statoil forged components specification tr1831

Governing document Classification: Internal

Specification for Manufacturing of Forged and Hot Formed Components in Low Alloy Steel

Concept development and engineering (CD&E) Technical and professional requirement, TR1831, Final Ver. 1.03, valid from 2010-03-16 Owner: Chief Engineer Validity area: Statoil/All locations/All value chains/On- and offshore

Governing document Specification for Manufacturing of Forged and Hot Formed Components in Low Alloy Steel

Classification:Internal

Concept development and engineering (CD&E), Technical and professional requirement, TR1831, Final Ver. 1.03, valid from 2010-03-16 Page 2 of 10 Validity area: Statoil/All locations/All value chains/On- and offshore

1 Objective, target group and warrant........................................................................................................................ 3 2 Requirements...................................................................................................................................................................... 3

2.1 Design....................................................................................................................................3 2.2 General requirements.............................................................................................................3 2.3 Steelmaking ...........................................................................................................................4 2.4 Chemical composition ............................................................................................................5 2.5 Forging ..................................................................................................................................6 2.6 Hot forming ...........................................................................................................................6 2.7 Heat treatment .......................................................................................................................6 2.8 Sour service requirements ...................................................................................................... 6 2.9 Mechanical testing test sampling and extent of testing .......................................................6 2.10 Mechanical testing required properties................................................................................8 2.11 Retesting and corrective/remedial actions..............................................................................8 2.12 Non-destructive testing .........................................................................................................8 2.13 Tolerances .............................................................................................................................8 2.14 Certification ...........................................................................................................................9 2.15 Marking..................................................................................................................................9

3 Documents to be forwarded to Company.............................................................................................................. 9 4 Additional information ................................................................................................................................................... 9

4.1 Definitions and abbreviations.................................................................................................9 4.2 Changes from previous version ..............................................................................................9 4.3 References .............................................................................................................................9




1 Objective, target group and warrant This Technical Requirement (TR) describes the minimum requirements for manufacturing of forged or hot formed components made of low alloy C-Mn steel (i.e. grades F60, F65 or WPHY 60, WPHY 65) for use in pipeline systems. The document is applicable for components intended for both sour and non-sour service conditions. This document is warranted in Facilities, concept development and engineering (FR02)

2 Requirements

2.1 Design The components shall be designed in accordance with the requirements of the following standards and codes. Component Specification/Code Note 90o Tee ASME B.31.8 Y-pieces ASME B.31.8 Elbow ASME B.31.8 Insulating joints

ASME B.31.8 End cap ASME B.31.8

If a component is subjected to loads or geometry other than covered by ASME B.31.8 (including hydrostatic testing), design is to be by an FE analysis according to ASME VIII, Div. 2, App. 4 or an equivalent recognised standard.

The transition between a component and other items (e.g. connecting linepipe) where the material thickness or yield strength is unequal shall be according to ASME B31.8 Appendix 1 or an equally recognised code. For piggable components, the internal diameter shall be given in the purchase order. The purchase order shall specify if the components shall be equipped with pup-pieces (of line pipe- or similar material) or if rings for welding procedure qualification shall be provided.

2.1.1 Pressure testing Strength- and leak testing shall be the most stringent of the requirements of ASME B.31.8 and chapter 2.9.3 Testing of Manifold System in TR1230 Subsea Structures and Manifolds.

2.2 General requirements All production shall be based on a qualified and accepted Manufacturing Procedure Specification (MPS). A Quality Plan (QP) describing relevant QA/QC activities shall be established. Components made to this document can be either forged or hot formed. Forgings shall comply with the requirements of ASTM A694 and of this document. Hot formed products shall comply with the requirements of ASTM A860 and of this document. Welding shall be performed according to the design standard.




Welding shall be to the requirements in the relevant design codes or equivalent recognized standard. When joining materials with different specified minimum yield strength (SMYS), the mechanical properties of the weld metal shall meet that specified for the material with the higher yield strength. Weld repair of base material is not acceptable. End caps shall not be manufactured from bar stock

2.3 Steelmaking The steel shall be fully killed and made to a fine grain melting practise. The material shall be produced by using basic oxygen furnace, electric arc furnace, vacuum arc re-melting furnace (VAR) or electro slag re-melting furnace (ESR). The steel melt shall be vacuum degassed.




2.4 Chemical composition The chemical composition shall be within the limits given in the table below.

C Mn* Si P S Ni Cr Mo V Cu Al Nb Ti N B Ca CE** Min

% 1.0 0.2 0.7 0.1 0.2 0.02 0.1 0.02 0.44

Max %

0.12 1.5 0.4 0.015 0.003 1.0 0.25 0.4 0.05 0.4 0.06 0.02 0.01 0.012 0.001 0.006 0.50

* For sour service: Mn max 1.4 **

1556NiCuVMoCrMnCCE

An alternative chemical composition may be accepted by Company, provided it can be documented that the mechanical properties will be met. Product analysis shall be conducted for components from each heat.




2.5 Forging Each forged product shall be hot worked as close as practical to the final shape and size with a minimum reduction ratio of 4:1. The principal forging directions shall be given by the manufacturer in a sketch.

2.6 Hot forming Hot forming, including extrusion of branches shall be done within a temperature range of 8001000oC. Adequate temperature control shall be performed during the forming operation and the component shall be allowed to cool in still air after forming.

2.7 Heat treatment All forged components shall be supplied in the Quenched and Tempered condition. Hot formed components shall be supplied in the Quenched and Tempered or Normalized condition. For components intended for welding, the tempering temperature shall be minimum 620C. The T between tempering and any PWHT shall be minimum 30C. The furnace temperature shall be controlled within 14oC. Thermocouples shall be attached to one component for the entire heat treatment process for each heat treatment batch. Dummy components with representative shape, weight and wall thickness may be used. The thermocouple shall record temperature during the entire heat treatment process. The supplier shall establish procedures for stacking of components during heat treatment, and transfer time from furnace to complete immersion in the quench bath shall be specified and not exceed 90 seconds. The temperature shall under no circumstances drop into the two phase region (




All mechanical testing shall be conducted after final heat treatment. The test material shall normally represent the thickest section of the component. The testing may be performed on a prolongation of the weld neck provided written acceptance from Company. All test samples and test sample locations/directions shall be detailed in a sketch. An example of such a sketch is given in Figure 1.

Figure 1. Mechanical test specimen location. Distances are from the forged surface. Forgings One component from each lot (i.e. components of the same size, type and form from each heat and heat treatment batch, whichever occurs most frequently) shall be tested as follows: two tensile specimens taken from the base material in transverse direction at 1/3 thickness, two sets of Charpy V-notch specimens taken in the transverse direction 2mm below the inner

and outer surface with the notch perpendicular to the components surface, two sets of Charpy V-notch specimens taken in the transverse direction at 1/3 thickness with

the notch perpendicular to the components surface, metallographic samples taken at 2mm below outer and inner surface and at 1/3T, 1/2T and

2/3T. A minimum of 3 hardness measurements shall be taken on each sample. The metallographic samples shall be documented by micrographs taken at 400x magnification. The distance from a second surface to the test specimens shall be at least 1/3T. Welded components Production testing of component welds shall be performed if specified in the purchase order.

The extent of testing shall be subjected to agreement.




End caps For end caps formed from plate, one end cap from each heat treatment batch shall be tested as follows: Four tensile specimens, two longitudinally and two transverse, One set Charpy V-notch impact specimens in longitudinal direction and one in transverse

direction. One metallographic sample with minimum three hardness measurements (HV10). The samples shall be removed from the area of greatest deformation at 1/2T.

2.10 Mechanical testing required properties All mechanical testing shall be made by an accredited laboratory. The reduction of area for tensile samples shall be at least 35%. Charpy V-notch impact requirements: Grade Test temperature Min average (J) Min single (J) All -46oC or as given in the purchase

order 60 45

2.11 Retesting and corrective/remedial actions If any mechanical test fails to meet the requirements, the retest shall normally be performed on two new components from the same heat treatment batch. Alternatively, after written consent from the purchaser, retesting may be performed on the failed component. If one or both of these tests fail, each of the remaining components of the heat treatment batch shall be tested. Failed components shall be considered as not acceptable for delivery. New tempering is permitted. Only one attempt of re-tempering is acceptable. Each heat treatment batch must be fully re-tested following new tempering. After written consent from the purchaser, a new complete heat treatment cycle (including quench and tempering) may be conducted for rough machined components.

2.12 Non-destructive testing NDT shall be in accordance with design standard/code. All final NDT shall be conducted after final heat treatment and final machining, and minimum 24 hours after completion of any welding.

2.13 Tolerances Components or pup-pieces intended to be welded to line pipe shall have end dimensional tolerances for diameter, ovality, and wall thickness equal to or better than the tolerances of the joining line pipe. This shall be specified in the Project specific Material Data Sheet (PMDS).




2.14 Certification Certification shall be according to EN 10204, certificate type 3.1.

2.15 Marking The component shall be marked to ensure full traceability to the heat and heat treatment lot. Additional marking shall be as specified in the purchase order.

3 Documents to be forwarded to Company The following documents shall, when requested, be forwarded to Company for review prior to production: Manufacturing Procedure Specification Quality Plan The above documents shall as a minimum include project specific information of the following: Chemical composition Mechanical testing

o Laboratory for mechanical testing o Charpy impact transition temperature curve (if available) o Test coupon extraction/location o Sketch of mechanical test sampling for each component

Welding Procedure Specifications (WPS) and Welding Procedure Qualification Records (WPQR) Post-Weld Heat Treatment (PWHT) Heat treatment Non-Destructive Testing (NDT) Forging procedure Hot forming procedure

4 Additional information

4.1 Definitions and abbreviations HV10 Hardness Vickers MPS Manufacturing Procedure Specification NDT Non-Destructive Testing SMYS Specified Minimum Yield Strength QA/QC Quality Assurance/Quality Control

4.2 Changes from previous version There is no previous version of this document.

4.3 References The following standards are referred to in this TR document:




ASTM A694 Standard Specification for Carbon and Alloy Steel Forgings for Pipe Flanges, Fittings, Valves, and Parts for High-Pressure Transmission Service ASTM A860 High-strength butt-welding fittings of wrought high-strength low-alloy steel. ASME B31.3 Process Piping ASME B31.8 Gas Transmission and Distribution Piping Systems ISO 15156/NACE MR0175 Petroleum and natural gas industries Materials for use in H2S-containing environments in oil and gas production NS-EN 10204 Metallic products Types of inspection documents TR2023 H2S Cracking resistant materials TR1230 Subsea Structures and Manifolds