dnvgl-se-0241 qualification of steel forgings for subsea ... · — dnvgl-rp-0034 steel forgings...

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SERVICE SPECIFICATION

DNVGL-SE-0241 Edition February 2018

Qualification of steel forgings for subseaapplications

FOREWORD

DNV GL service specifications contain procedural requirements for obtaining and retainingcertificates and other conformity statements to the objects, personnel, organisations and/oroperations in question.

© DNV GL AS February 2018

Any comments may be sent by e-mail to [email protected]

This service document has been prepared based on available knowledge, technology and/or information at the time of issuance of thisdocument. The use of this document by others than DNV GL is at the user's sole risk. DNV GL does not accept any liability or responsibilityfor loss or damages resulting from any use of this document.

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Service specification — DNVGL-SE-0241. Edition February 2018 Qualification of steel forgings for subsea applications

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This is a new document.

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CONTENTS

Changes – current.................................................................................................. 3

Section 1 Introduction............................................................................................ 51.1 General............................................................................................. 51.2 Objective...........................................................................................51.3 Scope................................................................................................ 51.4 Application........................................................................................51.5 References........................................................................................ 61.6 Definitions.........................................................................................6

Section 2 Service overview..................................................................................... 82.1 General process................................................................................ 82.2 DNV GL services............................................................................... 82.3 Request for qualification...................................................................82.4 DNV GL personnel.............................................................................82.5 Documentation..................................................................................92.6 Deliverables...................................................................................... 92.7 Retention of statements................................................................... 9

Section 3 Qualification process............................................................................. 103.1 Service module A, qualification of manufacturer............................ 103.2 Service module B, manufacturing procedure qualification.............. 13

Appendix A ...........................................................................................................16A.1 Sample - statement of conformity - module A................................ 16

Appendix B ...........................................................................................................17B.1 Sample - statement of conformity - module B................................ 17

Changes – historic................................................................................................18


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SECTION 1 INTRODUCTION

1.1 GeneralA joint industry project (JIP) on standardization of steel forgings for subsea applications was successfullycarried out in the period from 2013 to 2016. Led by DNV GL and with broad participation from oil companies,subsea equipment contractors and forging manufacturers, the JIP resulted in harmonized technical andquality management requirements.Two DNV GL recommended practices (RP) were developed based on the results from the JIP:

— DNVGL-RP-0034 Steel forgings for subsea applications— DNVGL-RP-B202 Steel forgings for subsea applications - quality management requirements.

DNVGL-RP-0034 covers the harmonized technical requirements and is aimed at supporting a stockingphilosophy, reducing delivery time, engineering and production costs, and at improving material quality offorgings.DNVGL-RP-B202 covers the harmonized qualification and surveillance requirements and is aimed atsupporting further a stocking philosophy and at ensuring trust in the supply chain of critical forgings. Someof the important achievements in the JIP to ensure trust in the supply chain are alignment on roles andresponsibilities, competence and experience, quality oversight/surveillance and documentation.

1.2 ObjectiveThe objective of this service specification (SE) is to ensure transparent, efficient and consistent delivery ofDNV GL services related to qualification of manufacturers and manufacturing procedures for steel forgingsused in subsea applications.

1.3 ScopeThis service specification describes DNV GL services related to quality management of steel forgings forsubsea applications specified in DNVGL-RP-B202.The document contains procedural requirements for obtaining and retaining DNV GL conformity statementsto:

— qualification of manufacturers— manufacturing procedure qualification (MPQ).

The document specifies the obligations of the customer as well as DNV GL's service obligations to thecustomer.The production phase as specified in DNVGL-RP-B202 is outside the scope of this service specification.

1.4 ApplicationThis service specification is applicable to manufacturers of steel forgings and qualification of such forgings inaccordance with DNVGL-RP-B202.Consistent with DNVGL-RP-B202, the qualification services described herein are provided by DNV GL as athird party and DNV GL's customer is a contractor or manufacturer.Subject to agreement with DNV GL, this SE may also be used for qualification of forgings intended for otherthan subsea applications or for forgings intended for subsea applications but which are outside the scope ofDNVGL-RP-B202.


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1.5 ReferencesThe RPs listed in Table 1-1 include provisions and guidance which, through reference in this text, constituteprovisions and guidance of this SE. The latest edition applies unless dated references are given.

Table 1-1 Normative references

Document code Title

DNVGL-RP-0034 Steel forgings for subsea applications

DNVGL-RP-B202 Steel forgings for subsea applications - quality management requirements

1.6 Definitions

1.6.1 TermsFor the purpose of this SE, the definitions of terms in Table 1-2 apply.

Table 1-2 Definitions of terms

Term Definition

assessment a process which evaluates activities, facilities, or systems against requirements or expectations

audit systematic, independent, and documented process for obtaining objective evidence andevaluating it objectively to determine the extent to which audit criteria are fulfilled (ISO9000:2015)

company end user of subsea equipment

contractor entity that provides subsea equipment to a company or company's main contractor

customer the immediate contractual partner to DNV GL, for whom DNV GL has committed to perform aqualification service

inspector person authorized by DNV GL to perform surveillance of manufacturing procedure qualificationor production

manufacturer entity that provides steel forgings for components in subsea equipment to contractor

material specialist person authorized by DNV GL to perform technical assessments, technical audits andsurveillance of agreed activities during manufacturing procedure qualification or production

qualification activities carried out for verification

qualifying company entity responsible for qualification of manufacturers and manufacturing procedure qualification

special/critical process process that includes melting and casting of ingots, forging, heat treatment, material testingand non-destructive testing (NDT)

statement ofconformity

a formal statement issued by DNV GL to confirm that requirements to an individual qualificationphase, i.e. qualification of manufacturer or manufacturing procedure qualification have beenfulfilled

surveillance planned assessment and verification to confirm that forgings meet requirements


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Term Definition

technical audit qualifying company audit of potential manufacturer to assess and verify capability to meettechnical requirements

third party independent entity hired by contractor or manufacturer to perform material specialist orinspector activities at manufacturer's site

verification confirmation through the provision of objective evidence that specified requirements have beenfulfilled (ISO 9000:2015)

1.6.2 AbbreviationsAbbreviations used in this SE are listed in Table 1-3.

Table 1-3 List of abbreviations

Abbreviation Description

CVN Charpy V-notch

ITP inspection and test plan

JIP joint industry project

MPQ manufacturing procedure qualification

MPQR manufacturing procedure qualification report

MPS manufacturing procedure specification

PQM pre-qualification meeting

RP recommended practice

SE service specification

SFC steel forging class

SMYS specified minimum yield strength

SOC statement of conformity

1.6.3 Verbal formsFor the purpose of this SE, the definitions of verbal forms in Table 1-4 apply.

Table 1-4 Definitions of verbal forms

Term Definition

shall verbal form used to indicate requirements strictly to be followed in order to conform to thedocument

should verbal form used to indicate that among several possibilities one is recommended asparticularly suitable, without mentioning or excluding others, or that a certain course of actionis preferred but not necessarily required

may verbal form used to indicate a course of action permissible within the limits of the document


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SECTION 2 SERVICE OVERVIEW

2.1 General processThe quality management process described in DNVGL-RP-B202 involves requirements for qualification ofmanufacturer and MPQ, which shall be satisfactory met prior to regular production of forgings. The twoqualification phases and subsequent production phase are outlined in Figure 2-1.Qualification of manufacturer is required for all steel forging classes (SFC). The objective is to obtain andmaintain confidence in the capability of a manufacturer to meet requirements in DNVGL-RP-0034.MPQ is required for SFC 2 and SFC 3. The objective is to demonstrate and verify that proposedmanufacturing process results in products meeting specified requirements in DNVGL-RP-0034.This SE is concerned with the two qualification phases and the corresponding services offered by DNV GL.The production phase requires involvement by contractor or third party as specified in DNVGL-RP-B202 but isoutside the scope of this SE.

Figure 2-1 Qualification and production phases for forgings

2.2 DNV GL servicesWhen DNV GL is contracted as qualifying company, DNV GL perform the activities specified in DNVGL-RP-B202 for an individual qualification phase or both phases combined. The associated services are referred toas service modules as follows:

— service module A, qualification of manufacturer— service module B, manufacturing procedure qualification.

It should be noted that the individual qualification phases depend on each other, i.e. MPQ may only beperformed after successful qualification of manufacturer. Consequently, service module B may only beordered after qualification of manufacturer by a qualifying company.

2.3 Request for qualificationThe customer shall prepare a request for qualification that shall at least contain:

— information about the relevant qualification phase— information about the manufacturer, its location and any subcontracted activities— any other information relevant for the qualification, e.g. previous or existing qualifications performed by a

contractor.

The customer shall submit the request to DNV GL

2.4 DNV GL personnelDNV GL shall ensure the necessary competence and availability of personnel for the service.


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Material specialists and inspectors shall meet the competence requirements specified in DNVGL-RP-B202. Inaddition, they shall be qualified in accordance with DNV GL's competence schemes. A list of qualified materialspecialists will be made available to the customer on request.

2.5 Documentation

2.5.1 Manufacturer documentationThe manufacturer's documentation submitted to DNV GL shall be in the English language. The documentationshall be complete and self-explanatory. The content shall meet the requirements of DNVGL-RP-B202.Each document submitted for review shall have a unique and clear reference which also identifies the actualrevision of the document. The documentation shall be controlled according to the quality managementsystem of the manufacturer.Documents to be submitted are further described in [3.1.3] for service module A and [3.2.3] for servicemodule B.

2.5.2 DNV GL review of documentsDNV GL shall review the manufacturer's documentation and issue comments for documents subject toverification.Verification comments related to nonconformities or issues not fully addressed shall be responded to by themanufacturer. Such comments remain open until a satisfactory response and updated documentation allowsDNV GL to close the comment.Comments issued for information need not be responded to by the manufacturer.

2.6 DeliverablesDNV GL may issue deliverables during the execution of the verification and qualification scope and at itscompletion. The purpose of the deliverables is to document the scope of work performed by DNV GL and theconclusions reached.For service modules A and B, a statement of conformity (SOC) may be issued provided that all requirementsare fulfilled and that there are no open verification comments. If there are open verification comments,intermediate documentation will be the final deliverable.Detailed description of documents issued by DNV GL in the different stages of the qualification process aregiven in Sec.3. See also deliverables specified in DNVGL-RP-B202.

2.7 Retention of statementsRetention of a statement of conformity in the validity period is conditional on fulfilment of conditions given in[3.1.4.5] and [3.2.4.6].A statement of conformity may be suspended or withdrawn if the fulfilment of conditions has been found notto be maintained.


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SECTION 3 QUALIFICATION PROCESS

3.1 Service module A, qualification of manufacturer

3.1.1 ProcessA qualification of manufacturer process goes through the steps specified in DNVGL-RP-B202 and as presentedin Figure 3-1.

Pre-audit questionnaire filled in by manufacturer

Initial technical assessment

Technical audit

Both steps satisfactory?

SFC 1 qualified manufacturer.For SFC 2 and 3, proceed to MPQ.

Qualification process stopped

No

Yes

Assessment report

Audit report

Statement of conformity

Verification comments

Figure 3-1 Steps and deliverables in the qualification of manufacturer process

3.1.2 Scope of involvement3.1.2.1 GeneralDNV GL shall perform the activities specified in DNVGL-RP-B202 as further described in [3.1.2.2] and[3.1.2.3].

3.1.2.2 Initial technical assessmentPrior to the initial technical assessment, DNV GL shall provide a pre-audit questionnaire to the manufacturerand request the manufacturer to fill in and submit the questionnaire, see Table 3-1. DNV GL shall assess theinformation provided in the questionnaire and review supporting documentation.DNV GL's deliverable is an assessment report, see [3.1.4.1].


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3.1.2.3 Technical auditPrior to the technical audit, DNV GL shall provide an audit checklist to the manufacturer and request themanufacturer to submit the documents listed in Table 3-1. Following review of the procedures for special/critical processes, DNV GL shall perform the audit at the manufacturer's site(s) including the manufacturer'ssuppliers of activities specified in DNVGL-RP-B202. The audit shall be scheduled such that regular productionactivities and processes can be observed during the audit.The audit scope, team, preparation, execution, reporting and follow-up shall be as specified in DNVGL-RP-B202.DNV GL's deliverables are verification comments for procedures for special/critical processes and an auditreport, see [3.1.4.2] and [3.1.4.3].

3.1.3 Documents to be submittedThe manufacturer shall prepare and submit the documents listed in Table 3-1.

Table 3-1 Documents to be submitted for qualification of manufacturer

Step Document

Pre-audit questionnaire filled in (questionnaire provided by DNV GL)Initial technical assessment

Supporting documentation, as specified in questionnaire

Process flow chart, see DNVGL-RP-B202

Master register or list identifying procedures, see DNVGL-RP-B202

Technical audit

Procedures for special/critical processes, see DNVGL-RP-B202

3.1.4 Deliverables3.1.4.1 Assessment reportDNV GL shall issue a report to the customer documenting the initial technical assessment, including arecommendation whether to proceed with the technical audit. In the event of a recommendation not toproceed with the technical audit, DNV GL shall notify the customer and shall identify the reasons for therecommendation.

3.1.4.2 Verification commentsFollowing review of procedures for special/critical processes, DNV GL shall issue verification comments to thecustomer.

3.1.4.3 Audit reportDNV GL shall issue a report to the customer documenting the technical audit, including the review andverification of procedures for special/critical processes.

3.1.4.4 Statement of conformityProvided satisfactory initial technical assessment, document review and technical audit, DNV GL shall issue astatement of conformity (SOC) to the customer to confirm that requirements to qualification of manufacturerhave been fulfilled. The SOC shall contain:

— a unique identifier of the SOC— the name and address of the manufacturer— references to this service specification and DNVGL-RP-B202— unique references to the assessment report and audit report— date of issue


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— signature of material specialist and project sponsor.

See [A.1] for sample SOC.

3.1.4.5 Validity and maintenance of statement of conformityThe SOC is valid for a period of five years from the date of issue. Maintenance of the SOC is conditional onongoing review of quality performance and reassessment every five years, see DNVGL-RP-B202.The scope and conditions for DNV GL review of quality performance during the validity period shall beclarified and documented between the manufacturer and DNV GL prior to issuing the SOC.The manufacturer shall inform DNV GL if there are any significant changes to the conditions upon which theSOC was based.

3.1.4.6 Administration of deliverablesDNV GL shall keep a register of all SOCs and their referenced reports, including withdrawn and expiredcertificates.Valid DNV GL SOCs are listed in DNV GL approval finder on DNV GL's web site www.dnvgl.com unlessotherwise requested by the manufacturer.

www.dnvgl.com


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3.2 Service module B, manufacturing procedure qualification

3.2.1 ProcessA manufacturing procedure qualification process goes through the steps specified in DNVGL-RP-B202 and aspresented in Figure 3-2.

Qualified manufacturer

Review MPS and ITP

Attend PQM

All steps satisfactory?

Qualified manufacturing procedure

No

Yes

Verification comments

PQM minutes

Surveillance during MPQ Site visit report

Review MPQRVerification comments

Endorsed MPQR front page

Statement of conformity

Figure 3-2 Steps and deliverables in the MPQ process


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3.2.2 Scope of involvement3.2.2.1 GeneralDNV GL shall perform the activities specified in DNVGL-RP-B202 as further described in [3.2.2.2] to[3.2.2.5].

3.2.2.2 Review manufacturing procedure specification and inspection and test planPrior to manufacture of the qualification forging, DNV GL shall request the manufacturer to submit themanufacturing procedure specification (MPS) and inspection and test plan (ITP), see Table 3-2. DNV GL shallperform review and verification of the MPS and ITP for the qualification forging.DNV GL's deliverables are verification comments, see [3.2.4.1].

3.2.2.3 Attend pre-qualification meetingPrior to manufacture of the qualification forging, a pre-qualification meeting between the manufacturer andDNV GL shall be conducted. DNV GL shall assess the manufacturer's readiness to start the manufacture andshall establish the surveillance to be performed by DNV GL during manufacturing procedure qualification(MPQ).DNV GL's deliverable is minutes of meeting, see [3.2.4.2].

3.2.2.4 Surveillance during manufacturing procedure qualificationDNV GL shall perform surveillance during the MPQ in accordance with the approved ITP established in thePQM.DNV GL's deliverables are site visit reports, see [3.2.4.3].

3.2.2.5 Review manufacturing procedure qualification reportAfter satisfactory qualification testing, the manufacturer shall establish and submit the manufacturingprocedure qualification report (MPQR), see Table 3-2. DNV GL shall perform review and verification of theMPQR.DNV GL's deliverables are verification comments and endorsed MPQR front page, see [3.2.4.1] and [3.2.4.4].If acceptance criteria in DNVGL-RP-0034 are not met at ½ T position for the thickest section, it is permissibleaccording to DNVGL-RP-0034 to perform engineering analysis to determine if properties are fit for use.Engineering analysis is based on knowledge of design of the component for which the forging is intended.This knowledge is held by the contractors. DNV GL as qualifying company does not perform engineeringanalysis.Any need for engineering analysis will be highlighted on the endorsed MPQR front page.

3.2.3 Documents to be submittedThe manufacturer shall prepare and submit the documents listed in Table 3-2 for review and approval.

Table 3-2 Documents to be submitted for manufacturing procedure qualification

Step Documents Remark

MPS, see DNVGL-RP-B202Review MPS and ITP

ITP, see DNVGL-RP-B202

Review and approval prior tomanufacture of qualification forging

Review MPQR MPQR, see DNVGL-RP-B202 Review and approval after satisfactoryqualification testing

Procedures for special/critical processes shall be submitted for information if qualification of manufacturerhas been performed by another qualifying company than DNV GL.


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3.2.4 Deliverables3.2.4.1 Verification commentsFollowing review of MPS, ITP and MPQR, DNV GL shall issue verification comments to the customer.

3.2.4.2 Minutes of meetingDNV GL shall issue minutes of meeting to the customer after the pre-qualification meeting. The minutes shallas a minimum contain:

— purpose— date, time and location— name of participants, their role and company represented— agenda— issues agreed— actions.

3.2.4.3 Site visit reportsDNV GL shall issue site visit reports to the customer. The reports shall describe the extent of the surveillanceincluding any findings, nonconformities and possible recommendations.DNV GL shall report important findings to the customer immediately after surveillance.

3.2.4.4 Endorsed MPQR front pageProvided satisfactory review of MPQR, DNV GL shall approve the MPQR and transmit the signed and stampedMPQR front page to the customer.

3.2.4.5 Statement of conformityProvided satisfactory completion of all steps shown in Figure 3-2, DNV GL shall issue a SOC to the customerto confirm that requirements to manufacturing procedure qualification have been fulfilled. The SOC shallcontain:

— a unique identifier of the SOC— the name and address of the manufacturer— references to this service specification and DNVGL-RP-B202— product specific information: SFC, grade, SMYS, critical thickness, CVN test temperature— unique reference to the MPQR— date of issue— signature of material specialist and project sponsor.

See [B.1] for sample SOC.

3.2.4.6 Validity of statement of conformityThe SOC is valid from the date of issue on the condition that the essential varables from MPQ remainunchanged.

3.2.4.7 Administration of deliverablesDNV GL shall keep a register of all SOCs and their referenced MPQRs, including withdrawn statements.Valid DNV GL SOCs are listed in DNV GL approval finder on DNV GL's web site www.dnvgl.com unlessotherwise requested by the manufacturer.

www.dnvgl.com


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APPENDIX A

A.1 Sample - statement of conformity - module A


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APPENDIX B

B.1 Sample - statement of conformity - module B

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CHANGES – HISTORICThere are currently no historical changes for this document.

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