dep 37.81.20.38-gen - feb 2013 structural rolled shapes

DEP SPECIFICATION

MANUFACTURE, TESTING, AND INSPECTION OF WELDABLE STRUCTURAL ROLLED SHAPES GRADES

345-483 N/MM2 (50 70 KSI) FOR PRIMARY STEEL APPLICATIONS IN DEEPWATER OFFSHORE

STRUCTURES (BASED ON ASTM A6)

DEP 37.81.20.38-Gen.

February 2013

ECCN EAR99

DESIGN AND ENGINEERING PRACTICE

© 2013 Shell Group of companies All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, published or transmitted, in any form or by any means, without the prior

written permission of the copyright owner or Shell Global Solutions International BV.

This document contains information that is classified as EAR99 and, as a consequence, can neither be exported nor re-exported to any country which is under an embargo of the U.S. government pursuant to Part 746 of the Export Administration Regulations (15 C.F R. Part 746) nor can be made available to any national of such country. In addition, the information in this document cannot be exported nor re-exported to an end-user or for an end-use that is prohibited by Part 744 of the Export

Administration Regulations (15 C.F.R. Part 744).

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This document has been supplied under license by Shell to:Shell [email protected] 26/02/2014 22:29:12

ECCN EAR99 DEP 37.81.20.38-Gen. February 2013

PREFACE

DEP (Design and Engineering Practice) publications reflect the views, at the time of publication, of Shell Global Solutions International B.V. (Shell GSI) and, in some cases, of other Shell Companies.

These views are based on the experience acquired during involvement with the design, construction, operation and maintenance of processing units and facilities. Where deemed appropriate DEPs are based on, or reference international, regional, national and industry standards.

The objective is to set the standard for good design and engineering practice to be applied by Shell companies in oil and gas production, oil refining, gas handling, gasification, chemical processing, or any other such facility, and thereby to help achieve maximum technical and economic benefit from standardization.

The information set forth in these publications is provided to Shell companies for their consideration and decision to implement. This is of particular importance where DEPs may not cover every requirement or diversity of condition at each locality. The system of DEPs is expected to be sufficiently flexible to allow individual Operating Units to adapt the information set forth in DEPs to their own environment and requirements.

When Contractors or Manufacturers/Suppliers use DEPs, they shall be solely responsible for such use, including the quality of their work and the attainment of the required design and engineering standards. In particular, for those requirements not specifically covered, the Principal will typically expect them to follow those design and engineering practices that will achieve at least the same level of integrity as reflected in the DEPs. If in doubt, the Contractor or Manufacturer/Supplier shall, without detracting from his own respons bility, consult the Principal.

The right to obtain and to use DEPs is restricted, and is typically granted by Shell GSI (and in some cases by other Shell Companies) under a Service Agreement or a License Agreement. This right is granted primarily to Shell companies and other companies receiving technical advice and services from Shell GSI or another Shell Company. Consequently, three categories of users of DEPs can be distinguished:

1) Operating Units having a Service Agreement with Shell GSI or another Shell Company. The use of DEPs by these Operating Units is subject in all respects to the terms and conditions of the relevant Service Agreement.

2) Other parties who are authorised to use DEPs subject to appropriate contractual arrangements (whether as part of a Service Agreement or otherwise).

3) Contractors/subcontractors and Manufacturers/Suppliers under a contract with users referred to under 1) or 2) which requires that tenders for projects, materials supplied or - generally - work performed on behalf of the said users comply with the relevant standards.

Subject to any particular terms and conditions as may be set forth in specific agreements with users, Shell GSI disclaims any liability of whatsoever nature for any damage (including injury or death) suffered by any company or person whomsoever as a result of or in connection with the use, application or implementation of any DEP, combination of DEPs or any part thereof, even if it is wholly or partly caused by negligence on the part of Shell GSI or other Shell Company. The benefit of this disclaimer shall inure in all respects to Shell GSI and/or any Shell Company, or companies affiliated to these companies, that may issue DEPs or advise or require the use of DEPs.

Without prejudice to any specific terms in respect of confidentiality under relevant contractual arrangements, DEPs shall not, without the prior written consent of Shell GSI, be disclosed by users to any company or person whomsoever and the DEPs shall be used exclusively for the purpose for which they have been provided to the user. They shall be returned after use, including any copies which shall only be made by users with the express prior written consent of Shell GSI. The copyright of DEPs vests in Shell Group of companies. Users shall arrange for DEPs to be held in safe custody and Shell GSI may at any time require information satisfactory to them in order to ascertain how users implement this requirement.

All administrative queries should be directed to the DEP Administrator in Shell GSI.



TABLE OF CONTENTS

1. INTRODUCTION ........................................................................................................ 5 1.1 SCOPE ........................................................................................................................ 5 1.2 DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS ......... 5 1.3 DEFINITIONS ............................................................................................................. 5 1.4 CROSS REFERENCES .............................................................................................. 7 1.5 SUMMARY OF MAIN CHANGES ............................................................................... 7 1.6 COMMENTS ON THIS DEP ....................................................................................... 7 1.7 DUAL UNITS ............................................................................................................... 7

2. GENERAL ................................................................................................................... 8 2.1 QUALITY REQUIREMENTS, QP AND MPS .............................................................. 8 2.2 CONTRACTOR PROCUREMENT SPECIFICATION AND APPROVAL BY THE

PRINCIPAL AND THE CONTRACTOR ...................................................................... 8 2.3 LOWEST ANTICIPATED SERVICE TEMPERATURE ............................................... 8 2.4 ADDITIONAL REQUIREMENTS ................................................................................ 8 2.5 UNDERLYING INDUSTRY SPECIFICATION ............................................................ 8 2.6 TRACEABILITY .......................................................................................................... 8 2.7 INFORMATION TO BE CONVEYED TO ROLLED SHAPE

MANUFACTURER/SUPPLIER ................................................................................... 9 2.8 SUMMARY OF DOCUMENT SUBMITTALS REQUIRING APPROVAL BY THE

PRINCIPAL AND THE CONTRACTOR ...................................................................... 9 2.9 PREPRODUCTION MEETING ................................................................................... 9 2.10 POST-JOB PRODUCTION HISTOGRAMS ............................................................... 9 2.11 INSPECTION CERTIFICATES ................................................................................... 9

3. PROCESS OF MANUFACTURE AND CHEMICAL COMPOSITION ...................... 10 3.1 STEELMAKING PROCESS ...................................................................................... 10 3.2 FINE AUSTENITIC GRAIN SIZE .............................................................................. 10 3.3 CHEMICAL COMPOSITION ..................................................................................... 10 3.4 REDUCTION RATIO ................................................................................................. 11 3.5 ROLLING METHOD AND HEAT TREATMENT ....................................................... 11 3.6 CASTING METHOD ................................................................................................. 11

4. CHEMICAL PROPERTIES AND TESTS ................................................................. 12 4.1 HEAT ANALYSIS ...................................................................................................... 12 4.2 PRODUCT ANALYSIS .............................................................................................. 12

5. MECHANICAL PROPERTIES AND TESTS ............................................................ 12 5.1 MECHANICAL PROPERTIES .................................................................................. 12 5.2 LONGITUDINAL TENSILE TESTS ........................................................................... 13 5.3 THROUGH-THICKNESS (Z-DIRECTION) TENSILE TESTS .................................. 13 5.4 CVN TESTS .............................................................................................................. 14 5.5 DROP WEIGHT TESTS [FOR SHAPES WITH FLANGE/LEG THICKNESS ≥

15.9 MM (⅝-IN) ONLY] ............................................................................................. 14

6. ULTRASONIC EXAMINATION (FOR SHAPES REQUIRING THROUGH THICKNESS TENSILE TESTS ONLY) .................................................................... 15

6.1 PROCEDURE AND ACCEPTANCE CRITERIA ....................................................... 15 6.2 SYSTEM DETAILS ................................................................................................... 15 6.3 REFERENCE STANDARDS..................................................................................... 15 6.4 ULTRASONIC EXAMINATION RESULTS ............................................................... 15

7. VISUAL EXAMINATION AND SURFACE CONDITIONING ................................... 16 7.1 COVERAGE .............................................................................................................. 16 7.2 VISUAL ACCEPTANCE CRITERIA .......................................................................... 16 7.3 REMOVAL OF IMPERFECTIONS ............................................................................ 16 7.4 REPAIR WELDING ................................................................................................... 16 7.5 PREPARATION OF REPAIR WELD EXCAVATIONS ............................................. 16 7.6 DETAILS OF SURFACE CONDITIONING REQUIREMENTS ................................. 16

8. REFERENCES ......................................................................................................... 17



APPENDICES

APPENDIX A TABLES........................................................................................................... 19



1. INTRODUCTION

1.1 SCOPE

This new DEP specifies requirements and gives recommendations for manufacture, testing and inspection of weldable structural rolled shapes Grades 345-483 N/mm2 (50-70 ksi) for use in primary steel (Material Quality Level 2) applications in the fabrication of deepwater offshore structures, manufacture of rig and well systems, marine mechanical or mooring system equipment intended for application on deepwater offshore structures.

Steel rolled shapes governed by this DEP are identified on AFC drawings and in project documents by the prefix “GR” followed by the grade (minimum yield strength in N/mm2) and the suffix “B” or “BZ” (indicative of Material Quality Level 2 and whether or not through-thickness , i.e., “Z” direction, tensile testing is required), e.g., GR345B or GR345BZ.

This DEP is based on ASTM A6.

This new DEP-Gen. supersedes former Deepwater Standard DEP 37.81.20.38-EPP dated July 2006.

1.2 DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS

Unless otherwise authorized by Shell GSI, the distribution of this DEP is confined to Shell companies and, where necessary, to Contractors and Manufacturers/Suppliers nominated by them. Any authorized access to DEPs does not for that reason constitute an authorization to any documents, data or information to which the DEPs may refer.

This DEP is intended for use in facilities related to offshore oil and gas production. This DEP may also be applied in other similar facilities.

When DEPs are applied, a Management of Change (MOC) process shall be implemented; this is of particular importance when existing facilities are to be modified.

If national and/or local regulations exist in which some of the requirements could be more stringent than in this DEP, the Contractor shall determine by careful scrutiny which of the requirements are the more stringent and which combination of requirements will be acceptable with regards to the safety, environmental, economic and legal aspects. In all cases, the Contractor shall inform the Principal of any deviation from the requirements of this DEP which is considered to be necessary in order to comply with national and/or local regulations. The Principal may then negotiate with the Authorities concerned, the objective being to obtain agreement to follow this DEP as closely as possible.

1.3 DEFINITIONS

1.3.1 General Definitions

The Contractor is the party that carries out all or part of the design, engineering, procurement, construction, commissioning or management of a project or operation of a facility. The Principal may undertake all or part of the duties of the Contractor.

The Manufacturer/Supplier is the party that manufactures or supplies equipment and services to perform the duties specified by the Contractor.

The Principal is the party that initiates the project and ultimately pays for it. The Principal may also include an agent or consultant authorized to act for, and on behalf of, the Principal.

The word shall indicates a requirement.

The word should indicates a recommendation.



1.3.2 Specific Definitions

Term Definition

"B" Steel designation suffix indicating Material Quality Level 2 “Primary” steel

"BZ" Steel designation suffix indicating Material Quality Level 2 “Primary” steel requiring through-thickness properties

AFC drawings Approved for Construction drawings

Delivery Condition +AR

As-rolled delivery condition. As-rolled refers to the delivery condition without any special rolling and/or heat treatment conditions.

Delivery Condition +M

Thermomechanical rolled delivery condition (a.k.a. thermomechanical control processing, or TMCP). Delivery condition +M can include processes with an accelerated cooling rate either with or without tempering, including self-tempering. Delivery condition +M excludes direct quenching and quenching and tempering or quenching and ageing.

Delivery Condition +N

Normalized or normalized rolling delivery condition. Normalized rolling (a.k.a controlled rolling) is a rolling process in which the final deformation is carried out in a particular temperature range leading to a material condition equivalent to that obtained after normalizing so that the specified values of the mechanical properties are retained even after normalizing.

Delivery Condition +Q

Quenched and tempered or quenched and aged delivery condition. The quenching operation consists of cooling a ferrous product more rapidly than in still air. Quenching also includes direct quenching. The tempering operation refers to a heat treatment applied to a ferrous product, generally after quench hardening or other heat treatment, to bring the properties to the required level. It consists of heating to specific temperatures (<Ac1) and soaking one or more times followed by cooling at an appropriate rate.

Grade Minimum yield strength in N/mm2.

LAST Lowest anticipated service temperature

Pcm Ito-Bessyo composition parameter

1.3.3 Abbreviations

Term Definition

CIL Charpy impact longitudinal.

CVN Charpy V-notch.

DWT Drop-weight test.

HAZ Heat affected zone.

MPS Manufacturing Procedure Specification. Reference ISO 9000, paragraphs 2.7.2.c, 2.7.2.e, 3.4.5 and 3.7.3. The MPS shall clearly specify the sequence of operations and process controls to be implemented at each manufacturing step as well as specifically annotate any procedures, processing parameters, or requirements that deviate from this DEP. It is required that the PCP be approved by the Principal and the Contractor, if the Contractor is responsible for procurement.

MTR Material Test Report, a.k.a. mill certificate. A report that includes results of chemical analyses, mechanical properties tests, visual and nondestructive tests and dimensional inspections.



Term Definition

QP Quality Plan. Reference ISO 9000, paragraphs 2.7.2.b and 3.7.5. A plan that includes inspection and test requirements. The plan provides columns or spaces for the Principal and the Contractor (if the Contractor is responsible for procurement) to indicate 3rd-party inspector inspection activities, e.g., monitor, witness, hold points, etc. It is required that the QP be approved by the Principal and the Contractor, if the Contractor is responsible for procurement.

1.4 CROSS REFERENCES

Where cross references to other parts of this DEP are made, the referenced section number is shown in brackets ( ). Other documents referenced by this DEP are listed in (8).

1.5 SUMMARY OF MAIN CHANGES

This DEP is a revision of the Deepwater Standard of the same number dated July 2006.

1.6 COMMENTS ON THIS DEP

Comments on this DEP may be submitted to the Administrator using one of the following options:

Shell DEPs Online

(Users with access to Shell DEPs Online)

Enter the Shell DEPs Online system at https://www.shelldeps.com

Select a DEP and then go to the details screen for that DEP.

Click on the “Give feedback” link, fill in the online form and submit.

DEP Feedback System (Users with access to Shell Wide Web)

Enter comments directly in the DEP Feedback System which is accessible from the Technical Standards Portal http://sww.shell.com/standards.

Select “Submit DEP Feedback”, fill in the online form and submit.

DEP Standard Form (Other users)

Use DEP Standard Form 00.00.05.80-Gen. to record feedback and email the form to the Administrator at [email protected].

Feedback that has been registered in the DEP Feedback System by using one of the above options will be reviewed by the DEP Custodian for potential improvements to the DEP.

1.7 DUAL UNITS

This DEP contains both the International System (SI) units, as well as the corresponding US Customary (USC) units, which are given following the SI units in brackets. When agreed by the Principal, the indicated USC values/units may be used.


https://www.shelldeps.com/

http://sww.shell.com/standards

mailto:[email protected]


2. GENERAL

2.1 QUALITY REQUIREMENTS, QP AND MPS

The rolled shape Manufacturer/Supplier shall implement an ISO 9001 Quality Management System or equivalent as approved by the Principal and the Contractor, if the Contractor is responsible for procurement.

A Quality Plan (QP) and a Manufacturing Procedure Specification (MPS) shall be specifically developed for each order and shall be approved by the Principal and the Contractor (if the Contractor is responsible for procurement) prior to commencement of manufacturing operations.

Table A.1 specifies a minimal list of manufacturing steps and process control variables that shall be defined, including acceptable ranges and aim values where applicable in the MPS.

2.2 CONTRACTOR PROCUREMENT SPECIFICATION AND APPROVAL BY THE PRINCIPAL AND THE CONTRACTOR

This DEP may be used directly for procurement or, at the Contractor’s option, the Contractor may prepare a detailed procurement specification that is compatible with the Contractor’s document format and quality system. As a minimum, the Contractor’s procurement specification shall incorporate all requirements contained herein and shall require approval by the Principal.

The rolled shape Manufacturer/Supplier and manufacturing facilities, as identified in the MPS, shall require approval by the Principal and the Contractor, if the Contractor is responsible for procurement.

2.3 LOWEST ANTICIPATED SERVICE TEMPERATURE

The default lowest anticipated service temperature (LAST) is -10°C (14°F), unless otherwise specified in project documents or on AFC drawings.

2.4 ADDITIONAL REQUIREMENTS

Rolled shape web, flange and leg thicknesses, sizes (width/length), and any special or additional dimensional tolerances (e.g., straightness), non-destructive testing, marking, surface finish (other than as rolled) or other requirements not covered specifically by this DEP will be addressed in project documents or on AFC drawings and subsequently included in the rolled shape procurement documents. If such additional requirements are specified, they shall be included in the MPS.

2.5 UNDERLYING INDUSTRY SPECIFICATION

Rolled shapes shall be manufactured and tested in accordance with ASTM A6 except that repair welding of rejectable defects by the rolled shape Manufacturer/Supplier shall not be allowed. Modifications, specific deletions or identifications of non-applicable parts and requirements additional to ASTM A6 are given herein. Some statements and/or required values in ASTM A6 may be repeated in this DEP for clarity or special emphasis; however, unless specifically deleted or waived by this DEP, all provisions of ASTM A6 shall apply.

Alternative underlying industry specifications may be approved by the Principal and the Contractor (if the Contractor is responsible for procurement) on a case-by-case basis. The underlying industry specification shall be identified in the MPS.

In cases where there are conflicting requirements between this DEP and referenced industry specifications, the requirements of this DEP shall take precedence.

2.6 TRACEABILITY

Traceability of each rolled shape shall be maintained with respect to the following, as applicable:

a. Heat



b. Heat treat sequence or batch

c. Production lot

2.7 INFORMATION TO BE CONVEYED TO ROLLED SHAPE MANUFACTURER/SUPPLIER

Table A.2 provides a summary of information to be conveyed to the rolled shape Manufacturer/Supplier in the rolled shape procurement documents in order for the rolled shape Manufacturer/Supplier to be able to properly supply product in compliance with this DEP.

2.8 SUMMARY OF DOCUMENT SUBMITTALS REQUIRING APPROVAL BY THE PRINCIPAL AND THE CONTRACTOR

Various documents are identified by this DEP as requiring submittal to the Principal and the Contractor (if the Contractor is responsible for procurement) for approval. Documents shall be submitted to the Principal and the Contractor (if the Contractor is responsible for procurement) in a timely manner as specified in project documents, or otherwise by Principal or the Contractor (if the Contractor is responsible for procurement) in order to allow for the formal review and approval process. Table A.3 provides a summary of required document submittals.

2.9 PREPRODUCTION MEETING

If required by the Principal or the Contractor (if the Contractor is responsible for procurement) a preproduction meeting shall be held at the rolled shape Manufacturer/Supplier’s manufacturing facility prior to commencement of manufacture in order to discuss and assure common understanding of the QP and MPS in relation to the order. This preproduction meeting, when required, shall be a designated Hold Point in the QP.

2.10 POST-JOB PRODUCTION HISTOGRAMS

If required by the Principal or the Contractor (if the Contractor is responsible for procurement) a summary report of results containing histograms of chemical, mechanical and dimensional properties measured and recorded, as required in the QP and MPS, shall be supplied by the rolled shape Manufacturer/Supplier at the completion of the order.

2.11 INSPECTION CERTIFICATES

Inspection certificates (a.k.a. MTR’s or mill certificates) shall conform to ASTM A6 paragraph 14 and ISO 10474 Test Report Type 3.2.



3. PROCESS OF MANUFACTURE AND CHEMICAL COMPOSITION

3.1 STEELMAKING PROCESS

All rolled shapes shall be manufactured from steel that has been fully killed per paragraph 3.1.9 of ASTM A6. A statement describing the steelmaking process and refining sequence shall be provided in the MPS. If new or nonconventional steelmaking technology (e.g., TiN, TiO, ultra low Al, etc.) is utilized to enhance HAZ toughness or other properties, it shall be so stated in the MPS.

3.2 FINE AUSTENITIC GRAIN SIZE

Rolled shapes with a thickness greater than 12.7 mm (0.5 in) shall have a fine austenitic grain size per ASTM A6 paragraph 8.3.

3.3 CHEMICAL COMPOSITION

Rolled shape chemical composition shall conform to the applicable steel grade specified and listed in Table A.4, or a modification thereof as approved by the Principal and the Contractor (if the Contractor is responsible for procurement) with additional restrictions given below. A table of acceptable ranges and aim values for all intentionally added elements and residual elements specifically addressed either in the selected chemical composition specification or this DEP shall be provided in the MPS.

Chemical composition specifications given in Table A.4 are not necessarily equivalent, even within the same grade and selection of a specific composition.

a. Manufacturer/Supplier shall take into consideration the specific application as well as the ability of the chemical composition to meet the mechanical properties requirements specified in (5), i.e., tensile properties and toughness in the specified flange, web and leg thicknesses, sampling location and orientation, and at the specified test temperatures.

b. Alternative or proprietary chemical composition specifications not listed in Table A.4 may be approved by the Principal and the Contractor (if the Contractor is responsible for procurement) on a case-by-case basis.

c. Chemical composition specifications listed in Table A.4 that require normalizing heat treatment may alternatively be quenched and tempered in order to achieve specified mechanical properties. However, heat-treatment procedures shall, as required by (3.5), be specified in the MPS.

Only those elements included in the chemical composition specifications given in Table A.4 (or alternates specifically approved by the Principal and the Contractor, if the Contractor is responsible for procurement) shall be added. Any element intentionally added shall be reported in the inspection certificates. Nitrogen, niobium (columbium), aluminium, titanium, and all elements included in the Pcm formula given below shall be reported in the inspection certificates.

Specific deviations or modifications and/or the addition of supplementary requirements to the chemical composition specifications listed in Table A.4 shall be approved by the Principal and the Contractor, if the Contractor is responsible for procurement. Unless more restrictive ranges are required by the chemical composition specifications listed in Table A.4, the following elemental limits shall apply to the heat analysis:

Element Wt.% (max.)

Sulphur (S) 0.015

Sulphur (S) 0.010 (for rolled shapes requiring through-thickness tensile testing only)

Phosphorus (P) 0.020

Titanium1,2 (Ti) 0.020

Vanadium1 (V) 0.080



Niobium1 (Nb,Cb) 0.050

Boron (B) 0.0005

Nitrogen (N) 0.012 Note: 1) These limits apply to intentional additions. Residual, unintentional levels shall be limited to

0.015 wt.% maximum.

2) Titanium may be increased to 0.030 wt.% maximum for continuously cast product with Ti/N ratio ≤ 6.0.

The Ito-Bessyo composition parameter (Pcm), as calculated by the formula given below, shall be ≤ 0.23 unless a more restrictive Pcm is imposed by the selected chemical composition specification, as required or unless otherwise approved by the Principal and the Contractor, if the Contractor is responsible for procurement. The maximum acceptable Pcm shall be stated in the MPS.

Pcm = C + Si/30 + (Mn + Cu + Cr)/20 + Ni/60 + Mo/15 + V/10 + 5B

3.4 REDUCTION RATIO

The rolling reduction from ingot or continuously cast slab, bloom or “dogbone” shape to rolled shape web, flange and leg thickness shall be ≥ 3:1 unless otherwise approved by the Principal and the Contractor, if the Contractor is responsible for procurement. The minimum allowable rolling reduction shall be stated in the MPS, along with the continuous cast slab, bloom or “dogbone” shape configuration/dimensions or starting ingot dimensions.

3.5 ROLLING METHOD AND HEAT TREATMENT

Plates shall be delivered in either the +AR, +N, +M or +Q delivery conditions. +N or +M delivery conditions may also be followed by a tempering or ageing treatment. Plates with a thickness greater than 32 mm (1.25 inch) shall be delivered in either the +N, +M or +Q delivery conditions.

A statement describing the delivery condition, including any normalizing, accelerated cooling, quenching, tempering, self tempering or ageing temperatures and times, shall be provided in the MPS.

3.6 CASTING METHOD

A statement describing the casting method, e.g., ingot, continuous cast slabs, blooms or “dogbone” shapes, etc., shall be provided in the MPS.



4. CHEMICAL PROPERTIES AND TESTS

4.1 HEAT ANALYSIS

A heat analysis for each heat of steel shall be included in the inspection certificates in accordance with ASTM A6 paragraph 7.1. The heat analysis shall be taken from the stream during ingot teeming or, for continuous cast product, from the stream, tundish or continuous casting mould during casting.

Pcm shall be calculated and reported in the inspection certificates for each heat, on the basis of heat analysis.

4.2 PRODUCT ANALYSIS

Results of a product analysis from one rolled shape per heat, in accordance with ASTM A6 paragraph 7.2 and ASTM A6 Supplementary Requirement S2, shall be included in the inspection certificates.

5. MECHANICAL PROPERTIES AND TESTS

5.1 MECHANICAL PROPERTIES

The mechanical property tests specified in (5.2) through (5.5) shall be performed on a representative test shape selected on a production lot basis, as a minimum, unless otherwise specified or approved by the Principal and the Contractor, if the Contractor is responsible for procurement.

a. Mechanical property tests on individual shapes may also be performed on a mother- piece-by-mother-piece basis, at the rolled shape Manufacturer/Supplier’s option.

b. Mechanical property tests shall be conducted on rolled shapes that are in the final as-rolled or heat treated condition, as applicable, except that limited cold straightening is allowed. No subsequent rolling or heat treatment by the rolled shape Manufacturer/Supplier is allowed without retesting.

c. A production lot shall be defined as all rolled shapes that do not exceed 50 mt (or 50 st) total weight, of the same section designation, nominal weight per unit length (i.e., flange or leg thickness), and grade that have been produced in an uninterrupted rolling sequence from the same heat and uninterrupted continuous heat treat sequence or heat treat furnace charge, as applicable.

d. Production lot groupings shall be approximately evenly spaced in the production sequence. The Principal and the Contractor, (if the Contractor is responsible for procurement) or a 3rd-party inspector approved by the Principal and the Contractor (if the Contractor is responsible for procurement) if present at the manufacturing facility, shall be allowed to participate in the selection of the representative test shape selected for testing.

If any specimen shows defective machining, develops flaws, or is otherwise ruled invalid, it shall be discarded and another specimen used.

If initial test results (and retests where allowed) on the representative test shape fail to meet the requirements of (5.2) through (5.5), then all material in the production sequence after the last acceptable test result and prior to the next acceptable test result shall be considered as a "non-conforming group". In this case, the rolled shape Manufacturer/Supplier shall pick from one of the following three options:

a. Reject all material in the non-conforming group.

b. Qualify individual rolled shapes from the non-conforming group on a mother-piece-by-mother-piece basis.

c. Test mother pieces to each side of the failed representative test shape in the production sequence until acceptable test results are achieved, which then qualifies all material in the non-conforming group that is bounded in the production sequence



by acceptable test results.

Only those tests that the representative test shape failed to pass are required to be performed.

5.2 LONGITUDINAL TENSILE TESTS

One longitudinal tensile test specimen shall be extracted from the representative test shape specified in (5.1) and tested in accordance with ASTM E8 at room temperature.

a. Specimen orientation shall be longitudinal to the final rolling direction.

b. Either standard 40 mm (1 ½ in) wide full thickness plate type specimens per ASTM E8 Figure 1 or standard 12.5 mm (0.500 in) round specimens per ASTM E8 Figure 8 may be utilized at the rolled shape Manufacturer/Supplier’s option.

c. The longitudinal centerline of round specimens shall not be more than 1/4-T from the mid thickness of the thickest leg or flange, as applicable, unless otherwise specified or approved by the Principal and the Contractor, if the Contractor is responsible for procurement.

d. Test specimen longitudinal centerline shall correspond to a position that is at least one third the distance from the outer edge of the flange or thickest leg to the web or heel of the shape (reference ASTM A673 Figure 2), unless otherwise specified or approved by the Principal and the Contractor, if the Contractor is responsible for procurement.

e. The test specimen size, type and location shall be specified in the MPS.

Longitudinal tensile test results shall comply with the requirements of Table A.5 for the specified grade, unless otherwise specified or approved by the Principal and the Contractor, if the Contractor is responsible for procurement.

a. For grades not listed in Table A.5 but within the ranges given, linear interpolation is acceptable for the determination of minimum and maximum yield strength requirements and minimum ultimate tensile strength requirements.

b. Test result acceptance criteria shall be specified in the MPS.

If retests are allowed by ASTM A6 paragraphs 13.2 and 13.3, then additional specimens may, at the rolled shape Manufacturer/Supplier's option, be extracted from material immediately adjacent to failed specimen(s) (if any) and retested as specified above. Results from the additional specimen(s) shall meet specified requirements.

5.3 THROUGH-THICKNESS (Z-DIRECTION) TENSILE TESTS

For grade designations having the letter “Z” in the grade designation suffix, through-thickness (Z-direction) tensile test specimens shall be extracted from the representative test shape specified in (5.1) and tested in accordance with ASTM A770 and with ASTM A770 Supplementary Requirement S1 (tensile strength ≥ 80% of the specified minimum tensile strength specified for the grade).

a. Test specimen location shall correspond to a position that is at least one third the distance from the outer edge of the flange or thickest leg to the web or heel of the shape (reference ASTM A673 Figure 2), unless otherwise specified or approved by the Principal and the Contractor, if the Contractor is responsible for procurement.

b. The test specimen size, type and location shall be specified in the MPS.

Through-thickness tensile test result acceptance criteria shall be specified in the MPS.

Even though ASTM A770 is normally used for through-thickness tensile testing of material with thickness ≥ 25 mm (1.0 in), this DEP requires that it shall still be utilized to conduct the through-thickness tensile tests of material < 25 mm (1 in). In these cases; however, the steel rolled shape Manufacturer/Supplier shall demonstrate by preparation and etching of sample specimens that the means of attaching the welded prolongations (reference ASTM A770 paragraph 4.4.1) does not result in an HAZ that extends into the central 50 %



of the tested plate thickness, as approved by the Principal and the Contractor, if the Contractor is responsible for procurement.

5.4 CVN TESTS

Three CIL (per Figure 2 of ASTM A673) CVN specimens shall be extracted from the representative test shape defined in (5.1) and tested in accordance with ASTM E23 (simple beam method unless otherwise approved by the Principal and the Contractor, if the Contractor is responsible for procurement).

a. The longitudinal centerline of the CVN specimens shall be at least 1/4-T from the original surface of the thickest leg or flange, as applicable, unless otherwise specified or approved by the Principal and the Contractor, if the Contractor is responsible for procurement.

b. CVN specimen longitudinal centerline shall correspond to a position that is at least one third the distance from the outer edge of the flange or thickest leg to the web or heel of the shape (reference ASTM A673, Figure 2), unless otherwise specified or approved by the Principal and the Contractor, if the Contractor is responsible for procurement.

c. CVN specimens shall be standard Type A specimens in accordance with Figure 1 of ASTM E23.

CVN test temperature shall be ≤ LAST - 20 °C (LAST - 4 °F). For example, if the LAST has been designated to be -10 °C (i.e. the default value), then the test temperature shall be T ≤ -10 - 20 = -30 °C.

CVN test method, specimen location, specimen orientation and test temperature shall be specified in the MPS. Both absorbed energy and % shear fracture appearance shall be reported in the inspection certificates.

Unless otherwise specified or approved by the Principal and the Contractor (if the Contractor is responsible for procurement) test results (absorbed energy and percent shear fracture appearance) shall meet the requirements of Table A.6 for the specified grade and specified flange or maximum leg thickness.

a. For grades or flange/leg thicknesses not listed in Table A.6 but within the values given, linear interpolation is acceptable for the determination of the minimum absorbed energy requirements.

b. If the results from only one specimen fail to meet specified absorbed energy or percent shear fracture requirements but are no less than 70% of the required minimum values, then three additional specimens may, at the rolled shape Manufacturer/Supplier’s option, be extracted and tested in accordance with (5.4).

c. Test results from all additional specimens shall meet specified requirements.

d. CVN test result acceptance criteria shall be specified in the MPS.

5.5 DROP WEIGHT TESTS [FOR SHAPES WITH FLANGE/LEG THICKNESS ≥ 15.9 MM (⅝-IN) ONLY]

Unless otherwise approved by the Principal and the Contractor (if the Contractor is responsible for procurement) two Type P-3 DWT specimens shall be extracted from a representative shape as specified in (5.1) and tested in accordance with ASTM A6 Supplementary Requirement S6 and ASTM E208.

a. After specimens are extracted, no subsequent rolling or heat treatment, other than limited cold straightening, is allowed by the rolled shape Manufacturer/Supplier without retesting.

b. The longitudinal centerline of DWT specimens shall be at least 1/4-T from the original surface of the thickest leg or flange, unless otherwise specified or approved by the Principal and the Contractor, if the Contractor is responsible for procurement.



c. Test specimen longitudinal centerline shall correspond to a position that is at least one third the distance from the outer edge of the flange or thickest leg to the web or heel of the shape (reference ASTM A673, Figure 2), unless otherwise specified or approved by the Principal and the Contractor, if the Contractor is responsible for procurement.

Test temperature shall be ≤ LAST.

DWT specimen location and test temperature shall be specified in the MPS.

Both DWT specimens shall exhibit "no-break" performance.

a. If only one of the two specimens exhibits "break" performance, then two replacement specimens may, at the steel plate Manufacturer/Supplier's option, be extracted from material immediately adjacent to the failed specimen and retested as specified above.

b. Both replacement specimens shall exhibit "no break" performance.

DWT testing specified above is not required if percent shear fracture results from all CVN tests specified in (5.4) are ≥ 90 %.

DWT results acceptance criteria shall be specified in the MPS.

6. ULTRASONIC EXAMINATION (FOR SHAPES REQUIRING THROUGH THICKNESS TENSILE TESTS ONLY)

6.1 PROCEDURE AND ACCEPTANCE CRITERIA

Grade designations having the letter “Z” in the grade designation suffix shall be ultrasonically examined by straight beam in accordance with ASTM A6 Supplementary Requirement S8 and ASTM A898, with Acceptance Standard Level 1.

6.2 SYSTEM DETAILS

Details of the ultrasonic examination system shall be specified in the MPS.

6.3 REFERENCE STANDARDS

Ultrasonic reference standards shall be manufactured from carbon or low alloy steel that is acoustically similar to the shapes being inspected.

6.4 ULTRASONIC EXAMINATION RESULTS

Results of all ultrasonic examinations shall be included in the inspection certificates.



7. VISUAL EXAMINATION AND SURFACE CONDITIONING

7.1 COVERAGE

Each rolled shape shall be visually inspected with the surfaces in a condition such that they can be readily examined for defects. Coverage for visual examination shall be 100% of all surfaces unless otherwise approved by the Principal and the Contractor, if the Contractor is responsible for procurement.

7.2 VISUAL ACCEPTANCE CRITERIA

In addition to the requirements of ASTM A6 paragraphs 9.1 and 9.3, rolled shapes shall be free of tears, scabs, blisters, laps, cracks or other similar surface imperfections. The maximum allowable depth of other localized discontinuities (e.g., rolled-in scale, seams or pits) shall not exceed the values presented in Table A.7 for the nominal thickness of the product.

7.3 REMOVAL OF IMPERFECTIONS

Imperfections prohibited by (7.2) shall be removed by grinding, or chipping and grinding, The resulting ground area shall be faired (4 to 1 minimum) smoothly into the surrounding metal and the resulting ground out depression shall not exceed the limits specified in ASTM A6 paragraph 9.3.1.

7.4 REPAIR WELDING

Repair welding of rejectable defects by the rolled shape Manufacturer/Supplier shall not be allowed. Compliance with this requirement shall be stated on the inspection certificates.

7.5 PREPARATION OF REPAIR WELD EXCAVATIONS

Shapes containing imperfections or discontinuities requiring removal as specified by (7.2) but whose removal would violate the limitations specified by (7.3) shall have such imperfections or discontinuities removed by the rolled shape Manufacturer/Supplier by grinding, chipping and grinding, or other mechanical means that will leave an excavation suitable for subsequent repair welding by the structural fabrication Contractor.

Repair welding shall conform to the following:

a. The total area of repair weld excavations on any one piece shall not exceed 1 % of the total surface area of that piece.

b. Additional limitations on remaining material below repair weld excavations and maximum depth of repair weld excavations shall be as required by ASTM A6, paragraphs 9.3.2.2 and 9.3.2.3.

c. The rolled shape Manufacturer/Supplier shall encircle repair weld excavations with white or yellow paint, unless otherwise approved by the Principal and the Contractor, if the Contractor is responsible for procurement.

d. Pieces requiring subsequent repair welding shall be marked with a special colour code (to be proposed by the rolled shape Manufacturer/Supplier for approval by the Principal and the Contractor, if the Contractor is responsible for procurement) on one cut end or across the rolled face of one flange or leg, adjacent to one end.

Prior to shipment, the rolled shape Manufacturer/Supplier shall indicate, via facsimile or electronic transmission, the number of pieces contained in each shipment that will require subsequent repair welding and a listing of the number of repair welds and approximate surface area of repair welding to be required for each piece for acceptance by the Principal and the Contractor, if the Contractor is responsible for procurement.

7.6 DETAILS OF SURFACE CONDITIONING REQUIREMENTS

Specific details pertaining to the surface conditioning requirements specified by this section shall be specified in the MPS or its referenced documents.



8. REFERENCES

In this DEP, reference is made to the following publications: NOTES: 1. Unless specifically designated by date, the latest edition of each publication shall be used,

together with any amendments/supplements/revisions thereto.

2. The DEPs and most referenced external standards are available to Shell staff on the SWW (Shell Wide Web) at http://sww.shell.com/standards/.

SHALL STANDARDS

DEP feedback form DEP 00.00.05.80-Gen.

AMERICAN STANDARDS

Rolled shapes with improved notch toughness API SPEC 2MT2

Standard specification for general requirements for rolled structural steel bars, plates, shapes, and sheet piling

ASTM A6/A6M

Standard specification for structural steel for ships ASTM A131

Standard specification for high-strength low-alloy columbium-vanadium structural steel

ASTM A572

Standard specification for sampling procedure for impact testing of structural steel

ASTM A673

Standard specification for structural steel for bridges ASTM A709

Standard specification for through-thickness tension testing of steel plates for special applications

ASTM A770

Standard specification for straight beam ultrasonic examination of rolled steel structural shapes

ASTM A898

Standard specification for high-strength low-alloy steel shapes of structural quality, produced by quenching and self-tempering process (QST)

ASTM A913

Standard specification for structural steel shapes ASTM A992

Standard test methods for tension testing of metallic materials ASTM E8/E8M

Standard test methods for notched bar impact testing of metallic materials

ASTM E23 REV A

Standard test method for conducting drop-weight test to determine nil-ductility transition temperature of ferritic steels

ASTM E208

EUROPEAN STANDARDS

Hot rolled products of structural steels - Part 3: Technical delivery conditions for normalized/normalized rolled weldable fine grain structural steels

EN 10025-3

Hot rolled products of structural steels - Part 4: Technical delivery conditions for thermomechanical rolled weldable fine grain structural steels

EN 10025-4

Weldable structural steels for fixed offshore structures - Technical delivery conditions

EN 10225


http://sww.shell.com/standards/


INTERNATIONAL STANDARDS

Quality management systems – Fundamentals and vocabulary ISO 9000

Quality management systems – Requirements ISO 9001

Steel and steel products - Inspection documents ISO 10474



APPENDIX A TABLES

Table A.1 Minimal list of manufacturing steps and process-control variables for inclusion in the MPS

Specific shape-rolling mill and steel-production facility

Specific steel making method or melting practice (EAF-VD, BOF-LRF-VD, etc.), nominal proportions of scrap (by designated scrap grade) and hot metal charge, nominal weight of heat and any hot metal treatment (degassing, desulfurization, injection refining, etc.)

Method of inclusion shape control and procedure for verifying metallurgical effectiveness

Chemical composition allowable range and aim values (including limits on residual elements) and maximum Pcm

Casting method (top poured ingot, bottom poured ingot or continuous slab, bloom or “dogbone” shape), usage of argon shrouding and implementation of strand cast soft reduction

Segregation control procedures (electromagnetic stirring, electromagnetic braking, etc.) and segregation quality control procedures (sulphur or phosphorous prints of slab, bloom or “dogbone” cross sections and testing frequency) for continuous cast product

Control of sequential casting (i.e. intermix) for continuous cast product

Continuous cast slab, bloom or “dogbone” crossectional dimensions or ingot size and weight and relationship to rolled shape dimensions

Hydrogen flake control method (bake out, slow cool, stack, etc.)

Ingot, slab, bloom or “dogbone” reheat temperature and time at temperature

Roughing mill start and finish temperature and total reduction

Finishing mill or controlled rolling start and finish temperature

Total reduction and reduction per pass in finishing mill or during controlled rolling

Cross rolling ratio

Normalizing temperature and time

Austenitizing temperature and time

Rolled shape temperature at start of accelerated cooling or direct quenching

Rolled shape temperature at finish of accelerated cooling or direct quenching and method of controlling

Tempering or ageing temperature and time and relationship to chemical composition



Table A.2 Information to be conveyed to rolled shape Manufacturer/Supplier

Grade (N/mm2)

LAST, if different than default of -10°C (14°F)

Flange/Web/Leg thicknesses, sizes, quantities and any special dimensional tolerances, marking or surface finish requirements

Additional non-destructive testing requirements, if applicable

Alternative underlying industry specification, if different than ASTM A6

Requirement for a preproduction meeting

Requirement for post job production histograms

Specific steel composition specification selected from (Table A.4) or approved alternate and any deviations or modifications, additional restrictions or Supplementary Requirements

Mechanical testing frequency, if different than production lot basis

Tensile test specimen location, if different than ¼-T

Through-thickness tensile testing, if required

CVN specimen location, if different than ¼-T

CVN absorbed energy requirements, if different than (Table A.6)

DWT specimen location, if different than ¼-T

Ultrasonic Testing, if required



Table A.3 Document submittals requiring approval by the Principal and the Contractor, if the Contractor is responsible for procurement

Required Timing of Document Submittal(1)

Rolled Shape Manufacturer/Supplier’s Quality Plan (QP)

Rolled Shape Manufacturer/Supplier’s Manufacturing Procedure Specification (MPS)

Contractor's procurement specification, if applicable

Document describing the number of pieces contained in each shipment which will require subsequent repair welding and a listing of the number of repair welds and approximate surface area of repair welding to be required for each piece. Prior to each shipment. For acceptance by the Principal and the Contractor, if the Contactor is responsible for procurement.

Note: 1. There is a basic requirement that the first three documents all be approved by the Principal and the Contractor, if the Contactor is responsible for procurement, prior to the commencement of rolled shape manufacture; however, the responsible Principal or the Contractor, if the Contactor is responsible for procurement, project staff will fill in this column with the precise requirements, e.g., 2 weeks after contract award, etc. that are deemed necessary to meet project schedule.



Table A.4 Approved chemical composition specifications(1)(2)(3)(4)(6)

GR345 GR414 GR448(5) GR483(5)

API SPEC 2MT2 Class A ASTM A131 AH36, DH36, EH36 ASTM A572 Grade 50 Type 1 ASTM A709 Grade 50 Type 1 ASTM A913 Grade 50

Grades S355N,

S355NL Grades S355M,

S355ML rade S355

(6)Arcelor HISTAR 355,355L (6)Arcelor HISTAR 355 TZ,TZK OFFSHORE

Grade 60 Type 1

Grade 60 EN 10025-3 Grades S420N, S420NL, S460N, S460NL EN 10025-4 Grades S420M, S420ML, S460M, S460ML EN 10225 Grades S420, S460 (6)Arcelor HISTAR 460,460L (6)Arcelor HISTAR 460 TZ,TZK OFFSHORE

ASTM A572 Grade 65 Type 1 ASTM A913 Grade 65 EN 10025-3 Grades S460N, S460NL EN 10025-4 Grades S460M, S460ML EN 10225 Grades S460 (6)Arcelor HISTAR 460,460L (6)Arcelor HISTAR 460 TZ,TZK OFFSHORE

ASTM A913 Grade 70

NOTE: 1) Pcm ≤ 0.23 for all compositions. Pcm > 0.23 may be specifically approved by the Principal and the Contractor, if the Contactor is responsible for procurement, on a case by case basis; however, this is typically granted only for steels with C ≤ 0.10 wt.%.

2) Subject to thickness limitations contained in the individual referenced specifications which will achieve the specified minimum yield strength required by this DEP in the thickness(es) ordered.

3) Additional composition restrictions specified in (3.3) also apply.

4) Chemical compositions given in this table are not necessarily equivalent, even within the same steel grade, and selection of a specific composition shall take into consideration the specific application as well as the ability of the composition to meet requirements specified in this DEP (i.e., grade and toughness in the specified web/flange/leg thicknesses, sampling location and orientation and test temperatures).

5) Proprietary, nonstandard chemical compositions may be utilized for these Grades as approved by the Principal and the Contractor, if the Contactor is responsible for procurement.

6) Pre-approved Manufacturer’s, trade names and compositions shall be as noted in the requisition sheets.



Table A.5 Tensile requirements

GR345 GR414 GR448 GR483

MINIMUM YIELD STRENGTH(1)

345 N/mm2 (50 ksi)

414 N/mm2 (60 ksi)

448 N/mm2 (65 ksi)

483 N/mm2 (70 ksi)

MAXIMUM YIELD STRENGTH(1)

483 N/mm2 (70 ksi)

552 N/mm2 (80 ksi)

586 N/mm2 (85 ksi)

621 N/mm2 (90 ksi)

MINIMUM ULTIMATE TENSILE STRENGTH

448 N/mm2 (65 ksi)

517 N/mm2 (75 ksi)

552 N/mm2 (80 ksi)

565 N/mm2 (82 ksi)

MINIMUM ELONGATION IN 2-IN (50 MM) GAUGE LENGTH(2)

21% 19% 17% 16%

MINIMUM REDUCTION IN AREA

40% 40% 40% 40%

NOTE: 1) Yield strength may be determined by either the 0.2 % offset method or the 0.5 % total extension under load method; however, the method used shall be reported in the inspection certificates.

2) % elongation value may be reduced by 2% from the values in the table for 200 mm (8 in) gauge length.



Table A.6 CVN absorbed energy requirements(1)(2)

MAXIMUM SPECIFIED THICKNESS FOR WEB/FLANGE/LEG

GR345 GR414 GR448 GR483

T ≤ 76.2 mm (3 in) 50 J (37 ft.lbs.)

60 J (45 ft.lbs.)

65J (48 ft.lbs.)

70 J (52 ft.lbs.)

76.2 mm (3 in) < T ≤ 101.6 mm (4 in)

64 J (47 ft.lbs.)

75 J (55 ft.lbs.)

84 J (62 ft.lbs.)

92 J (68 ft.lbs.)

T > 101.6 mm (4 in) * * * *

* These values will be specified by the Principal and the Contractor, if the Contactor is responsible for procurement, on a case-by-case basis.

NOTES: 1) Test temperature shall be ≤ LAST – 20 °C (LAST - 36 °F). For example, if the LAST has been designated to be -10 °C (i.e., the default value), then the test temperature shall be T ≤ -10 - 20 = -30 °C.

2) In addition to the absorbed energy requirement, percent shear fracture appearance shall be ≥ 50 %.



Table A.7 Maximum permissible depth of discontinuities

NOMINAL THICKNESS OF PRODUCT MAXIMUM PERMISSIBLE DEPTH OF DISCONTINUITY

t < 20 mm (0.75 in) 1.2 mm (0.047 in) or 25%t, whichever is less

20 mm (0.75 in) ≤ t < 40 mm (1.5 in) 1.7 mm (0.067 in)

40 mm (1.5 in) ≤ t < 75 mm (3.0 in) 2.5 mm (0.098 in)

75 mm (3.0 in) ≤ t 3.0 mm (0.118 in)


dep 37.81.20.38-gen - feb 2013 structural rolled shapes

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