Professional Documents
Culture Documents
ON NORSOK STANDARD
10/10/2014
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DICIPLINES
• STRUCTURAL
• PIPING
• COATING
• EICT
• CDB
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NORSOK STANDARDS
To ensure adequate safety, value adding & cost effectiveness for petroleum industry
development & operations.
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NORSOK standards
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M-101 “Structural Steel Fabrication”
Scope:
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Correlation between steel quality level, MDS number &
steel grade/designations
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Correlation between steel quality level, MDS number &
steel grade/designations
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NORSOK Standard M120
Material data sheets for structural steel
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WPQR – Range of approval
( Welding Procedure Qualification Record )
For welding of steels in all strength classes
1. 0.02Pcm and 0.03 CEV are allowed more than the qualified
procedure.
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Welder & Welding Operators Qualifications
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Welding /Visual Inspector & NDE Operators Qualifications
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FABRICATION AND WELDING REQUIREMENTS
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Forming
Cold forming (i.e. below 250°C)
For steel quality level I and II, the deformation limit without
documentation of mechanical properties is 5%.
If percentage of strain is more than 5%, then either heat treatment shall be performed, or strain ageing tests
shall be carried out according to the procedure in the next slide.
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Assembly
In tubular joints, unless otherwise shown on design drawings, longitudinal weld
joints should be placed with minimum distance of 75mm (or) minimum 2 times
chord thickness, as shown in the figure below.
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Assembly
In tubular joints, unless otherwise shown on design drawings, circumferential weld joints,
minimum distance between the welds should be as shown in the figure below.
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Tapering
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Seal / Blind
Temporary cut-outs
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Fabrication Control
Doubler plates - All attachments in the splash zone shall be attached to the structure
by using doubler plate.
Tack weld shall normally have a length of Min.100MM For thickness less
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Preheating & PWHT Control
Preheating- Preheating for more than 50Deg⁰C should be achieved by electric heating
elements.
Attachments
• Temporary attachments shall be cut minimum 3 mm from the base metal and ground.
• The ground area shall be visually examined and magnetic particle/ penetrant tested.
Post weld heat treatment (PWHT)
• Required for structural welds
a) Steel quality level I or II,
b) Quality level III with Re >400 MPa, for nominal thickness > 50 mm.
Unless welding procedure qualified with (CTOD) fracture toughness.
• PWHT shall be carried out in accordance with a procedure.
• The temperature difference between different parts of the structure during soaking time shall not
exceed 30⁰C within the heated area.
• Double sided heating shall be used as far as possible.
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PRODUCTION TESTS
• Production tests shall be selected on weldments in critical
regions to verify that the specified requirements have been
meet. Minimum one test coupon is required from each
applied welding process.
• Test coupons shall be welded in a manner which realistically
simulates the actual production welding, normally as
extension of the production weld, and meet the requirements
for welding procedure approval tests.
• CTOD testing is not required for production testing.
• If a production test fails, the reason for the failure shall be
determined and remedial action implemented.
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NON-DESTRUCTIVE TESTING (NDT)
Final Inspection and NDT
• Final inspection and NDT of structural steel welds
- Only after 48 hours after completion except where
PWHT is required.
• The time delay may be reduced to 24 hours
- for steel grades with SMYS <=355MPa,
- for steel grades with SMYS <= 420MPa for plate
thicknesses < 40 mm.
• For PWHT: The final NDT shall be carried out when all heat
treatment have been completed.
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Monitoring & Control of Defect Rate
Weekly defect rate OR repeated occurrence of planar defects in inspection category B, C & D need to be
monitored & triggered in two levels.
• Trigger level 1
If a defect rate for any method exceeds 10 % per Week
- Then 100% inspection should be carried out for all welds in question, irrelevant of the required
inspection category for the welds.
• Trigger level 2
If a defect rate for any method of inspection is between 5 - 10 % per Week,
- Then NDT should be extended in two steps.
• Step 1.
• A defect rate for any NDT method exceeding 5 % (1% for MT) for a single week
- Doubling of the extent of NDT according to the inspection category.
- Spot extent shall be increased to 20%.
Step 2.
• If the defect rate for the extended testing under Step 1 > 5 %
- Increased to 100 % for all welds in question.
• The increased NDT extent
- shall cover welds of the same inspection categories,
- welded in the same period of time when the high defect rate was produced
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Control of Defect Rate
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Table shown Extent of NDT for Structural
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Extent of visual examination and NDT
• Ultrasonic testing to reveal the presence of possible weld metal transverse cracking shall be included for
butt welds with thickness > 25 mm.
• The testing shall be performed on minimum 5% of welds in inspection category A and B for SAW (12) and
FCAW (131 and 136)
• Determination of inspection categories for joints subjected to static & fatigue loads, As per N001, Table 4.
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Extent of visual examination and NDT requirement
• During the initial fabrication the extent of UT and MT of inspection category B and C welds shall be
intensified, normally to twice the level given in table 9.1.
• In addition table 9.1, the following shall apply for inspection category A & B:
a) One film at each end for longitudinal welds of tubular (including tubular for nodes and stubs).
b) Where radiographic testing is required, intersection welds, and those locations where presence of
defects is deemed to be most harmful, shall be tested.
c) Ultrasonic and radiographic testing shall not overlap, except when 100% UT is specified.
d) Ultrasonic testing is normally not applicable for thicknesses less than 10 mm. For such
thicknesses, UT may be replaced with RT. In general, RT should be considered if UT is not
possible. Radiographic testing is normally not applicable for thicknesses above 40 mm.
e) MT shall be performed on both external and internal surface as accessible or as required by the
designer.
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Structural steel welds.
Visual & MT-acceptance criteria for structural steel welds
• Structural steel welds. Visual and MT-acceptance criteria for structural steel weld
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Repair and re-repair welding
The excavated area shall have smooth transitions to the metal surface and allow good access for
both NDT after excavation & subsequent repair welding.
After excavation, complete removal of the defect shall be confirmed by MT or PT. PWHT shall be
performed after repair if specified for the original weld.
The excavated groove shall be minimum 50 mm long, measured at defect depth even if the defect
itself is smaller.
Defects spaced less than 100 mm shall be repaired as one continuous defect.
After repair welding the complete weld (i.e. the repaired area plus at least 100 mm on each side)
shall be subjected at least to the same NDT as specified for the original weld.
Repair welding may only be carried out twice in the same area.
After Repair, Inspection & NDT of structural steel welds shall not be carried out before 48 hours
after completion except where PWHT is required. The time delay may be reduced to 24 hours for
steel grades with SMYS of 355MPa or lower, and for steel grades with SMYS of 420MPa or lower for
plate thicknesses below 40 mm.
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Correction of welds containing defects.
• All repairs shall be carried out in accordance with established procedures.
• Welds containing cracks shall not be repaired, until the reason for the cracking
has been determined. If necessary, the defective part of the weld shall be cut
out for further examination. Crater cracks may be repaired by grinding followed
by NDT & subsequent repair welding according to an accepted repair welding
procedure.
• When weld defects are removed by grinding only, the final weld surface & the
transition to the base material shall be smooth. Removal of defects shall be
verified by local visual inspection, aided by applicable NDT methods. If
applicable, the remaining thickness in the ground area shall be measured.
Repair welding is required if the remaining thickness is less than that specified.
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Applicable NORSOK Piping Standards
The intention of this standard is to provide additional requirement regarding welding & Inspection of piping systems
designed to ASME B31.3 for hydrocarbon production & process systems & supporting utility systems
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Welding Requirements M-601
General
All welding & related activities shall comply with the requirements of ISO 3834-2 & additional
requirements of this NORSOK standard.
The root pass of welds in stainless steels Type 6Mo, Type 25Cr duplex & Ni-alloys for
seawater service shall be made with filler metal.
A non-slag producing welding process shall be used for the root pass on all single sided
welds in all stainless steels, nickel based & titanium based alloys carbon steel
For welding of high-alloyed austenitic stainless steels with PREN ≥ 40 (e.g. UNS S32654
& UNS S34565) the requirements given to stainless steel Type 6Mo herein shall apply.
Welding of O-lets
The weld bevel of O-lets shall be completely filled up to weld line on the O-lets.
Prior to welding, sufficient root gap & miss match shall be ensured as per WPS.
Production test
Production tests shall be taken when specified. ( per each weld process )
Each production test shall be tested and documented as for the relevant welding
procedure qualification test unless otherwise agreed. 35
Inspection & Non Destructive Testing (NDT)
General
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PED & NDT Groups
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Extent of Non-Destructive Testing
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Acceptance Criteria
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Acceptance Criteria For Others NDT Group
Weld zones in stainless steels, nickel & titanium alloys shall be visually
examined on the inside & outside & fulfill the following criteria or alternatively
evaluated as acceptable in accordance with pictures included in Annex B:
The oxidation levels showing light brown to brown color are acceptable;
Oxidation levels showing a narrow band of dark brown color & intermittent
spots of blue color are acceptable;
Darker or more extensive oxidation colors are not acceptable, & shall be
chemically or mechanically removed. For titanium the weld shall be cut out &
re-welded.
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Positive Material Identification (PMI)
PMI shall be performed on ready installed piping systems in stainless steel materials
& Ni-alloy based materials prior to any pressure testing or coating operation.
SS Type 6Mo,22/25Cr duplex & 3.5%Ni base metal & welds – 100%
The testing shall be uniformly distributed to cover the different type of components,
manufacturer, pre-fabrication sites & installation sites.
For piping systems in stainless steel & Ni-base alloys carrying seawater & systems
with MDT below minus 50 °C, the extent of PMI shall be increased to 100 %.
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Acceptance Criteria-Visual Inspection, Magnetic Particle
& Penetrant Testing
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Extent of Acceptance Criteria-Visual Inspection, Magnetic Particle
& Penetrant Testing
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Figure shows Acceptance Criteria-Visual Inspection,
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Acceptable Oxidations Of Welds In Stainless Steels
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Acceptable Oxidations Of Welds In Stainless Steels
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Weld Inspection Control
General
Job-package: Only approved drawings, latest revision & specifications are used.
Welding numbering system & identification/traceability.
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Checkpoints Before Welding
Drawing
• Material, marking/coding/traceability & handling
• Beveling/cutting, groove preparation, fit up and staggering of adjacent longitudinal welds (
by greater of the 2t or 50mm )
• Welding equipment & use: tools, welding machine etc. (check of calibration/maintenance
to be confirmed by stickers)
• Preheating & protection against wind, rain etc., if necessary
• Purging gas, if necessary (type & flow-rate is set/applied as per WPS)
• Procedure for tack-welding. Tack-welding (parameter control)
• Correct welding consumables are drawn from the stores through indent slips.
• Equipment/tools accommodated as required by the type of material
• Renovation/cleaning, ready for welding
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Checkpoints During Welding
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Checkpoints After Welding
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Fabrication Of Pipework NORSOK L004
General requirements
Prefabricated pipe spools shall be cleaned, painted.
All tools shall be restricted to the relevant material group to avoid rust contamination and
shall be marked to avoid mixing of tools for different materials. Different grades of stainless
steel materials can be handled with the same tools.
Separate tools shall be used for titanium materials.
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Colour code on
Weld finish colour
Clamps
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Dimensional Tolerances For Flanges
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Other Fabrication Requirement
All welded branch connections shall be jointed to the header with full penetration welds.
Stub-in connections shall be set-on type. Set-in type is not acceptable.
Reinforcement pads or saddles required by specifications & drawings shall be of the same material as the
main pipe
Branch reinforcement pads or each segment thereof shall be provided with a minimum 3.0mm drilled &
tapped hole prior to fitting to the pipe, pad should be made in one piece before fitting onto pipe.
Pipe coupling
Seal faces of mechanical couplings/hubs & flanges shall be protected during fabrication & storage.
Where possible couplings/hubs shall be protected by fitting & hand tightening the complete coupling
assembly.
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Equipment/ Flange Connections Alignment
All equipment shall be blanked, either by pressure test blanks, spades or blinds, to stop the ingress of internal pipe
debris.
Flanges connecting to strain sensitive mechanical equipment (e.g. pumps, compressors, turbines, etc.) shall be fitted-
up in close parallel & lateral alignment prior to tightening the bolting. Unacceptable forces transferred on to the
nozzles shall be prevented.
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Gaskets & Bolting Requirement During/After Erection
Gaskets
Bolting
Manually pulled flange bolts & stud bolts shall extend fully through their nuts with minimum one, maximum
five threads.
Hydraulic bolt tightening shall be used on all bolts greater than 1" diameter.
Nuts & bolts shall have their grade marks visible after installation. Stud bolts cut from long lengths of studding
shall have material grade stamped on end of each cut.
To archive the required bolt tension lubrication is important, all flange bolts, stud bolts threads as well as nut
spot faces shall be thoroughly lubricated prior to fitting.
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Support & Global Tolerance During Installation Piping Spool
Pipe support
Where spring support are installed the spring shall locked gagged until commissioning/start up.
Pipes shall not normally be supported by other pipes, i.e. individual supporting is required.
Vent holes in wear plates & trunnion are generally not required. However, when the wear plate or trunnion
covers a circumferential weld that has not been pressure tested, a vent hole is required for leak detection.
Hook-up termination points shall be within ±25 mm in all directions. Over length may be provided where required.
Installation tolerances of piping components shall be as required by the individual service of the piping component
including requirements for
Maintenance access,
Position relative to surrounding steelwork, equipment, cable tray & heating, ventilation & air conditioning (HVAC) duct
routings,
Positioning of pipe supports relative to the structural steel,
Pipe stress
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Pipework Flushing & Hydro Test
Hydro flushing
Pneumatic flushing
Where water is not desirable in the piping system (e.g. instrument/utility air), flushing by pressurized air or
PAS shall be carried out. When pressurized air is used, the minimum velocity shall be 35m/s.
Pressure Test
The test pressure shall, unless otherwise specified, be in accordance with ASME B31.3. The test pressure
shall be calculated based on the maximum design pressure of the piping class (not the design pressure of the
individual line) at 20 ºC.
Test preparation
Pressure, temperature & time recorders shall be used for all hydrostatic tests. The pressure shall be shown in
barg.
Minimum of one gauge shall be positioned at the highest point & one recorder to be positioned at the lowest
point.
Accuracy of pressure gauge shall be at least 1-2% at full scale & 1-2% for the recorder.
The test pressure shall be within 60% of the gauge range (20% from top & 20% from bottom).
If there is a deviation of more than 2% between gauge & recorder during test, the test shall be stopped & the
equipment recalibrated.
Piping joints & welds shall not be insulated or physically covered until satisfactory completion of testing in
accordance with this specification, All joints may be primed & painted prior to pressure testing.
Ball, plug, slab gate valves & other valves where the cavity pressure may differ from the bore pressure, shall
be pressure tested in the half open position. All other valves shall be tested in the fully open position. When
check valves are included in pressure test they shall be jacked open or have their internals removed
Where the test pressure to be applied to the piping is greater than the maximum allowable test pressure for
valves, the valves shall be blinded off on the side to be tested, or removed & replaced by dummy spools.
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Pneumatic Testing
A pressure of 0.5 barg shall be introduced in the system & a leak test to performed.
The pressure shall gradually be increased to 50% of the specified test pressure & kept for minimum 10
minutes to equalize strain.
The pressure shall then be increased in steps of 10% of the specified test pressure, until the specified test
pressure is reached.
At each step, the pressure shall be kept for 10 minutes minimum to equalize strain.
The specified test pressure shall be kept for 1 hour. The pressure shall than be reduced to the design
pressure before examining for leakage.
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Drying & Cleanliness after test
Blowing by dry air or Pressurized Air Shock Blowing to remove any trapped water to be performed.
If more than 3 months to commissioning, drying shall be followed by preservation with nitrogen to keep the
pipe system completely dry & to avoid condense.
Verification of cleanliness
All systems shall be internal visual inspected for acceptable cleanliness by spot check.
If pipe configuration in critical parts of systems as defined in table 1, annex B is too complicated for visual
inspection, the PAS (Periodic acid-Schiff) method or other suitable methods shall be used for verification of
cleanliness.
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CHEMICAL CLEANING
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HOT OIL FLUSHING
General
A detailed procedure for hot oil flushing shall be developed out prior to start.
Filters used for hot oil flushing shall be:
3μm ABS for hydraulic systems.
<= 10μm ABS for lube and seal oil.
Filling of lubricant oil shall take place through filters with 10μm ABS.
Flushing & sampling to verify cleanness shall take place at turbulent flow, upstream any filters. The Reynolds
number shall be min. 4000.
The level of cleanness shall be documented from an automatic particle counter or a membrane checked in a
microscope before a flushing operation is considered finalized.
A flow meter shall be installed to verify flow used during flushing operation.
Maximum water content in oil used for flushing shall be less than 500ppm.
Marking
Piping spools or systems that have been chemical cleaned or hot oil flushed shall be marked in a unique
manner.
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Tightness Testing
A tightness test (sensitive leak test) can be performed to check that all external (e.g. mechanical joints, stuffing box)
and internal (closed valves) potential leakage points meet the maximum leakage requirements. The tightness test is
performed during commissioning phase, after all construction work is finished & mechanical completion is achieved.
The leak test shall be performed with a suitable test medium. The test medium can be divided into the following four
types:
• Type 1 medium: N2He (1 % He)
• Type 2 medium: N2
• Type 3 medium: Air
• Type 4 medium: Medium with equal or lower viscosity than actual service medium
The different test medium shall be used in connection with the following services:
Type 1 medium: All services containing toxic or flammable gases or volatile liquids, including first valve connecting
utility systems. Both external & internal leakage points to be checked.
Type 2 medium: Utility systems containing gas where O2 present in the system is not acceptable. Only external leakage
points to be checked.
Type 3 medium: Utility systems containing gas where O2 present in the system is acceptable. Only external leakage
points to be checked.
Type 4 medium: All other services not falling into category type 1, 2 or 3 medium. Only external leakage points to be
checked.
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System Colour Coding Of Piping
Purpose
The purpose of having a system for colour coding of piping is to ensure quick recognition of medium & flow direction for any
system.
Types of markers
Adhesive band/plastic tape glued to the pipe surface
Shall be used inside living quarters/ administration/ service buildings (HVAC-controlled areas).
Laminated plastic signs
Shall be used on all painted carbon steel piping & on insulated piping
Laminated plastic signs, mounted in aluminum or stainless steel frame brackets
Shall be used on all pipes of stainless & hiqh-alloyed materials,
On all pipes with a surface operating temperature of more than 60 °C,
On all pipes of OD 76,2 mm (3 in) and below & all tubing of OD 25 mm & below.
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Positioning Of Markers
Markers shall be installed with the arrow pointing in the direction of flow. The following special application rules shall
be followed:
Markers shall be positioned specially considering operational aspects of the plant& shall be easily readable from deck,
platform or ordinary access way. Ladders, scaffolding or other temporary equipment shall not be needed for
identification of markers;
Markers shall be placed on each side of bulkheads, decks & other penetration points;
Markers shall be positioned on the pipe close to major components of the actual system (vessel, pumps etc.);
Each valve (spade, spacer, spectacle blind, inline item and removable special items) shall carry a minimum of one
identification tag plate (number plate) in addition to makers tag.
The number plate shall be of stainless steel on which the tag number shall be permanently printed.
Minimum plate size shall be 20 mm x 50 mm with capital letters of height minimum 5 mm. The tags shall be fastened
close to the valve, not onto the valve. This to ensure the tag in position even if the valve is removed or dismantled
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NORSOK STANDARD M-501
Surface Preparation & Protective Coating
The NORSOK standards cover both paints, metallic coatings & application of spray-on passive fire
protective coatings.
The aim of the NORSOK standards is to obtain a coating system, which ensures
that health, safety and environmental impacts are evaluated and documented
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Health, Safety & Environment
The following documentation shall be provided & used when evaluating coating systems
Chemical name of organic solvent, OAR number according to Norwegian regulations, & VOC content in
g/l.
Combustibility.
Content of quartz & heavy metals in blast cleaning media shall be given.
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Thermally Spray Metallic Coatings
Coating materials:
• The coating shall be firmly adherent and the surface shall be uniform, free of lumps, loosely adherent
spattered metal, bubbles, ash formation, defects and uncoated spots.
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Thermally Spray Metallic Coatings
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Thermally Spray Metallic Coatings
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Sprayed on Passive Fire Protection
Application of passive fire protective coating shall be in accordance with the recommendations given by the
manufacturer of the material.
Thickness of coating to checked after curing & before topcoat by drilling holes or ultrasonic techniques.
The surface finish shall conform to the reference sample prepared during CPT & manufacturer application
guide.
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Sprayed on Passive Fire Protection
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NORSOK requirement for Surface Preparation
& Protective Coating Personnel
Personnel carrying out inspection or verification shall be qualified in accordance with NS 476 Inspector level
III, or certified as NACE coating inspector level III.
Inspectors according to NS 476 Inspector level II, may carry out the inspection work under the supervision of
an inspector level III.
Supervisors and foremen shall be qualified to tradesman level and should be qualified in accordance with NS
476 Inspector level II, or NACE level II.
Supervisors, foremen or QC personnel involved in application of passive fire protection shall in addition, be
trained & certified according to the procedures of the manufacturer of the passive fire protective material.
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Inspection & Testing Standard requirement for
Surface Preparation & Protective Coating page 1
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Inspection & Testing Standard requirement for
Surface Preparation & Protective Coating page 2
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NORSOK STANDARD
ELECTRICAL SYSTEMS
EICT
NORSOK
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NORSOK STANDARD E-001
ELECTRICAL SYSTEMS
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NORSOK STANDARD E-001
ELECTRICAL SYSTEMS
GUIDE LINE
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NORSOK STANDARD E-001
ELECTRICAL SYSTEMS
AIM - To achieve:
Reliability of service
Convenience of operation
Ease of maintenance
Maximum efficiency
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NORSOK STANDARD E-001
ELECTRICAL SYSTEMS
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NORSOK STANDARD E-001
ELECTRICAL SYSTEMS
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NORSOK STANDARD E-001
ELECTRICAL SYSTEMS
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NORSOK STANDARD I-001
FIELD INSTRUMENTATION
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NORSOK STANDARD E-001
ELECTRICAL SYSTEMS
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NORSOK STANDARD E-001
ELECTRICAL SYSTEMS
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NORSOK STANDARD I-001
FIELD INSTUMENTATION
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NORSOK STANDARD I-001
FIELD INSTRUMENTATION
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NORSOK STANDARD I-001
FIELD INSTRUMENTATION
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NORSOK STANDARD I-001
FIELD INSTRUMENTATION
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NORSOK STANDARD T-001
TELECOM SYSTEMS
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NORSOK STANDARD T-001
TELECOM SYSTEMS
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NORSOK STANDARD S-002
WORKING ENVIRONMENT REQUIREMENTS
All work areas shall have a layout that provides for easy and
access for operation, inspection , reading and maintenance.
Permanent means of access shall be provided for all
equipment (JB, Motor, Valve, light, Instruments) that needs
to be accessible for operation attention during start up,
normal operation, shut down or in an emergency.
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NORSOK STANDARD S-002
WORKING ENVIRONMENT REQUIREMENTS
first
Do it RIGHT at time is the most
PRODUCTIVE
approach
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Implementation
Of Colored zones
Three Different Zones should be set up , based
on the degree of completion of the building.
GREEN ZONE: Green Zone in areas where only
the basic (Cold work) construction exists in
defined area. (After blasting & painting)
YELLOW ZONE: Yellow Zone in areas where the
building is undergoing the installation of
services within a relatively clean environment.
RED ZONE: Red Zone in areas with final
architectural finishing is taking place under
controlled environment.
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CLEAN AND DRY BUILDING
What is Green?
1. Water Tight 2.Clean and
& Ventilation Dry
Environment
3.Commence 4.Access
out fitting control &
Defined
(Cold work)
walking path
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CLEAN AND DRY BUILDING
3. Air
conditioned
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CLEAN AND DRY BUILDING
Temporary air use to DH unit with required temperature and Relative Humidity
value in green zone
Provide temporary air use AHU ( Air Handle unit ) with required temperature
and Relative Humidity value in yellow zone
Maintain dust particle count in Green and Yellow zone ( particle count Min
0.3µm based on 1 CF)
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CLEAN AND DRY BUILDING
To meet INSTA
800N standard
Ceiling Wall
Furniture &
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Fixtures Floor
Implementation
Of C&DB
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Implementation
Of C&DB
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