
Position deviation oI main box
interIace
5.6-1A d1 ReI. Centre
Line
- "3
Out oI straightness 5.6-1B d2 L " 0,10 "10
Buckling oI plates 5.6-1C d3 H, W "0,5 "10
Radial and tangential stub end
deviation
5.6-1C,
5.6-1E
d4 ReI. Centre
Line
- "5
Pos. deviation oI load bearing
stiIIeners incl. inclination
5.6-1D d5 ReI. Centre
line
- "5
OIIset oI centrelines at centre
oI node
5.6-1E,
5.6-1F
d6 ReI. Centre
Line
- "!
Fig. E.5.6.1 Box nodes tolerance references
Rev. 4, Nov. 2000
E.5.7 Tubular Nodes
Type oI deviation Figure Notation ReI. length Allow oI
reI. length
Max.
deviation
mm
Overlength oI stub 5.7-1A l2 L2 25
-0
Overlength oI 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$ oI arc "6
Position oI intersection point
node can / stub
5.7-2 E Grid
system
"6
Internal stiIIeners
-Position
-Inclination oI web
-Flange width
-Bow oI web
-Rotation oI Ilange
-Eccentricity oI Ilange
on web
-Height oI stiIIeners
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 oI
stubs/barrel
5.7-1A Wall
thickness
25 8
Straightness oI barrel 5.7-1A L 1/1200 10
The centre line oI stub shall be within 0.2$ Irom the stub angle speciIied on the design drawings.
Maximum position deviation measured at the intersection oI 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 Ior:
! CircumIerence
! Out-oI Roundness (Ovality)
! Local out-oI roundness
! Out-oI circularity
are deIined in Section E.5.3
Rev. 4, Nov. 2000
Fig. A
Fig. B (tolerance reIerences)
Fig. C (tolerance reIerences - internal stiIIeners)
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, Ilatness, web and rib
positions shall be speciIied on the design drawings.
The nominal axes, work points, rib centrelines etc. shall be properly marked on each element
interIace(s) to adjacent main steel.
Rev. 4, Nov. 2000
During installation oI cast and Iorged items, special care shall be taken that the parent plate edges
are located within prepared Iace oI casting / Iorging.
See also ISO-8062 standard Ior tolerances.
E.5.9 Curved and cylindrical shell
For elements including curved shells (such as semi submersible`s pontoons) special dimensional
procedures shall be implemented Ior measurement and computing.
Sylindrical shells.
The maximum deviation Irom the nominal radius, measured at ringstiIIeners or at bulkheads shall
not exceed the value:
( r
a
- r )* 0,005 r
r
a
actual distance Irom the cylinder axis to the shell wall
r nominal radius oI the shell
Components deIined as Cylindrical Shell to be speciIied on design drawings.
E.5.10 Conical transitions
At both ends oI a cone, the maximum deviation Irom the nominal radius shall not exceed the value:
( r
a
- r )* 0,005 r
where r
a
Actual distance Irom the cylinder axis to the cone wall
r Nominal radius at cone end
Requirements Ior internal stiIIeners shall be in accordance with table 5.7.
Rev. 4, Nov. 2000
E.6 ASSEMBLY TOLERANCES
E.6.1 Topsides and modules
Type oI deviation Figure Notation ReI. Allowable
oI reI.
length
Max.
deviation
mm
Position oI any point oI main
steel
6.1-1 X1,Y1 Grid system "10
Position oI support node 2) 6.1-1 X2, Y2,
Z2
Grid system "6
Position oI liIting node 6.1-1 X2, Y2,
Z2
Grid system "10
Elevation oI decks and mezz.
decks sag./hog.
6.1-1 H1, H2,
H3
Grid system "10
Footings deviation Irom
elevation reIerence 1)
6.1-1 H Grid system "5
For truss Irames without any deIined support points the elevation reIerence should be based on a
mean oI all levelled points on main steel.
NOTES:
1) Maximum allowable deviation shall also apply to mating surIace level at stab-in onto
jacket legs.
2) Includes Main Support Frame (MSF) stab-in nodes and module Iooting nodes.
Fig. E.6.1-1 Topside and module tolerance references
Rev. 4, Nov. 2000
E.6.2 1acket and other tubular frame structures
E.6.2.1 Assembly tolerances
Type oI deviation Figure Notation ReI. Max. dev. mm
Position deviation
oI centre oI nodes 6.2.1-A
&x, &y Grid system +12
Rotation oI 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 oI leg
ring stiIIeners and
diaphragms +6
Inclination oI
ringstiIIeners 6
Straightness oI
legs / chords 6.2.1-B/C &I L X+10
Straightness oI
braces 6.2.1-C &I L X+L/1000
Position oI
intersecting braces Grid system "15
NOTE: Local tolerances Ior sliding and pivoting ends shall be speciIied on the structural drawings.
Rev. 4, Nov. 2000
Fig. E.6.2-1 1acket and tubular frame structures - assembly tolerances
Rev. 4, Nov. 2000
E.6.2.2 Final Tolerances for 1acket, Interface 1acket/MSF
Type oI deviation Figure Notation ReIerence Max. dev.
mm
Horizontal position
deviation oI centre oI
stab-in cans
6.2.2 Vx, Vy
V
+ (VxVy)
Grid system
1)
"6
"8
Jacket:
Distance between centre
oI column to centre oI
any column at stab-in
cans
6.2.2 F L "12
Jacket:
Mating surIace level at
stab-in
Grid system
2)
+3
MSF:
Distance between centre
oI column to centre oI
any column at stab-in
cans
6.2.2 F L "6
Ovality oI stab-in can As in section
E.5.3b
Horizontal position
deviation oI caissons,
risers, J-tube
Grid system "6
NOTES:
1) The position oI the stab-in cans shall, iI the situation allowes, be related to the top-
side stab-in cones with the tolerances stated above.
2) The jacket legs shall by preIerence be cut within above tolerances aIter grout is cured.
II survey oI the deck Iootings show out-oI acceptable elevation/Ilatness tolerances, reI. Section
E.6.1, the measured deviations shall be considered incorporated when cutting the legs in order to
minimise loads due to diIIerential settlements in Iootings.
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 oI the centre oI pile guides/sleeves shall be "25 mm related to the
coordinate system.
Local alignment oI sleeves 20 mm.
Radius oI spacer plates "5 mm.
Rev. 4, Nov. 2000
E.6.2.4 Piles
Type oI deviation Figure Notation ReI. Max. dev.
mm.
Length "100
Diameter between
spacerplates
6.2.4 d1 As speciIied on
drawing
Diameter in driving
head
6.2.4 d2 As speciIied on
drawing
End perpendicularity
in driving head
6.2.4 P As speciIied 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 oI the centre oI the conductor guides shall be "10 mm related to the
coordinate system Ior top el. and "15 mm Ior the other elevations related to the same coordinate
system.
The maximum deviation oI any conductor guide Irom 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 oI deviation Figure Notation ReI. 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 oI deviation Figure ReI. Max. dev. mm
Global position oI column top /
bottom
6.3.1-1
6.3.1-2
Global
grid system "15
Distance between top / bottom
oI two columns
6.3.1-1
6.3.1-2
"30
Local position oI 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 Iabricated using a grid system with origo in the aIt perpendicular, and in accordance
with section E.3 oI this annex. Based on the grid system a reIerence system according to section
E.4.6.1 should be permanently marked onboard the ship.
E.6.4 Subsea structures
Subsea structures should be Iabricated 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 speciIied in a separate document to be prepared by the designer,
taking into account the structural aspects as well as the mechanical Iunctional tolerances and
equipment interIace tolerances.
E.7.2 Skid Beams
Skid beam tolerances shall be speciIied in a separate document to be prepared by the designer,
taking into account the structural aspects as well as the mechanical Iunctional tolerances and
equipment interIace tolerances.
E.7.3 Outfitting Structure
! This section covers all primary and secondary outIitting structures.
! The diIIerence in elevation oI 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 Irom the dimensions shown
on the AFC drawings.
! Fabrication oI handrails shall be perIormed to such a degree oI 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 oI plumb by more than 6 mm on each 3000 mm
section and not more than 26 mm over the total height oI the structure.
! Wherever tolerances are not shown on the drawings, or speciIied elsewhere, Iabrication work
shall be accurate to within 10 mm oI all nominal dimensions.
! Matching holes Ior bolted connections shall not exceed 2 mm diIIerence in location.
E.7.4 Installation Aids
Installation aid structures such as primary and secondary guides and bumpers shall be Iabricated and
installed in accordance with acceptable tolerances Ior relevant elements/structures deIined in this
document.
SpeciIic tolerance requirements are shown on respective drawings, and shall be mandatory.
E.7.5 Grillages
Load out grillage, barge grillage and seaIastening shall be Iabricated and installed in accordance
with acceptable tolerances Ior relevant structures/elements deIined in this document.
(ReI. section E.4.8)
SpeciIic tolerance requirements shall be shown on respective drawings and shall be mandatory.
E.7.6 Cranes
ReIerence standard: ENV 1090-1 applies.

Structural Steel Fabrication Norsok Standard M101

Загружено:

Сведения о документе

Исходное описание:

Авторское право

Доступные форматы

Поделиться этим документом

Поделиться или встроить документ

Параметры публикации

Этот документ был вам полезен?

Это неприемлемый материал?

Авторское право:

Доступные форматы

Structural Steel Fabrication Norsok Standard M101

Загружено:

Авторское право:

Доступные форматы

NORSOK STANDARD

STRUCTURAL STEEL FABRICATION

Вам также может понравиться