NORSOK standard M-650 Rev. 4, September 2011 QTR. No.:002 bis

Transcription

1 DQ002 bis -1 NORSOK standard M-650 Rev. 4, September 2011 QTR. No.:002 bis Manufacturer name/address/ Web page: Reference standard EQTR Extension of the Qualification Test Record n 002 rev. n 01 NORSOK M-650 ACIERIES HACHETTE ET DRIOUT 11 Avenue du général Sarrail, Saint-Dizier (France) NORSOK M650 rev04; M630 rev05 (MDS D56 rev4). Rev. No.:00 Material designation and MDS No.: Manufacturing summary doc. No.: Products and manufacturing process(es) A995 Grade5A MDS D56 rev04 PSP063 Steel foundry (carbon and stainless steel) Sand moulding Rev. No.:06 Mandatory conditions and subcontractors: Heat treatment in furnace MGRI and MGRIII. Weld repair by HD 94/09. Other information: TÜV Rheinland report number TÜV Rheinland report number 3.2 EN certificate on destructive tests. WPS: HD 94/9 Qualification expires: Products and manufacturing process(es): Tested and Qualified Thickness and Weight Test record No. Tested thickness (mm) Qualified thickness (mm) Test piece weight (kg) Qualified weight (kg) Casting A995 Gr 5A DQ002 bis rev All Qualification/Acceptance signatures Manufacturer: Aciéries Hachette et Driout Prepared by/date: Checked by/date J WISNIEWSKI le 20/03/2012 D FLAMENT le 20/03/2012 The manufacturer and this QTR are evaluated and found to be in compliance with the requirements of NORSOK M-650 for supply of the above listed products and materials. This acceptance does not exempt any purchaser from his responsibility to ensure that this qualification is valid or his products within the essential variables of NORSOK M-650. Qualified/Accepted by (company name/address): Signature/Date:

2 DQ002 bis -2 QUALIFICATION FILE DOSSIER DE QUALIFICATION CONTENT CONTENU Section Content Page 1 Description of the component tested for the extension of the qualification: - Sketch of the component. - Location and orientation of the test specimens. Description de la pièce sacrificielle utilisée dans le cadre de cette extension: 3 - Schéma de la pièce. - Présentation des lieux de prélèvement pour la réalisation des essais mécaniques. 2 Heat treatment of the component. Traitement thermique de la pièce sacrificielle. 7 3 Results of the tests - Non Destructive tests ; Radiographic testing and Liquid penetrant testing - Destructive tests : Mechanical and corrosion tests Résultats des essais réalisés : 8 - Test non destructifs; contrôle radiographique et ressuage. - Essais destructifs ; essais mécaniques et essais de corrosions. 4 Conclusions 9 5 Minutes of meeting from visit to manufacturer by Sulzer. Compte rendu de réunion avec le client Sulzer. 10 Annex A Quality plan n 34/11. Plan qualite n 34/ Annex B TÜV report n Rapport TÜV n Annex C Thermal processing instruction. Procédure de traitement thermique (version anglaise). 24 Annex D D1:Heat treatment curves of the furnace MGRI. D2: Temperatures measured at each thermocouple. D3: Zoom on the curves C2 when the furnace reached the set point temperature (1140 C). 25 D1 : Courbes de traitement thermique du four MGRI. D2 : Températures relevées à chaque thermocouple. D3 : Zoom sur la courbe C2. Annex E E1 : Liquid penetrant testing certificate. E2: Radiographic testing certificate. E1: PV de contrôle par ressuage. 28 E2 : PV de contrôle radiographique. Annex F 3.2 certificate from the TÜV. Certificat 3.2 du TÜV. 33 Annex G Destructive tests: Mechanical properties. Résultats des essais mécaniques. 35 Annex H Micrographic reports. PV des micrographies. 36 Annex I Corrosion tests. PV des essais de corrosions. 42 Remark: All the contents listed in the Norsok M650 rev 4 in the paragraph 11.2 are presented in the qualification test record (QTR) n 002 rev n 1 obtai ned the The current document is an extension of the QTR. Remarque : Tout le contenu obligatoire listé dans la Norsok M650 révision 4 dans le paragraphe 11.2 est présenté dans la QTR n 002 rev n 1 obtenue le 27/06/2011. Le document présent est une extension de la QTR.

3 DQ002 bis -3 I- Description of the sacrificial component SECTION 1 A sacrificial component is designed for the extension of the qualification. The component is a quarter of a flange with a thickness of 180 mm (picture 1). The reference of the piece is NORSOK 180MM GR5A. The quality plan 34/11 is presented in the annex A. Fig. 1 : Sketch of the 1/4 of the flange. A test block is attached to the piece. The dimensions of the test block are 250*180*200 mm3. II- Positions of the samples for the destructive tests The samples are taken in the middle of the sacrificial flange. The picture 2 is a sketch of the piece, the volume where all the sacrificial tests are realized is colored.

4 DQ002 bis -4 Part of the piece where all the destructive tests will be realized. Fig. 2 : Sketch of the sacrificial piece. The positions of each destructive test are presented on the pictures 3 and 4. For the test block, the corrosion tests are realized in the middle of the block. Each sample has a unique number. Each number gives an indication about the position of the sample in the flange or in the test block, for example: - FLA_180_MID_T: is a sample for a Tensile test (T) located in the middle (MID) of the flange (FLA) in the higher part of the flange (180 for 180 mm). - FLA_70_C: is a sample for a Corrosion test (C) located in the flange (FLA) in the part with a thickness of 70 mm (70). - EPR_1/4_R: is a sample for an Impact test (R) located in the ¼ of the test block (EPR).

5 Fig. 3: Position of the destructive tests in the test blocks (transversal section of the test block). DQ002 bis -5

6 DQ002 bis -6 Fig. 4: Positions of the destructive tests in the sacrificial component (section of the flange in the colored part of the picture 2). The sketch (and the destructive tests) are realized and validated with the TÜV Rheinland. The positions of the samples were chose in accordance with the Norsok M650 rev 4 and the M630 rev 5 (MDS D56).

7 DQ002 bis -7 SECTION 2 Heat treatment of the component See in the annex B the TÜV Rheinland report number The sacrificial piece and his test block are heat treated in the furnace MGRI. The procedure applied is presented in the annex C. The charge is instrumented with ten thermocouples. With the presence of the TÜV Rheinland: - The homogeneity of the furnace is controlled during the heat treatment of the sacrificial piece. The analyses of the curves were realized with the TÜV. The table of the data is below. As specified in the TÜV report (annex B) the furnace respects the Norsok M650 rev 4. The heat treatment curves are grouped in the annex D: - The curve n D-1 is the curve of the furnace (temp erature used by the control panel to regulate the temperature in the furnace). - The graph n D-2 regroups the curves recorded for each thermocouple in the charge. - The curve n D-3 is a zoom on the graph n D-2 when the furnace reached the set point temperature (1140 C, represented with the curve co ntrol ). Only three thermocouples are presented, the thermocouple in the heart of the sacrificial flange (TC10), the thermocouples 8 and 15 which are in the middle of risers. Each riser is put in an opposite part of the furnace. The curves show that 45 min is necessary to reach the set point temperature in the heart of the flange.

8 DQ002 bis -8 SECTION 3 Controls of the sacrificial component a- Non destructive tests The liquid penetrant testing certificate and the radiographic testing certificate are in the annex E. The sacrificial piece and the test block are conformed to the Norsok M630 rev 5 MDS D56. b- Destructive tests The tests were realized with the TÜV. The 3.2 certificate is in the annex F. The locations of all the destructive tests are presented on the pictures 3 and 4. The results are presented in the following annex: - Annex G: Mechanical results - Annex H: Micrographic reports - Annex I: Corrosion reports* *: The corrosion tests are realized according to the G48 method A (annex I1) in order to be conform to the Norsok specifications (MDS D56 rev 4). The A923 method C corrosion test is also realized (annex I2). This standard is out of the Norsok specifications M650 and M630 and the results are given for information. c- Conclusions The sacrificial piece and his test block are fully conformed to the Norsok M650 rev 4 and the Norsok M630 rev 5 MDS56. For information: The results are equally conformed to the Clair Ridge Amec/RDS specification: CLB- FC-0X-MT-SPE-0005_B2 and the Quad 204 BP/KBR specification: QD-BR-MT-DAT-0001 Rev B2.

9 DQ002 bis -9 SECTION 4 Conclusions A sacrificial component is designed for the extension of the qualification. The component is a quarter of a flange with a thickness of 180 mm. The sacrificial piece and his test block (thickness 180 mm) is heat treated according to the Norsok M650 rev 4 in the MGRI furnace of the Aciéries Hachette et Driout company (AHD). An instrumented charge is used to show that the furnace presents an homogeneity in accordance with the API Spec 6A:2010/ISO 10423:2009, Annex M, ASTM A 991 and the Annex B of the Norsok M650 rev4. The destructive and non-destructive tests prove that the sacrificial piece and his test block are fully conformed to the Norsok M650 rev 4 and the Norsok M630 rev 5 MDS56. All the work was realized under the control of the TÜV Rheinland. For information: The results are equally conformed to the Clair Ridge Amec/RDS specification: CLB- FC-0X-MT-SPE-0005_B2 and the Quad 204 BP/KBR specification: QD-BR-MT-DAT-0001 Rev B2.

10 SECTION 5 Minutes of meeting from visit to manufacturer by Sulzer DQ002 bis -10

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13 ANNEX A: Quality plan n 34/11 DQ002 bis -13

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15 ANNEX B: TÜV Rheinland report number DQ002 bis -15

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24 ANNEX C: Thermal processing instruction (English version). DQ002 bis -24

25 ANNEX D: Heat treatment curves D1: Curves from the furnace MGRI DQ002 bis -25

26 ANNEX D: Heat treatment curves D2: Temperatures recorded at each thermocouple in the charge DQ002 bis -26

27 ANNEX D: Heat treatment curves D3: Zoom on the curve D2 when the furnace reached the set point temperature (1140 C). DQ002 bis -27

28 ANNEX E E1: Liquid penetrant testing certificate DQ002 bis -28

29 ANNEX E2: Radiographic testing certificate. DQ002 bis -29

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33 ANNEX F: 3.2 certificate from the TÜV DQ002 bis -33

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35 ANNEX G : Mechanical properties DQ002 bis -35

36 ANNEX H : Micrographic reports DQ002 bis -36

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42 ANNEX I1: Corrosion tests according to the G48 method A (conform to the Norsok M630 rev5 specification) DQ002 bis -42

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48 ANNEX I2: Corrosion tests according to the A923 method C. DQ002 bis -48

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