DET NORSKE VERITAS. Report. Statoil ASA

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1 Report EC Master Material Components: Particular material appraisal in accordance with the Pressure Equipment Directive No. 97/23/EC Statoil ASA Report No./DNV Reg No.: / 12JUZTB-1 Rev 2,

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3 Table of Contents CONCLUSIVE SUMMARY INTRODUCTION SCOPE OF WORK ABBREVIATIONS METHODOLOGY General Assessment of TR Limitations Limitations to application Limitations to revisions RESULTS Cr duplex (UNS S31803) Materials Reference standards and grades Applicable material data sheets Assessment results Mechanical properties Ductility Toughness Forming Welding Documentation Marking Cr duplex (UNS S32760) Materials Reference standards and grades Applicable material data sheets Assessment results Mechanical properties Ductility Toughness Forming Welding Documentation Date : Page ii of ii

4 Marking Normal temperature carbon steel CSNT, not impact tested Materials Reference standards and grades Applicable material data sheets Assessment results Mechanical properties Ductility Toughness Forming Welding Documentation Marking High temperature carbon steel (CSHT11), not impact tested Materials Reference standards and grades Applicable material data sheets Assessment results Mechanical properties Ductility Toughness Forming Welding Documentation Marking Low temperature carbon steel CSLT, impact tested Materials Reference standards and grades Applicable material data sheets Assessment results Mechanical properties Ductility Toughness Forming Welding Documentation Marking AISI 316 type material Materials Reference standards and grades Applicable material data sheets Assessment results Date : Page iii of iii

5 Mechanical properties Ductility Toughness Forming Welding Documentation Marking Mo type material (UNS S31254) Materials Reference standards and grades Applicable material data sheets Assessment results Mechanical properties Ductility Toughness Forming Welding Documentation Marking High strength austenitic (UNS S34565) Materials Reference standards and grades Applicable material data sheets Assessment results Mechanical properties Ductility Toughness Forming Welding Documentation Marking Titanium grade Materials Reference standards and grades Applicable material data sheets Assessment results Mechanical properties Ductility Toughness Forming Welding Documentation Date : Page iv of iv

6 Marking Bolting Materials Reference standards and grades Applicable material data sheets Assessment results Mechanical properties Ductility Toughness Forming Welding Documentation Marking DISCUSSIONS Mechanical properties Ductility Toughness Forming Welding Documentation Marking CONCLUSIONS REFERENCES APPENDIX Appendix 1: Particular Material Appraisals Date : Page v of v

7 CONCLUSIVE SUMMARY Det Norske Veritas AS (DNV) as Notified Body No has been commissioned by Statoil ASA to perform a particular material appraisal (PMA) in accordance with the Directive No. 97/23/EC /2/ of the materials listed in Statoil doc. No. TR2000 EC Master Material Components. The work was sub-contracted to the Section NTANO716, i.e. the Section for Material Technology. A similar work was carried out in 2006 and 2007, ref. DNV report No J This report concluded compliancy provided some supplementary requirements were included. The background for this application was revision of the old material data sheets reviewed in 2006 and The scope was to review and evaluate if the new revisions also fully comply. The piping and valve specification TR2000 /3/ is the governing specification for piping and valves in Statoil. The document includes a TR2000 EC Master Material Component which is a set of dummy piping classes listing specific materials. Totally, TR2000 EC Master Material Components covers ten different types of material classes, e.g. 22Cr duplex, 25Cr duplex, Titanium grade 2, 6Mo-steel, etc. These types of material classes are further described in 204 different material data sheets. In practice, these material data sheets cover ASTM and API material specifications with supplementary requirements in order to reduce the risk for poor deliveries and/or in service problems. This report describes the assessment methodology and assessment results, and includes the DNV forms for the particular material appraisal (PMA) for the materials specified in TR2000 EC Master Material Components. See appendix 1 for the PMA forms. The work concludes that the material data sheets comply with the Pressure Equipment Directive No. 97/23/EC. Date : Page 0-6

8 1 INTRODUCTION Det Norske Veritas AS (DNV) as Notified Body No has been commissioned by Statoil ASA to perform a particular material appraisal (PMA) in accordance with the Directive No. 97/23/EC /2/ of the materials listed in Statoil doc. No. TR2000 EC Master Material Components. The work is a revision of the work carried out in 2006 and 2007, ref. DNV report No J This report concluded compliancy provided some supplementary requirements were included. The background for this application was revision of the old material data sheets reviewed in 2006 and The scope was to review and evaluate if the new revisions also fully comply. The piping and valve specification TR2000 /3/ is the governing specification for piping and valves in Statoil. The document includes a TR2000 EC Master Material Component which is a set of dummy piping classes listing specific materials. One specific piping class exist for each type of material, e.g.: - Normal temperature CMn steel; - Low temperature CMn steel; - Austenitic stainless steel; - 6Mo; - 22Cr duplex; - 25Cr duplex; etc. Each type of material is further described in Statoil material data sheets. One type of material is described in specific Statoil material data sheet as function of: - Manufacturing method, e.g. plate, forging, seamless pipe, etc; - Application, e.g. relevant for welding, sour service, etc. Totally, TR2000 EC Master Material Components covers ten different types of materials described in 204 different material data sheets. This report describes the assessment methodology and assessment results, and includes the DNV forms for the particular material appraisal (PMA) for the materials specified in TR2000 EC Master Material Components. See appendix 1 for the PMA forms. 2 SCOPE OF WORK The objective of the work has been to review all the material data sheets in TR2000 EC Master Material Components when ASME B31.3 is the design code and assess whether the essential safety requirements in the Directive No. 97/23/EC /2/ is met. Date : Page 0-7

9 3 ABBREVIATIONS CMn steel CSHT CSLT CSNT DNV MDS NDT PED PMA VDM WPQR Carbon manganese steel Carbon steel high temperature Carbon steel low temperature Carbon steel normal temperature Det Norske Veritas Material Data Sheet Non Destructive Testing Pressure Equipment Directive Particular material appraisal ThyssenKrupp Vereinigte Deutsche Metallwerke GmbH Welding Procedure Qualification Record 4 METHODOLOGY 4.1 General The standard DNV form for particular material appraisals contains the following check points: - Mechanical strength properties; - Ductility; - Toughness; - Forming; - Welding; - Certification; - Marking; For assessments, all check points reflect the actual application, i.e. design code, temperature range and pressure. The above is in line with the Guidelines given by the EU commission responsible for the Directive No. 97/23/EC. 4.2 Assessment of TR2000 For the present assessment, first step was to review all relevant material data sheets. The review was carried out in line with the check points in Sec The review was based on and reflects the following: - Directive No. 97/23/EC, Annex 1 - PED new approach - Guidelines for Materials; - Design code, i.e. ASME B31.3; - Statoil clarification Memo dated with subject TR2000 Piping and Valve Materials under PED. The usage of this standard based on ASME B31.3 ; Date : Page 0-8

10 - Statoil clarification Memo (rev.2) dated with subject TR2000 Piping and Valve Materials under PED. The usage of this standard based on ASME B31.3 ; Next step of the assessment was to establish the formal particular material appraisal (PMA) documents based on the actual application and findings observed. For PMA documents established, see Appendix 1. Normally, PMA documents are established for each specific material grade as defined in a certain material specification. However, due to the number of material data sheets and the structure of TR2000, DNV has established a PMA document for each type of material. 4.3 Limitations Limitations to application The results of this work are applicable for applications covered by the Directive 97/23/EC only. The results shall not be used as basis for approval for other applications, e.g. subsea applications Limitations to revisions This report refers to Statoil doc. TR2000 Piping and valve specification per This means applicable Material Data Sheets with revision date from to The results of the work and the enclosed PMA documents apply for further revisions of Statoil doc. TR2000 Piping and valve specification without any re-assessment of DNV /1/ provided any essential requirements and limitations are left unchanged, i.e.: - New/additional materials shall not be included; - Min. and max. design temperature shall not be decreased or increased, respectively; - Max. Carbon Equivalent, C, S and P shall not be increased; - Min. reduction ratio, where specified, shall not be removed or reduced; - Normalising or equivalent heat treatment condition, where specified, shall not be deleted; - Toughness requirements shall not be deleted and min. required adsorbed energy shall not be reduced; - The PED /2/ requirements with respect to Welding Procedure Qualification Testing, welding operator qualification and operator qualifications for non destructive testing shall not be modified; - Type of material certificates required and conditions shall not be modified; - All materials shall have unique marking and traceability; - For pipes without impact test requirements, the cold bending radius shall not be less than 3 x OD (three times the outer diameter). Other modifications are permitted without re-assessment by DNV /1/ provided ASME B31.3 and respective material standards are complied with. Date : Page 0-9

11 5 RESULTS Cr duplex (UNS S31803) Materials Reference standards and grades Table 5.1-1: Material standards and grades Material standard Grade ASTM A182 F51 ASTM A240 S31803 ASTM A790 S31803 ASTM A815 S31803-S, S31803-W and S31803-WX ASTM A928 S31803 cl.1, 3 or Applicable material data sheets Table 5.1-2: Statoil material data sheets MDS (Forgings) MDS (Pipes) MDS (Rolled) MDS (Fittings) DF101 DP101 DS101 DW101 DF102 DP102 DS102 DW102 DF103 DP103 DS103 DW103 DF104 DP104 DW104 DF105 DP105 DW107 DF106 DW108 DF107 DW109 DF109 DW110 DW Assessment results Mechanical properties Due to the fact that all product forms are not covered by ASME B31.3, allowable stresses for UNS S31803 according to ASME B31.3 Table A-1 are used for all materials. Date : Page 0-10

12 Elevated strength properties defined by other standards and codes have been checked: - ASME II Part D defines identical allowable stresses for all product forms; - EN , EN and EN define more or less same yield strength properties independent on product form. The allowable stresses for UNS S31803 according to ASME B31.3 Table A-1 are acceptable as basis for all product forms Ductility All specified materials have min. ductility exceeding 14%. The ductility requirements in the Directive No. 97/23/EC are fulfilled Toughness Minimum criteria for ISO Charpy-V impact testing are specified for all materials, except for forged plugs as defined in DF106. Omitting toughness requirements for the forged plugs are accepted based on the following: - The stresses in forged plugs are low compared to max. allowable stresses; - The dimensions are small, i.e. 0,5 to 1,0 inch, i.e. small wall thickness. - The forged plugs are delivered with EN test reports, i.e. the application is not intended for main pressure bearing parts. Due to the small thickness and low stresses, brittle fracture is not considered as a technical issue. This is also supported by the history of safe use. Consequently, the Directive No. 97/23/EC is fulfilled Forming The pipe and plate materials have sufficient formability as defined in ASME B31.3. Additional cold bending qualification requirements are defined in NORSOK L Welding The materials have sufficient weldability even though the S and P content are somewhat higher than in the harmonised material standards. See Sec. 6 for technical justification. Directive No. 97/23/EC requires that the WPQR and welding operators are qualified by a recognised third party organisation within the European Community. For the MDS s specified in Table 5.1-2, these requirements are fulfilled. Directive No. 97/23/EC requires that NDT personnel are qualified by a recognised third party organisation within the European Community. For the MDS s specified in Table 5.1-2, this requirement is fulfilled Documentation Inspection document in accordance with EN 10204:2004 is specified in the Statoil material data sheets. Consequently, the Directive No. 97/23/EC is fulfilled Marking All material data sheets require marking ensuring full traceability to the melt, heat treatment lot and certificate. Consequently, the Directive No. 97/23/EC is fulfilled. Date : Page 0-11

13 5.2 25Cr duplex (UNS S32760) Materials Reference standards and grades Table 5.2-1: Material standards and grades Material standard Grade ASTM A182 F55 ASTM A240 S32760 ASTM A790 S32760 ASTM A815 S32760-S, S32760-W and S32760-WX ASTM A928 S32760 cl. 1, 3 or Applicable material data sheets Table 5.2-2: Statoil material data sheets MDS (Forgings) MDS (Pipes) MDS (Rolled) MDS (Fittings) DF201 DP201 DS201 DW201 DF202 DP202 DS202 DW202 DF203 DP203 DS203 DW203 DF204 DP204 DW204 DF205 DP205 DW207 DF206 DW208 DF207 DW209 DW210 DW Assessment results Mechanical properties Due to the fact that all product forms are not covered by ASME B31.3, allowable stresses for UNS S32760 according to ASME B31.3 Table A-1 are used for all materials. Elevated strength properties defined by other standards and codes have been checked: - ASME II Part D defines identical allowable stresses for all product forms; Date : Page 0-12

14 - EN , EN and EN define more or less same yield strength properties independent on product form. It should be noted that EN for seamless pipes define somewhat higher acceptable stresses at elevated temperature (approximately 5%) however the min. specified yield strength at room temperature is also somewhat higher. The de-rating for all product forms are more or less the same. The allowable stresses for UNS S32760 according to ASME B31.3 Table A-1 are acceptable as basis for all product forms Ductility All specified materials have min. ductility exceeding 14%. The ductility requirements in the Directive No. 97/23/EC are fulfilled Toughness Minimum criteria for ISO Charpy-V impact testing are specified for all materials, except for forged plugs as defined in DF206. Omitting toughness requirements for the forged plugs are accepted based on the following: - The stresses in forged plugs are low compared to max. allowable stresses; - The dimensions are small, i.e. 0,5 to 1,0 inch, i.e. small wall thickness. - The forged plugs are delivered with 2.2 test reports, i.e. the application is not intended for main pressure bearing parts. Due to the small thickness and low stresses, brittle fracture is not considered as a technical issue. This is also supported by the history of safe use. Consequently, the Directive No. 97/23/EC is fulfilled Forming The pipe and plate materials have sufficient formability as defined in ASME B31.3. Additional cold bending qualification requirements are defined in NORSOK L Welding The materials have sufficient weldability. Directive No. 97/23/EC requires that the WPQR and welding operators are qualified by a recognised third party organisation within the European Community. For the MDS s specified in Table 5.2-2, these requirements are fulfilled. Directive No. 97/23/EC requires that NDT personnel are qualified by a recognised third party organisation within the European Community. For the MDS s specified in Table 5.2-2, this requirement is fulfilled Documentation Inspection document in accordance with EN 10204:2004 is specified in the Statoil material data sheets. Consequently, the Directive No. 97/23/EC is fulfilled Marking All material data sheets require marking ensuring full traceability to the melt, heat treatment lot and certificate. Consequently, the Directive No. 97/23/EC is fulfilled. Date : Page 0-13

15 5.3 Normal temperature carbon steel CSNT, not impact tested Materials Reference standards and grades Table 5.1-1: Material standards and grades Material standard Grade ASTM A105 - ASTM A106 B ASTM A234 WPB ASTM A672 C60 cl.22 API 5L B PSL1 E, and B PSL1 SAW Applicable material data sheets Table 5.3-2: Statoil material data sheets MDS (Forgings) MDS (Pipes) MDS (Rolled) MDS (Fittings) CF201 CP201 CW201 CF202 CP202 CW202 CF203 CP203 CF204 CP204 CF205 CF206 CF Assessment results Mechanical properties Allowable stresses within the applicable temperature range are defined in ASME B31.3 for each material grade Ductility All specified materials have min. ductility exceeding 14%. The ductility requirements in the Directive No. 97/23/EC are fulfilled. Date : Page 0-14

16 Toughness Normally, DNV as Notified Body No would require ISO Charpy V impact testing at minimum design temperatures if below 0 o C for these materials. However, due to the fact that the material data sheets restricts the chemical composition of the steels in line with the European harmonised material standards, and the fact that the stress level is 20% lower than for the European harmonised design codes, DNV has previously technically justified the use down to -15 o C for these materials /6/. These steels were previously also technically justified for usage down to -29 o C provided ASTM A105 is either grain refined, fully heat treated or manufactured with minimum reduction ratio 4: Forming The material specifications do not specify any restrictions to Nitrogen and no lower limit of Nitrogen-binding elements. For the materials in Table 5.3-1, cold forming is relevant for pipes. In order to reduce the risk for detrimental strain ageing, the bending radius shall not be less than three (3) times the outer pipe diameter Welding Materials intended for welding have restrictions in line with EN 13480, i.e. restrictions with respect to Carbon, Sulphur and Phosphorous. In addition, max. carbon equivalent has been defined. Consequently, the weldability is sufficient. Directive No. 97/23/EC requires that the WPQR and welding operators are qualified by a recognised third party organisation within the European Community. For the MDS s specified in Table 5.3-2, these requirements are fulfilled. Directive No. 97/23/EC requires that NDT personnel are qualified by a recognised third party organisation within the European Community. For the MDS s specified in Table 5.3-2, this requirement is fulfilled Documentation Inspection document in accordance with EN 10204:2004 is specified in the Statoil material data sheets. Consequently, the Directive No. 97/23/EC is fulfilled Marking All material data sheets require marking ensuring full traceability to the melt, heat treatment lot and certificate. Consequently, the Directive No. 97/23/EC is fulfilled. Date : Page 0-15

17 5.4 High temperature carbon steel (CSHT11), not impact tested Materials Reference standards and grades Table 5.4-1: Material standards and grades Material standard Grade ASTM A182 F11 cl.2 ASTM A234 WP11 cl.1 ASTM A335 P11 ASTM A cl.1 ASTM A739 1 ¼ Cr cl..2 (A cl.1) Applicable material data sheets Table 5.4-2: Statoil material data sheets MDS (Forgings) MDS (Pipes) MDS (Rolled) MDS (Fittings) WF101 WP101 WS101 WW101 WF102 WP102 WS102 WW102 WF103 WF104 WF105 WF106 WF107 WF Assessment results Mechanical properties Allowable stresses within the applicable temperature range are defined in ASME B31.3 for each material grade Ductility All specified materials have min. ductility exceeding 14%. The ductility requirements in the Directive No. 97/23/EC are fulfilled. Date : Page 0-16

18 Toughness Normally, DNV as Notified Body No would require impact testing at minimum design temperatures below 0 o C for these materials. However, due to the fact that the material data sheets restricts the chemical composition of the steels in line with the European harmonised material standards, and the fact that the stress level is 20% lower than for the European harmonised design codes, DNV has previously technically justified the use down to -29 o C for these materials /6/. It should also be noted that these steels are intended for elevated temperature service and for ambient conditions. Therefore, acceptance is granted for conditions in accordance with ASME B Forming The material specifications do not specify any restrictions to Nitrogen and no lower limit of Nitrogen-binding elements. For the materials in Table 5.4-1, cold forming is relevant for pipes. In order to reduce the risk for detrimental strain ageing, the bending radius shall not be less than three (3) times the outer pipe diameter Welding Materials intended for welding have restrictions in line with EN 13480, i.e. restrictions with respect to Carbon, Sulphur and Phosphorous. In addition, max. carbon equivalent has been defined. Consequently, the weldability is sufficient. Directive No. 97/23/EC requires that the WPQR and welding operators are qualified by a recognised third party organisation within the European Community. For the MDS s specified in Table 5.4-2, these requirements are fulfilled. Directive No. 97/23/EC requires that NDT personnel are qualified by a recognised third party organisation within the European Community. For the MDS s specified in Table 5.4-2, this requirement is fulfilled Documentation Inspection document in accordance with EN 10204:2004 is specified in the Statoil material data sheets. Consequently, the Directive No. 97/23/EC is fulfilled Marking All material data sheets require marking ensuring full traceability to the melt, heat treatment lot and certificate. Consequently, the Directive No. 97/23/EC is fulfilled. Date : Page 0-17

19 5.5 Low temperature carbon steel CSLT, impact tested Materials Reference standards and grades Table 5.5-1: Material standards and grades Material standard Grade ASTM A333 6 ASTM A350 LF2 cl.1 ASTM A420 WPL6 ASTM A impact and 70-impact ASTM A671 CC60 cl.22 and CC70 cl.22 ASTM A694 F52 ASTM A860 WPHY52 API 5L X52 PSL2 S, X52 PSL2 SAW Applicable material data sheets Table 5.5-2: Statoil material data sheets MDS (Forgings) MDS (Pipes) MDS (Rolled) MDS (Fittings) CF101 CP101 CS101 CW101 CF102 CP102 CS102 CW102 CF103 CP105 CS103 CW302 CF104 CP106 CS106 CF105 CP301 CF106 CP302 CF107 CP303 CF301 CF302 CF304 CF305 Date : Page 0-18

20 5.5.2 Assessment results Mechanical properties Allowable stresses within the applicable temperature range are defined in ASME B31.3 for each material grade, except for ASTM A694 grade F52 and ASTM A860 grade WPHY52. For these materials, allowable stresses are defined identical as for API 5L grade X52. In principle, these materials are similar therefore it has been normal practice in the offshore industry to use same allowable stresses for these materials Ductility All specified materials have min. ductility exceeding 14%. The ductility requirements in the Directive No. 97/23/EC are fulfilled Toughness Minimum criteria for ISO Charpy-V impact testing are specified for all materials. Consequently, the Directive No. 97/23/EC is fulfilled Forming The material specifications do not specify any restrictions to Nitrogen and no lower limit of Nitrogen-binding elements. For the materials in Table 5.5-1, cold forming is relevant for pipes. In order to reduce the risk for detrimental strain ageing, the bending radius shall not be less than three (3) times the outer pipe diameter Welding Materials intended for welding have restrictions in line with EN 13480, i.e. restrictions with respect to Carbon, Sulphur and Phosphorous. In addition, max. carbon equivalent has been defined. Consequently, the weldability is sufficient. Directive No. 97/23/EC requires that the WPQR and welding operators are qualified by a recognised third party organisation within the European Community. For the MDS s specified in Table 5.5-2, these requirements are fulfilled. Directive No. 97/23/EC requires that NDT personnel are qualified by a recognised third party organisation within the European Community. For the MDS s specified in Table 5.5-2, this requirement is fulfilled Documentation Inspection document in accordance with EN 10204:2004 is specified in the Statoil material data sheets. Consequently, the Directive No. 97/23/EC is fulfilled Marking All material data sheets require marking ensuring full traceability to the melt, heat treatment lot and certificate. Consequently, the Directive No. 97/23/EC is fulfilled. Date : Page 0-19

21 5.6 AISI 316 type material Materials Reference standards and grades Table 5.6-1: Material standards and grades Material standard Grade ASTM A182 F316 ASTM A ASTM A312 TP316 ASTM A358 TP316 cl.1, 3, 4 and 5 ASTM A403 WP316-S, WP316-W and WP316-WX Applicable material data sheets Table 5.6-2: Statoil material data sheets MDS (Forgings) MDS (Pipes) MDS (Rolled) MDS (Fittings) SF301 SP301 SS301 SW301 SF302 SP302 SS302 SW302 SF303 SP303 SS303 SW307 SF304 SP307 SW308 SF305 SW309 SF306 SW310 SF307 SW311 SF309 SW312 SW314 SW Assessment results Mechanical properties Allowable stresses within the applicable temperature range are defined in ASME B31.3 for each material grade. Date : Page 0-20

22 Ductility All specified materials have min. ductility exceeding 14%. The ductility requirements in the Directive No. 97/23/EC are fulfilled Toughness Austenitic stainless steel does not have ductile-brittle behaviour transition as function of temperature. The temperature limitations in ASME B31.3 with corresponding allowable stresses are acceptable Forming The pipe and plate materials have sufficient formability as defined in ASME B31.3. Additional cold bending qualification requirements are defined in NORSOK L Welding The materials have sufficient weldability. Directive No. 97/23/EC requires that the WPQR and welding operator are qualified by a recognised third party organisation within the European Community. For the MDS s specified in Table 5.6-2, this requirement is fulfilled. Directive No. 97/23/EC requires that NDT personnel are qualified by a recognised third party organisation within the European Community. For the MDS s specified in Table 5.6-2, this requirement is fulfilled Documentation Inspection document in accordance with EN 10204:2004 is specified in the Statoil material data sheets. Consequently, the Directive No. 97/23/EC is fulfilled Marking All material data sheets require marking ensuring full traceability to the melt, heat treatment lot and certificate. Consequently, the Directive No. 97/23/EC is fulfilled. Date : Page 0-21

23 5.7 6Mo type material (UNS S31254) Materials Reference standards and grades Table 5.7-1: Material standards and grades Material standard Grade ASTM A182 F44 ASTM A240 S31254 ASTM A312 S31254 ASTM A358 S31254 cl.1, 3 and 5 ASTM A403 S31254-S, S31254-W and S31254-WX Applicable material data sheets Table 5.7-2: Statoil material data sheets MDS (Forgings) MDS (Pipes) MDS (Rolled) MDS (Fittings) SF701 SP701 SS701 SW701 SF702 SP702 SS702 SW702 SF703 SP703 SS703 SW703 SF704 SP704 SW704 SF705 SW707 SF706 SW708 SF707 SW709 SF709 SW710 SW Assessment results Mechanical properties Allowable stresses are determined by Statoil AS. The allowable stresses calculated are based on: - Safety factors in accordance with ASME B31.3; Date : Page 0-22

24 - Minimum yield strength properties from VDM and Avesta for UNS N08926 and UNS S31254, respectively. The stricter values are used for determining the allowable stresses. The allowable stresses determined are accepted Ductility All specified materials have min. ductility exceeding 14%. The ductility requirements in the Directive No. 97/23/EC are fulfilled Toughness Austenitic stainless steel does not have ductile-brittle behaviour transition as function of temperature. The temperature limitations in ASME B31.3 with corresponding allowable stresses are acceptable Forming The pipe and plate materials have sufficient formability as defined in ASME B31.3. Additional cold bending qualification requirements are defined in NORSOK L Welding The materials have sufficient weldability. Directive No. 97/23/EC requires that the WPQR and welding operator are qualified by a recognised third party organisation within the European Community. For the MDS s specified in Table 5.7-2, these requirements are fulfilled. Directive No. 97/23/EC requires that NDT personnel are qualified by a recognised third party organisation within the European Community. For the MDS s specified in Table 5.7-2, this requirement is fulfilled Documentation Inspection document in accordance with EN 10204:2004 is specified in the Statoil material data sheets. Consequently, the Directive No. 97/23/EC is fulfilled Marking All material data sheets require marking ensuring full traceability to the melt, heat treatment lot and certificate. Consequently, the Directive No. 97/23/EC is fulfilled. Date : Page 0-23

25 5.8 High strength austenitic (UNS S34565) Materials Reference standards and grades Table 5.8-1: Material standards and grades Material standard Grade ASTM A182 F49 ASTM A312 S34565 ASTM A358 S34565 cl.1 or 3 ASTM A403 S34565-S and S WX Applicable material data sheets Table 5.8-2: Statoil material data sheets MDS (Forgings) MDS (Pipes) MDS (Rolled) MDS (Fittings) SF801 SP801 SW801 SF804 SP802 SW802 SF805 SP803 SW803 SF807 SW804 SW808 SW809 SW810 SW Assessment results Mechanical properties Allowable stresses within the applicable temperature range are defined in ASME B31.3 for each material grade Ductility All specified materials have min. ductility exceeding 14%. The ductility requirements in the Directive No. 97/23/EC are fulfilled. Date : Page 0-24

26 Toughness High strength austenitic stainless steel does not have ductile-brittle behaviour transition as function of temperature. The temperature limitations in ASME B31.3 with corresponding allowable stresses are acceptable Forming The pipe and plate materials have sufficient formability as defined in ASME B31.3. Additional cold bending qualification requirements are defined in NORSOK L Welding The materials have sufficient weldability. Directive No. 97/23/EC requires that the WPQR and welding operator are qualified by a recognised third party organisation within the European Community. For the MDS s specified in Table 5.8-2, these requirements are fulfilled. Directive No. 97/23/EC requires that NDT personnel are qualified by a recognised third party organisation within the European Community. For the MDS s specified in Table 5.8-2, this requirement is fulfilled Documentation Inspection document in accordance with EN 10204:2004 is specified in the Statoil material data sheets. Consequently, the Directive No. 97/23/EC is fulfilled Marking All material data sheets require marking ensuring full traceability to the melt, heat treatment lot and certificate. Consequently, the Directive No. 97/23/EC is fulfilled. Date : Page 0-25

27 5.9 Titanium grade Materials Reference standards and grades Table 5.9-1: Material standards and grades Material standard Grade ASTM B265 2 ASTM B363 WPT2-S, WPT2-W and WPT2-W S2 ASTM B381 F2 ASTM B861 2 ASTM B862 2, 2 S1.2.1 and 2S Applicable material data sheets Table 5.9-2: Statoil material data sheets MDS (forgings) MDS (pipes) MDS (rolled) MDS (fittings) TF101 TP101 TS101 TW101 TF102 TP102 TS102 TW102 TF103 TP103 TW103 TF105 TP104 TW106 TF106 TF Assessment results Mechanical properties Due to the fact that all product forms are not covered by ASME B31.3, allowable stresses for ASTM B265 grade 2 and ASTM B381 grade 2 according to ASME B31.3 Table A-1 are used for all materials. ASME II Part D defines allowable stresses for all listed product forms. The allowable stresses defined are identical for all product forms, except for ASTM B862 grade 2, i.e. welded pipes. The allowable stresses defined for ASTM B265 grade 2 and ASTM B381 grade 2 are acceptable for all product forms, except for welded pipes in accordance with ASTM B862. Date : Page 0-26

28 For welded pipes, welding efficient factor must be included. This is included in relevant Piping Class Data sheets Ductility All specified materials have min. ductility exceeding 14%. The ductility requirements in the Directive No. 97/23/EC are fulfilled Toughness Titanium does not have ductile-brittle behaviour transition as function of temperature. The temperature limitations in ASME B31.3 with corresponding allowable stresses are acceptable Forming The pipe and plate materials have sufficient formability as defined in ASME B31.3. Additional cold bending qualification requirements are defined in NORSOK L Welding The materials have sufficient weldability. Directive No. 97/23/EC requires that the WPQR and welding operator are qualified by a recognised third party organisation within the European Community. For the MDS s specified in Table 5.9-2, these requirements are fulfilled. Directive No. 97/23/EC requires that NDT personnel are qualified by a recognised third party organisation within the European Community. For the MDS s specified in Table 5.9-2, these requirement is fulfilled Documentation Inspection document in accordance with EN 10204:2004 is specified in the Statoil material data sheets. Consequently, the Directive No. 97/23/EC is fulfilled Marking All material data sheets require marking ensuring full traceability to the melt, heat treatment lot and certificate. Consequently, the Directive No. 97/23/EC is fulfilled. Date : Page 0-27

29 5.10 Bolting Materials Reference standards and grades Table : Material standards and grades Material standard Grade ASTM A193 B7, B8M2 and B16 ASTM A320 L7, L43 and B8M Applicable material data sheets Table : Statoil material data sheets MDS (CSNT, CSHT) MDS (CSLT) MDS (austenitic stainless) VN101 VN201 VN301 VN102 VN202 VN302 VN103 VN104 VN Assessment results Mechanical properties Allowable stresses within the applicable temperature range are defined in ASME B31.3 for each material grade Ductility All specified bolting materials have min. ductility 14% or higher. The ductility requirements in the Directive No. 97/23/EC are fulfilled Toughness The toughness requirements in ASME B31.3 and applicable apply. It means that bolting applicable for CSNT and CSHT lines are used down to -46 o C and -40 o C, respectively, depending on thickness without guaranteed toughness properties. The Directive No. 97/23/EC, Annex 1 ch. 7.5, requires guaranteed toughness properties if not otherwise technically justified. For technical justification, see Sec. 6. The toughness requirements in the Directive No. 97/23/EC are fulfilled. Date : Page 0-28

30 Forming Not applicable Welding Not applicable Documentation Statoil piping class data sheets require type 2.2 inspection documents in accordance with EN 10204:2004. This applies to both flange and clamp connector bolting. Based on assessment carried out by Statoil /4/, failure of one bolt does not result in fatal loss of integrity of the connection under pressure. Clamp connections have at least two bolts at each side. One bolt has the capacity to carry the pressure load and forces on the clamp connection. The documentation requirements in the Directive No. 97/23/EC are fulfilled Marking ASTM A193 and ASTM A320 require unique identification, either on each bolting material or on each bundle/box. The marking requirements in the Directive No. 97/23/EC are fulfilled. Date : Page 0-29

31 6 DISCUSSIONS 6.1 Mechanical properties Most of the materials are covered by ASME B31.3, i.e. allowable stresses are defined for applicable temperature ranges. For materials not covered by ASME B31.3, most of the materials are listed in ASME II Part D. The allowable stresses specified in ASME II Part D for pressure vessel applications are accepted. For materials not covered by ASME B31.3 and ASME II Part D the following has been accepted: - For all, use of allowable stresses specified for one product form, e.g. pipes, are accepted for other product forms, e.g. forgings. This acceptance is justified with comparison to other standards. - For 6Mo steels, the tensile properties are accepted as they are confirmed by material manufacturers, i.e. VDM and Avesta. 6.2 Ductility The Directive No. 97/23/EC, Annex 1 ch. 7.5, requires materials with minimum ductility at 14%. All materials in the Material Data Sheets covered by the review fulfil this requirement. 6.3 Toughness The Directive No. 97/23/EC, Annex 1 ch. 7.5, requires guaranteed toughness properties of steels that may be susceptible to brittle behaviour, e.g. ferritic steels. The bolting materials applicable for CSNT and CSHT lines are used down to -46 o C and -40 o C, respectively, without guaranteed toughness properties depending on thickness. Normally, DNV as Notified Body No would require impact testing for design temperatures below 0 o C in order to fulfil the Directive No. 97/23/EC. However, due to the fact that Statoil has assessed the risk /4/ and conclude that failure of one bolt does not result in fatal loss of integrity, the toughness criteria in TR2000 EC Master Material Components Piping and valve specification /3/ for bolting materials are accepted. This is also supported by use of recognised design code with listed materials where the experience is good. According to failure overview of bolting materials, the common failure mechanism is not related to brittle fracture due to poor toughness /5/. For materials applicable for CSNT and CSHT omitting toughness testing has been accepted down to min. design temperature -29 o C. This has previously been technically justified in DNV Report No J Date : Page 0-30

32 6.4 Forming In general, all the steels are considered to have fair formability according to ASME B31.3 and other ASME codes. In other standardisation schemes, e.g. EN, DNV, etc., standard practice is to specify max. allowable Nitrogen content and/or adding of Nitrogen-binding elements in order to avoid detrimental effects from strain ageing. Strain ageing may be relevant for pipes exposed to cold forming. Potentially, strain ageing is relevant for plates as well, however, plate materials are specified for blinds only (i.e. nonformed after rolling). In order to reduce the risk for detrimental effects from strain ageing, the Material Data Sheets should preferably include requirements for use of Nitrogen-binding elements and/or define maximum allowable Nitrogen-content. As an alternative, DNV has accepted to restrict the cold forming bending radius to minimum three (3) the outer pipe diameter. 6.5 Welding According to PED Annex 1 Ch , welding procedures for process piping in PED category II and III, shall be approved by a competent third-party. For same PED categories, the welders shall be approved by a recognised third-party organisation. In PED category III, the same applies for operators of non destructive testing as for welders. These requirements are covered by the Statoil Material Data Sheets. 6.6 Documentation All materials specify documentation in accordance with EN 10204:2004. Where type 3.1 inspection documents are specified, reference to acceptable quality assurance system certification is given. 6.7 Marking All materials specify unique marking, either by the relevant material specifications or by the relevant Material Data Sheets. 7 CONCLUSIONS The materials covered in this report are found to comply with the Pressure Equipment Directive No. 97/23/EC. Date : Page 0-31

33 8 REFERENCES /1/ Notified Body No. 0575, DNV NACNO Section for Product Certification /2/ Pressure Equipment Directive No. 97/23/EC /3/ Statoil doc. No. TR2000 EC Master Material Components Piping and valve specification /4/ ASME B31.3: 2010, Process Piping /5/ Statoil clarification Memo dated (rev.2), TR2000 Piping and Valve Materials under PED. The usage of this standard based on ASME B31.3 /6/ DNV Report No J-4639 dated , Assessment according to the Directive No. 97/23/EC Date : Page 0-32

34 APPENDIX 1 Particular Material Appraisals Date : Page 1-33

35 Particular Material Appraisal 22Cr duplex, impact tested Date: Revision: 0 Page: 1 (1) Pressure Equipment Manufacturer: - Material specifications: ASTM A790 1) ASTM A182 1) ASTM A815 1) ASTM A240 1) ASTM A928 1) Grade: S31803 F51 S31803 S31803 S31803 Application: Applications covered by Directive 97/23/EC Min. allowable temperature [ C]: -46 ºC Product form: Seamless pipes Forgings Wrought fittings Plates Welded pipes Applicable Design Code: ASME B31.3 Heat treatment condition: Max. allowable pressure [bar] According to ASME B31.3 Max. allowable temperature [ C] According to ASME B31.3 Compliance with Essential Safety Requirements Property Requirement Compliance Appropriate properties (Annex (a)) Sufficiently ductile (Annex (a)) (Annex 1 7.5) Sufficiently tough (Annex 1 4.1(a), Annex 1 7.5) Not significantly affected by ageing (Annex (c)) Suitable for intended processing (Annex (d)) Material Marking (Annex ) Type of Certificate (Annex 1 4.3) e.g. R e/t R m/20 if required R m/t. See Note 2 In steel; 14 % e.g. in steel; 27 Joule at 20 0 C or lowest operating temp. At intended operating temperatures e.g. welding, forming, etc Identifiable to Certificate Certified QA-system. Impact testing specified.. Covered by the applicable material data sheets. Covered by the applicable material data sheets Notes: 1. For compliancy, the materials shall be delivered in accordance with one of the following material data sheets: Product form Material data sheets Wrought fittings : DW101, DW102, DW103, DW104, DW107, DW108, DW109, DW110, DW111 Seamless pipes : DP101, DP105 Welded pipes : DP102, DP103, DP104 Forgings : DF101, DF102, DF103, DF104, DF105, DF106, DF107 Plates : DS101, DS102, DS The ASTM specifications do not specify elevated temperature properties for these steels. However, the allowable design stresses specified in ASME B31.3 are acceptable. All product forms are based on the allowable stresses as specified for ASTM A790 type UNS S This is technically justified in DNV Report No The applicable requirements of the Council Directive No. 97/23/EC is complied with if all conditions specified in this Particular Material Appraisal are fulfilled, i.e. the material referred to shall comply with the material specification, plus the Notes stated in this document. PMA established by Morten Johnsrud, Det Norske Veritas AS Det Norske Veritas AS, Norway. Notified Body No Place Oslo Date

36 Particular Material Appraisal 25Cr duplex, impact tested Date: Revision: 0 Page: 1 (1) Pressure Equipment Manufacturer: - Material specifications: ASTM A790 1) ASTM A182 1) ASTM A815 1) ASTM A240 1) ASTM A928 1) Grade: S32760 F55 S32760 S32760 S32760 Application: Applications covered by Directive 97/23/EC Min. allowable temperature [ C]: -46 ºC Product form: Seamless pipes Forgings Wrought fittings Plates Welded pipes Applicable Design Code: ASME B31.3 Heat treatment condition: Max. allowable pressure [bar] According to ASME B31.3 Max. allowable temperature [ C] According to ASME B31.3 Compliance with Essential Safety Requirements Property Requirement Compliance Appropriate properties (Annex (a)) Sufficiently ductile (Annex (a)) (Annex 1 7.5) Sufficiently tough (Annex 1 4.1(a), Annex 1 7.5) Not significantly affected by ageing (Annex (c)) Suitable for intended processing (Annex (d)) Material Marking (Annex ) Type of Certificate (Annex 1 4.3) e.g. R e/t R m/20 if required R m/t. See Note 2 In steel; 14 % e.g. in steel; 27 Joule at 20 0 C or lowest operating temp. At intended operating temperatures e.g. welding, forming, etc Identifiable to Certificate Certified QA-system. Impact testing specified.. Covered by the applicable material data sheets. Covered by the applicable material data sheets Notes: 1. For compliancy, the materials shall be delivered in accordance with one of the following material data sheets: Product form Material data sheets Wrought fittings : DW201, DW202, DW203, DW204, DW207, DW208, DW209, DW210, DW211 Seamless pipes : DP201, DP205 Welded pipes : DP202, DP203, DP204 Forgings : DF201, DF202, DF203, DF204, DF205, DF206, DF207 Plates : DS201, DS202, DS The ASTM specifications do not specify elevated temperature properties for these steels. However, the allowable design stresses specified in ASME B31.3 are acceptable. All product forms are based on the allowable stresses as specified for ASTM A790 type UNS S This is technically justified in DNV Report No The applicable requirements of the Council Directive No. 97/23/EC is complied with if all conditions specified in this Particular Material Appraisal are fulfilled, i.e. the material referred to shall comply with the material specification, plus the Notes stated in this document. PMA established by Morten Johnsrud, Det Norske Veritas AS Det Norske Veritas AS, Norway. Notified Body No Place Oslo Date

37 Particular Material Appraisal CSNT, not impact tested Date: Revision: 0 Page: 1 (1) Pressure Equipment Manufacturer: - Material specifications: ASTM A234 1) API 5L 1) ASTM A672 1) ASTM A106 1) ASTM A105 1) Grade: WPB B CC60, cl. 22 B - Application: Applications covered by Directive 97/23/EC Min. allowable temperature [ C]: -29 ºC Product form: Wrought fittings Welded pipes Welded pipes Seamless pipes Forgings Applicable Design Code: ASME B31.3 Heat treatment condition: Max. allowable pressure [bar] According to ASME B31.3 Max. allowable temperature [ C] According to ASME B31.3 Compliance with Essential Safety Requirements Property Requirement Compliance Appropriate properties (Annex (a)) Sufficiently ductile (Annex (a)) (Annex 1 7.5) Sufficiently tough (Annex 1 4.1(a), Annex 1 7.5) Not significantly affected by ageing (Annex (c)) Suitable for intended processing (Annex (d)) Material Marking (Annex ) Type of Certificate (Annex 1 4.3) e.g. R e/t R m/20 if required R m/t. See Note 2 In steel; 14 % e.g. in steel; 27 Joule at 20 0 C or lowest operating temp. At intended operating temperatures e.g. welding, forming, etc Identifiable to Certificate Certified QA-system. See Note 3. Chemical composition modified per applicable material data sheet. See also Note 4. Chemical composition modified per applicable material data sheet.. Covered by the applicable material data sheets. Covered by the applicable material data sheets Notes: 1. For compliancy, the materials shall be delivered in accordance with one of the following material data sheets: Product form Material data sheets Wrought fittings : CW201, CW202 Seamless pipes : CP201 Welded pipes : CP202, CP203, CP204 Forgings : CF201, CF202, CF203, CF204, CF205, CF206, CF Neither the ASTM specifications nor the API 5L specification specify elevated temperature properties for these steels. However, the allowable design stresses specified in ASME B31.3 are acceptable. 3. Normally, DNV as Notified Body No would require impact testing for design temperatures below 0 o C. Acceptance for design temperatures down to -29 o C have been accepted based on technical justification in DNV Report No J For cold bending not followed by heat treatment above transformation temperature, bending radius shall be no less than 3 x OD in order to avoid detrimental strain- and strain ageing effects. The applicable requirements of the Council Directive No. 97/23/EC is complied with if all conditions specified in this Particular Material Appraisal are fulfilled, i.e. the material referred to shall comply with the material specification, plus the Notes stated in this document. PMA established by Morten Johnsrud, Det Norske Veritas AS Det Norske Veritas AS, Norway. Notified Body No Place Oslo Date

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