DNVGL-RP-B202 Steel forgings for subsea applications ... · VAR vacuum arc re-melting VD vacuum...

The electronic pdf version of this document, available free of chargefrom http://www.dnvgl.com, is the officially binding version.

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RECOMMENDED PRACTICE

DNVGL-RP-B202 Edition March 2017

Steel forgings for subsea applications -quality management requirements

FOREWORD

DNV GL recommended practices contain sound engineering practice and guidance.

© DNV GL AS March 2017

Any comments may be sent by e-mail to [email protected]

This service document has been prepared based on available knowledge, technology and/or information at the time of issuance of thisdocument. The use of this document by others than DNV GL is at the user's sole risk. DNV GL does not accept any liability or responsibilityfor loss or damages resulting from any use of this document.

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Recommended practice — DNVGL-RP-B202. Edition March 2017 Steel forgings for subsea applications - quality management requirements

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CHANGES - CURRENT

This is a new document.

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AcknowledgementsThis recommended practice is developed based on results from a joint industry project (JIP). The followingcompanies, listed in alphabetical order, are acknowledged for their contributions to the JIP.

AkerBP Aker Solutions BP International Limited Brück

Celsa Chevron ConocoPhillips Dril-Quip

Ellwood Group, Inc. Eni ExxonMobil Franchini Acciai

Frisa GE OneSubsea Petrobras

Ringmill Scana Subsea Statoil TechnipFMC

Total

Further organisations have participated in the review process. DNV GL is grateful for the valuable co-operations and discussions with individuals in these organisations.

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CONTENTS

Changes - current...................................................................................................3Acknowledgements.................................................................................4

Section 1 Introduction............................................................................................ 71.1 General............................................................................................. 71.2 Scope and application.......................................................................71.3 Normative and informative references............................................. 71.4 Definitions and abbreviations........................................................... 8

Section 2 Requirements for qualifying company and personnel............................ 112.1 General........................................................................................... 112.2 Qualifying company........................................................................ 112.3 Material specialist...........................................................................112.4 Inspector........................................................................................ 11

Section 3 Qualification of manufacturers.............................................................. 123.1 General........................................................................................... 123.2 Initial technical assessment........................................................... 133.3 Technical audit................................................................................133.4 Assessment of existing manufacturer qualifications....................... 143.5 Maintaining qualified manufacturers...............................................15

Section 4 Manufacturing procedure qualification.................................................. 164.1 General........................................................................................... 164.2 Manufacturing procedure specification........................................... 174.3 Inspection and test plan.................................................................174.4 Pre-qualification meeting................................................................174.5 Manufacture and testing of qualification forging............................ 174.6 Surveillance.................................................................................... 174.7 Alternative surveillance methods....................................................174.8 Manufacturing procedure qualification report.................................184.9 Assessment of existing forging qualifications.................................18

Section 5 Production of forgings...........................................................................205.1 General........................................................................................... 205.2 Manufacturing procedure specification........................................... 205.3 Inspection and test plan.................................................................205.4 Manufacture and testing of production forging...............................20

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5.5 Surveillance.................................................................................... 205.6 Alternative surveillance methods....................................................205.7 Certification and documentation.....................................................20

Appendix A Pre-audit questionnaire......................................................................21

Appendix B Technical audit checklist.................................................................... 30

Appendix C Inspection and test plan qualification of forgings.............................. 37

Appendix D Inspection and test plan production of forgings................................ 39

Appendix E Manufacturing procedure qualification record front page................... 41

Changes - historic.................................................................................................42


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SECTION 1 INTRODUCTION

1.1 GeneralThis recommended practice (RP) contains criteria, requirements and guidance on quality management ofsteel forgings for subsea applications. The corresponding technical requirements for such forgings are givenin DNVGL-RP-0034.The RP has been written for general, world-wide application. Governmental regulations may includerequirements in excess of the provisions given by this RP.The objectives of this RP are:

— to provide an international and harmonised standard for quality management of steel forgings— to provide increased confidence, reduced lead time, enhanced stock keeping and interchangeability of

steel forgings— to simplify the quality management process and avoid duplication of quality activities— to serve as a contractual reference document between contractors and companies.

The RP is divided into five main sections:

— Sec.1 Introduction: Contains general information, scope and application, normative and informativereferences, definitions and abbreviations

— Sec.2 Requirements for qualifying company and personnel: Contains requirements related to competenceand experience of qualifying company, material specialist and inspector

— Sec.3 Qualification of manufacturers: Contains requirements for quality management related toqualification of forging manufacturers and maintaining qualified manufacturers

— Sec.4 Manufacturing procedure qualification: Contains requirements for quality management andsurveillance related to manufacturing procedure qualification (MPQ)

— Sec.5 Production of forgings: Contains requirements for quality management and surveillance related toproduction of forgings.

1.2 Scope and applicationThis RP specifies quality management and surveillance requirements applicable to manufacturing of steelforgings in accordance with DNVGL-RP-0034. The requirements cover qualification of forging manufacturers,manufacturing procedure qualification and surveillance of production.This RP has specific focus on the technical aspects of quality management relevant to forgings and someparticular quality management system (QMS) aspects. A full QMS and health, safety and environment (HSE)assessment and audit shall be conducted according to the contractor’s quality management system but thatis outside the scope of this RP. Assessment of financial and commercial viability of potential manufacturers isalso outside the scope of this RP.The requirements covered herein come in addition to and not instead of the requirements specified inDNVGL-RP-0034.Subject to agreement between contracting parties, this RP may also be used for quality management offorgings intended for other than subsea applications.

1.3 Normative and informative referencesIn the context of this document the term standard shall be understood to cover document types such ascodes, guidelines and recommended practices in addition to bona fide standards.The standards listed in Table 1-1 and Table 1-2 include provisions and guidance which, through reference inthis text, constitute provisions and guidance of this RP. The latest edition applies unless dated references aregiven.


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Other recognized standards may be used provided it can be demonstrated that they meet or exceed therequirements of the referenced standards.Any deviations, exceptions and modifications to the standards shall be documented and agreed between themanufacturer and contractor/third party and listed in the forging documentation/MPQR. When performingwork for a specific subsea project, company shall be notified of and agree to all deviations, exceptions andmodifications.

Table 1-1 Normative references

Document code Title

DNVGL-RP-0034 Steel forgings for subsea applications

ISO 9001 Quality Management Systems – Requirements

ISO/IEC 17020 Conformity assessment – General criteria for the operation of various types of bodiesperforming inspection

ISO/IEC 17025 General requirements for the competence of testing and calibration laboratories

Table 1-2 Informative references

Document code Title

ISO 19011 Guidelines for auditing management systems

1.4 Definitions and abbreviations

1.4.1 TermsFor the purpose of this RP, the definitions of terms in Table 1-3 and Table 1-4 apply.

Table 1-3 Definitions of terms – process and activity

Term Definition

assessment a process which evaluates activities, facilities, or systems against requirements orexpectations

audit (ISO 9000) systematic, independent, and documented process for obtaining audit evidence andevaluating it objectively to determine the extent to which audit criteria are fulfilled

special/critical process process that includes melting and casting of ingots, forging, heat treatment, materialtesting and NDT

surveillance planned assessment and verification to confirm that forgings meet requirements

technical audit qualifying company audit of potential manufacturer to assess and verify capability tomeet technical requirements

verification (ISO 9000) confirmation through the provision of objective evidence that specified requirementshave been fulfilled


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Table 1-4 Definitions of terms – organization and roles

Term Definition

company end user of subsea equipment

contractor entity that provides subsea equipment to a company or company’s main contractor

manufacturer entity that provides steel forgings for components in subsea equipment to contractor

manufacturer’s supplier entity that provides starting material to manufacturer or provider of sub-contractedmanufacturing, testing and NDT/inspection activities for manufacturer

material specialist person authorized by qualifying company to perform technical assessments, technicalaudits and surveillance of agreed activities during manufacturing procedure qualificationor production

inspector person authorized by qualifying company or contractor/third party to performsurveillance of manufacturing procedure qualification or production

third party independent entity hired by contractor or manufacturer to perform material specialist orinspector activities at manufacturer’s site

qualifying company entity responsible for qualification of manufacturers and manufacturing procedurequalification

1.4.2 Verbal formsFor the purpose of this RP, the definitions of verbal forms in Table 1-5 apply.

Table 1-5 Definitions of verbal forms

Term Definition

shall verbal form used to indicate requirements strictly to be followed in order to conform tothe document

should verbal form used to indicate that among several possibilities one is recommended asparticularly suitable, without mentioning or excluding others, or that a certain course ofaction is preferred but not necessarily required

may verbal form used to indicate a course of action permissible within the limits of thedocument

1.4.3 AbbreviationsTechnical abbreviations used in this RP are listed in Table 1-6.

Table 1-6 List of technical abbreviations

Abbreviation Description

AUT automatic ultrasonic testing

CE carbon equivalent

CTOD crack tip opening displacement


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Abbreviation Description

CVN Charpy V-notch

EAF electric arc furnace

ESR electro slag re-melting

HSE health, safety and environment

ITP inspection and test plan

LR ladle refining

MPQ manufacturing procedure qualification

MPQR manufacturing procedure qualification report

MPS manufacturing procedure specification

MT magnetic particle testing

MTR material test report

NCR non-conformance report

NDT non-destructive testing

PAUT phased array ultrasonic testing

PPM pre-production meeting

PQM pre-qualification meeting

QMS quality management system

RP recommended practice

SFC steel forging class

SMYS specified minimum yield strength

SPWHT simulated post weld heat treatment

UT ultrasonic testing

VAR vacuum arc re-melting

VD vacuum degassing

VT visual testing

QA quality assurance

QT quenched and tempered


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SECTION 2 REQUIREMENTS FOR QUALIFYING COMPANY ANDPERSONNEL

2.1 GeneralThis section contains requirements related to competence and experience of qualifying company, materialspecialist and inspector. See also Table 1-4.

2.2 Qualifying companyThe qualifying company shall be a contractor or a third party. The qualifying company shall be independentof the forging manufacturer and shall have an established track record with forged material to the subseaindustry.

2.3 Material specialistThe material specialist shall be a graduate material science/metallurgy engineer with at least three years’relevant experience or a mechanical engineer with at least five years’ relevant experience.

2.4 InspectorThe inspector shall be a person with technical degree or higher and at least two years’ relevant experience ora person with no formal education and at least five years’ relevant experience.The inspector shall have satisfactory knowledge of heat treatment, mechanical testing including sampling,NDT and the associated inspections to be performed.


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SECTION 3 QUALIFICATION OF MANUFACTURERS

3.1 GeneralThis section contains requirements for quality management related to qualification of forging manufacturersand maintaining qualified manufacturers. The objective is to obtain and maintain confidence in the capabilityof a manufacturer. This shall be accomplished by assessing and verifying that the manufacturers have thepersonnel, competence, procedures, systems/practices, facilities, equipment and experience needed forcompliance with requirements in DNVGL-RP-0034.Qualification of new manufacturers shall include the steps outlined in Figure 3-1 and as detailed in [3.2] and[3.4]. For assessment of existing manufacturer qualifications, see [3.4].Qualified manufacturers shall be maintained as detailed in [3.5].Qualifying companies shall have documented systems or procedures for qualification of manufacturers.

New manufacturer identified

Initial technical assessment [3.2]

Proceed?

Technical audit [3.3]

Satisfactory?

SFC 1: Qualified manufacturer

Qualification process stopped

Assessment report

Pre-audit questionnaire [Appendix A]

Audit report [3.3.5]

Technical audit checklist

[Appendix B]

Yes

No

No

SFC 2 and 3: Proceed to MPQ [4]

Yes

Figure 3-1 Outline of process steps in qualification of new manufacturers


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3.2 Initial technical assessmentAn initial technical assessment of the manufacturer shall be performed by the qualifying company. Theassessment shall be performed by a material specialist. More disciplines, e.g. quality assurance (QA), may beinvolved in the assessment. The assessment may be performed as a desktop study.Prior to the assessment, qualifying company shall request the manufacturer to fill in a pre-auditquestionnaire, see the template in App.A. Qualifying companies may develop and use their own questionnaireformats provided that they are updated or modified as necessary to include the items in App.A. Thequestionnaire with supporting documentation shall be returned by the manufacturer to qualifying company.The material specialist shall assess the information provided in the questionnaire and review supportingdocumentation to decide whether to proceed with technical audit. As far as practical, the material specialistshould ask follow-up questions and investigate alternative and/or mitigating actions for negative answersto any of the questions in App.A. These alternative and/or mitigating actions shall be explained in theassessment report or memo.Results of the assessment and review shall be documented in a suitable format, e.g. report or memo. Theresult shall be made available for manufacturer, when requested.

3.3 Technical audit

3.3.1 GeneralFollowing a positive recommendation from the initial technical assessment, the qualifying company shallperform a technical audit at the manufacturer’s site(s). The audit shall include the manufacturer’s suppliers ofany of the following sub-contracted activities:

— forging— heat treatment— non-destructive testing (NDT)— material testing, if the laboratory is not certified according to ISO 17025.

Where manufacture of starting material (ingots, blooms or billets) is sub-contracted, these suppliers need notbe audited by the qualifying company but shall be audited by the manufacturer. Ingot supplier audit reportsshall be made available for qualifying company review.

3.3.2 Scope of auditThe scope of the audit shall include detailed assessment and verification of the following:

a) personnel competence relevant to manufacturing and testing activitiesb) procedures for special/critical processesc) traceability of material throughout the whole processd) process for disposition OF non-conforming material or process failurese) facilities and equipment relevant to manufacturing and testing activitiesf) routines for maintenance and calibration of equipment relevant to manufacturing and testing activitiesg) previous experience with relevant materials and productsh) systems and procedures for selection and qualification of manufacturer’s suppliers.

Generic guidance for planning and conducting an audit is given in ISO 19011.

3.3.3 Audit team and preparationThe technical audit shall be performed by a material specialist. Where appropriate, the audit may beperformed in cooperation with or supported by a separate QMS audit team.


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The audit shall be prepared based on information provided in the pre-audit questionnaire including, whererelevant, other existing qualifications of the manufacturer.In further preparation for the audit, the following documents shall be reviewed:

— a typical process flow chart showing sequence of manufacturing and testing activities— a master register or list identifying all procedures that are applicable to control of special/critical

processes.

The audit scope and schedule shall be generated as a checklist. An audit checklist template is given in App.B.Qualifying companies may develop and use their own checklists provided that they are updated or modifiedas necessary to include the checklist items in App.B.

3.3.4 Audit executionThe audit shall be conducted using the audit checklist as given in [3.3.3].During the audit, information relevant to the audit objectives, scope and criteria shall be collected bymeans of appropriate sampling. All information shall be verified. Methods of collecting information includeinterviews, observations and review of documents. Only verifiable information shall be accepted as auditevidence.Relevant procedures shall be collected and reviewed while conducting the audit.Audit findings and conclusions shall be recorded and presented to manufacturer in a closing meeting.

3.3.5 Audit report and follow-upQualifying company shall establish a technical audit report. The report shall provide a complete, accurate,concise and clear record of the audit and shall contain the following information:

— audit objectives and scope— completed audit checklist— audit findings and conclusions.

The audit report shall be transmitted to the manufacturer.Manufacturer shall respond to audit findings with a written description of the planned corrective actionsand submit it to qualifying company for approval. Appropriate follow-up actions shall be performed anddocumented by qualifying company to verify that the corrective actions taken are effective at eliminating thecause of the original audit finding.The audit report, including documentation of follow-up actions to close any audit findings, shall betransmitted to the manufacturer and shall be made available for company, when requested.

3.4 Assessment of existing manufacturer qualificationsManufacturers with qualification in existence prior to the release of this RP may be acceptable provided that:

a) the manufacturer was audited and approved by contractor prior to the release of the first edition of thisRP

b) the manufacturer has produced and supplied critical forgings to contractor within the previous five yearsc) the forgings have a history of acceptable field performanced) a gap analysis is performed to determine what elements are in non-compliance with this RP, and a plan

is developed for upgrading the qualification to be compliant within three years from the date of release ofthe first edition of this RP.


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3.5 Maintaining qualified manufacturers

3.5.1 GeneralQualifying company shall maintain qualified manufacturers based on the following requirements:

— ongoing review of quality performance, as detailed in [3.4.2].— re-assessment every five years to verify that there are no significant changes to the conditions upon

which the qualifying company approval was based. These changes can be, but are not limited to:

— change in senior management including QA management— change in ownership— change in manufacturer’s suppliers— change in facilities, equipment, processes or procedures.

Validity of manufacturer qualifications shall be managed by the qualifying company’s QMS.

3.5.2 Quality performanceThe manufacturer’s quality performance shall be monitored and controlled. This may be in the form ofon-site assessment and/or review of suitable metrics such as product non-conformities, on-time delivery,corrective/preventive actions, and reject rate. Failure to meet established quality performance metrics bythe manufacture shall result in a documented performance improvement plan, and/or documented correctiveaction.


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SECTION 4 MANUFACTURING PROCEDURE QUALIFICATION

4.1 GeneralThis section contains requirements for quality management and surveillance related to manufacturingprocedure qualification (MPQ). This is only applicable for steel forging classes SFC 2 and SFC 3, as given inDNVGL-RP-0034.The process shall include the steps outlined in Figure 4-1 and as detailed in [4.2] to [4.8]. For assessment ofexisting forging qualifications, see [4.9].

Techincal audit approved [3]

Manufacturer develops MPS and ITP [4.2] and [4.3]

Accepted?

Pre-qualification meeting [4.4]

Results OK?

Qualified forging.Proceed to production [5]

ITP template [Appendix C]

andDNVGL-RP-0034

MPQR [4.8]

Review of MPS and ITP [4.2] and [4.3]

Manufacture and testing incl. surveillance [4.5],

[4.6] and [4.7]

Yes

Yes

No

MPQR front page

[Appendix E]

No

Figure 4-1 Outline of process steps in manufacturing procedure qualification


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4.2 Manufacturing procedure specificationBased on order information, the manufacturer shall develop a manufacturing procedure specification (MPS)for the qualification forging.Qualifying company’s material specialist shall review and approve the MPS. The MPS shall contain theinformation required in DNVGL-RP-0034 including references to applicable procedures/process controls.

4.3 Inspection and test planBased on order information, an inspection and test plan (ITP) shall be developed for the qualification forging.An ITP template is given in App.C. Other templates or forms may be developed and used provided they areupdated or modified as necessary to include the items, including required intervention points, in App.C.Qualifying company shall review and approve the ITP. The ITP shall contain the information required inDNVGL-RP-0034. Qualifying company’s own intervention points shall be marked up and shall as a minimuminclude verification and surveillance as given in App.C.

4.4 Pre-qualification meetingA pre-qualification meeting (PQM) between manufacturer and qualifying company shall be conducted toassess manufacturer’s readiness prior to start of the MPQ. Qualifying company’s material specialist shallattend the PQM.Surveillance to be performed by qualifying company’s material specialist and/or inspector shall be establishedin the PQM.Qualifying company shall document the PQM, e.g. by meeting minutes.

4.5 Manufacture and testing of qualification forgingManufacture and testing of qualification forging shall be in accordance with the approved MPS and shall meetall applicable requirements in DNVGL-RP-0034.

4.6 SurveillanceQualifying company’s material specialist and/or inspector shall perform surveillance during the MPQ asapproved in the ITP established in the PQM.Qualifying company shall document surveillance, e.g. by signed off ITP and/or surveillance/inspectionreports.

4.7 Alternative surveillance methodsAs an alternative to on-site inspection, the use of other inspection technique methods such as remoteinspection may be considered for acceptance. In such cases the methods applied shall be capable ofproviding the information normally obtained from an on-site inspection.Use of alternative inspection technique methods shall be documented and agreed between manufacturer andqualifying company in advance of the inspection.


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4.8 Manufacturing procedure qualification report

4.8.1 GeneralOn completion of satisfactory qualification testing, a manufacturing procedure qualification report (MPQR)with content as listed in [4.8.2] shall be established.The MPQR shall be prepared with a front page with format and content as shown in App.E.

4.8.2 Content of reportThe MPQR shall contain the following information relevant to manufacture and testing of the qualificationforging:

a) MPQR front page, see App.Eb) approved MPS and ITPc) starting material certificated) heat treatment documents and records, including:

— statement of compliance to relevant furnace calibration and temperature uniformity standard— furnace loading sketch— heat treatment charts.

e) test plan/sketch showing locations for tensile, Charpy V-notch (CVN), surface hardness, metallographicand any other testing required

f) results of qualification testing as required in DNVGL-RP-0034

g) non-destructive testing (NDT) procedures and reports

h) surveillance reports/signed off ITP.

4.8.3 Approval and distribution of reportQualifying company shall review the MPQR for completeness and compliance with all applicable requirementsin DNVGL-RP-0034 and this RP.On completion of satisfactory review, the qualifying company shall approve the MPQR by signing andstamping the MPQR front page. The signed and stamped MPQR front page shall be transmitted to themanufacturer.The MPQR shall be made available for company, when requested.

4.9 Assessment of existing forging qualificationsForgings with qualification in existence prior to the release of DNVGL-RP-0034 may be acceptable providedthat:

a) the qualification was reviewed and approved by contractor prior to the release of DNVGL-RP-0034 andthe first edition of this RP

b) the manufacturer has produced and supplied qualified forgings to contractor within the previous fiveyears

c) the forgings have a history of acceptable field performanced) a gap analysis is performed to determine what elements are in non-compliance with DNVGL-RP-0034

and this RP, and

— essential variables meet the requirements in DNVGL-RP-0034


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— deviations such as a missing test location or direction in qualification are agreed between thecontractor and company

— a plan is developed for upgrading the MPQR to be compliant within five years from the date of releaseof the first edition of this RP.


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SECTION 5 PRODUCTION OF FORGINGS

5.1 GeneralThis section contains requirements for quality management and surveillance related to production of forgings.

5.2 Manufacturing procedure specificationThe manufacturer shall prepare a MPS for production forgings.Contractor’s/third party’s materials discipline shall review and approve the MPS. For SFC 2 and SFC 3, theMPS shall have all essential variables from MPQ stated and shall contain the information required in DNVGL-RP-0034 including references to applicable procedures/process controls.

5.3 Inspection and test planThe manufacturer shall prepare an ITP for production forgings. An ITP template is given in App.D. Othertemplates or forms may be developed and used provided they are updated or modified as necessary toinclude the items, including required intervention points, in App.D.Contractor/third party shall review and approve the ITP. The ITP shall contain the information requiredin DNVGL-RP-0034. Contractor’s/third party’s own intervention points shall be marked up and shall as aminimum include verification and surveillance as given in App.D.

5.4 Manufacture and testing of production forgingManufacture and testing of production forging shall be in accordance with the approved MPS and shall meetall applicable requirements in DNVGL-RP-0034.

5.5 SurveillanceA pre-production meeting (PPM) between manufacturer and contractor/third party shall be conducted toassess manufacturer readiness prior to start of production.Contractor/third party inspector(s) shall perform surveillance of production as approved in the ITP.Contractor/third party shall document surveillance, e.g. by signed off ITP and/or surveillance/inspectionreports.

5.6 Alternative surveillance methodsAs an alternative to on-site inspection, use of other inspection technique methods such as remote inspectionmay be considered for acceptance. In such cases the methods applied shall be capable of providing theinformation normally obtained from an on-site inspection.Use of alternative inspection technique methods shall be documented and agreed between manufacturer andcontractor/third party in advance of the inspection.

5.7 Certification and documentationContractor/third party shall review manufacturer’s certificates with accompanying documentation and recordsfor completeness and compliance with all applicable requirements in DNVGL-RP-0034. Any concessionsrelated to products shall be included in the final documentation.Manufacturer’s certificates with accompanying documentation and records shall be transmitted for companyevaluation, when requested.


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APPENDIX A PRE-AUDIT QUESTIONNAIREAll items identified in this pre-audit questionnaire shall be completed by the manufacturer for thequalification process to commence. When all sections are completed, please fill in the information below andemail this document <in … format> with applicable supporting documents to <Company/Name>.

Manufacturer representative completing this questionnaire

Name and title

Manufacturer

Phone number E-mail address

Signature Date of submission

1. General information

1.1 Manufacturer information and contacts

1.1.1 Manufacturer name

1.1.2 Physical address

1.1.3 Postal address

1.1.4 Phone number

1.1.5 Web site

1.1.6 Type of ownership

1.1.7 Country of registration

1.1.8 Registration number

1.1.9 Registration year

1.1.10 Quality contact Quality e-mail

1.1.11 HSE contact HSE e-mail

1.1.12 Additional comments, if any:

1.2 Organization – management

Position Name E-mail address

CEO/managing director

Marketing/sales manager

Procurement manager

Production manager

Quality assurance manager

Quality control manager

HSE manager

1.2.1

Human resources manager


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1.3 Organization – personnel

Department Number of permanent employees Number of contracted personnel

Marketing/sales

Procurement

Engineering

Production planning

Production

Quality assurance

Quality control

Health, safety, environment(HSE)

1.3.1

Total (all departments)

1.3.2 How many graduatemetallurgical engineers are onstaff?

1.3.3 Name of responsible NDT level3

1.3.4 State if responsible NDT level3 is permanently employed orcontracted


1.3.6 Please attach organization chart

2. Quality management system (QMS)

2.1 QMS – certification

QMS standard Certificatenumber

Issued by Renewaldate

2.1.1


2.1.3 Please attach a copy of your QMS certificate(s)


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2.2 QMS – general

2.2.1 Do you have a quality policy? Yes __ No __

2.2.2 Do you have a quality manual? Yes __ No __

2.2.3 Do you have a documentation management system? Yes __ No __

2.2.4 Do you have a process/system for non-conformance report (NCR) handling? Yes __ No __

2.2.5 Do you provide ISO 10474/EN 10204 type 3.1 or 3.2 inspection certificates? Yes __ No __

2.2.6 Are permanent records maintained that relate to the products? Yes __ No __

2.2.7 How are these records stored?

2.2.8 Do you have a system for qualification and training of personnel? Yes __ No __

2.2.9 Do you have a system for qualification and evaluation of your suppliers? Yes __ No __


3. Product information and approvals

3.1 Product information

3.1.1 List in general all forged products that your company provides:

Have you supplied forged products to the subsea industry?

Yes __ No __3.1.2

If yes, please list type of forgings, applicable standards/specifications, grades, size and configurations:

3.1.3 Specify the forged products you wish to supply to the subsea industry:

Do you sub-contract (outsource) manufacturing or testing activities?

Yes __ No __3.1.4

If yes, please list sub-contracted activities and supplier names:


3.1.6 Please attach your reference list


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3.2 Product approvals

Has your company and products been approved by international oil companies? Yes __ No __3.2.1

If yes, please list approvals:

3.2.2 List your top clients in the oil and gas business by turn over from the last five years:

Has your company and products been approved by international classification societies, e.g.DNV GL, ABS, LR, BV?

Yes __ No __3.2.3

If yes, please list approvals:

3.2.4 List other relevant approvals or qualifications you have, e.g. ASME, API, PED, NORSOK:


3.2.6 Please attach a copy of your approvals and qualifications

4. Facilities and equipment

4.1 Facility (to be approved) – general information

Facility type Facility size (sq. m or sq. ft) Owned or rented/leased

Offices/administration

Manufacturing/workshops

Laboratories

Covered warehouses

Outside storage (uncovered)

4.1.1

Total

4.1.2 Currently how many shifts are in operation?

4.1.3 How many shifts are you capable of running?

4.1.4 What is the facility crane capacity limitation?



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4.2 Steelmaking

4.2.1 Do you have in-house melting and casting facilities?

Yes __ No __

Do you subcontract manufacture of ingots or billets?

Yes __ No __4.2.2

If yes, please list names and addresses of manufacturers:

In-house EAF __ LR __ VD__

ESR __ VAR __ Other __Specify:

4.2.3 Which steelmaking methodsare performed?

Subcontracted EAF __ LR __ VD__

ESR __ VAR __ Other __Specify:

4.2.4 Please describe methods/practices for scrapsource control, deoxidation, fine graintreatment, inclusion shape control (SFC 3) andheat analysis:

4.2.5 Is melting, refining and casting controlled anddocumented through formal procedure(s)?

Yes ___ No ___ Procedure no.:

4.2.6 How is traceability maintained duringsteelmaking?

4.2.7 Which records of steelmaking are maintained?

4.2.8 How and by whom are these recordscontrolled?


4.3 Forging

4.3.1 Which forging methods are performed in-house? Open die__ Closed die__ Ringrolling__

Other __Specify:

4.3.2 Which steels/materials are forged? Carbon__ Low alloy__ Stainless__ Other __Specify:

4.3.3 List product forms (rounds, squares etc), max. sizeand weight of forgings:

4.3.4 List annual production capacity:

4.3.5 List max. weight of ingots:

4.3.6 List type, number and capacity of heating furnaces:


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4.3.7 List furnace calibrations and means of temperaturecontrol:

4.3.8 List type, number and capacity of presses/hammers/ring rolling machines:

4.3.9 Is forging controlled and documented through formalprocedure(s)?

Yes __ No __ Procedure no.:

4.3.10 How is traceability maintained during forging?

4.3.11 How is hot work temperature monitored duringforging?

4.3.12 Which records of forging are maintained?

4.3.13 How and by whom are these records controlled?


4.4 Heat treatment

4.4.1 Which heat treatment processes are performed in-house?

Normalizing __ QT __ Other __Specify:

4.4.2 List type, number and capacity of furnaces:

4.4.3 Which standards are used for calibration of furnaces/equipment?

ISO 10423/API 6A __ AMS-H-6875__

Other __Specify:

4.4.4 List furnace/equipment calibrations and means oftemperature control:

4.4.5 Are preliminary heat treatment and rough machiningprior to quality heat treatment performed?

4.4.6 Is quality heat treatment controlled and documentedthrough formal procedure(s)?


4.4.7 How is traceability maintained during heattreatment?

4.4.8 Describe furnace loading practices:

4.4.9 How are temperatures and soaking times controlled?


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4.4.9 Describe method(s) of unloading from furnace andmax. transfer time to quench tank:

4.4.10 List number and size/volume of quench tanksincluding quenching medium, type of agitation andtemperature control:

4.4.11 How is surface metal temperature at removal fromquench tank controlled and measured?

4.4.12 Which records of heat treatment are maintained?

4.4.13 How and by whom are these records controlled?


4.5 Testing (excluding non-destructive testing)

4.5.1 Which tests are performed in-house? Tensile __CVN __

Hardness __

Grain size __Cleanliness __

CTOD __Product analysis __

Other __Specify:

4.5.2 Is the test laboratory QMSconforming to ISO 17025?

Yes __ No __ If certified, please attach a copy of the certificate.

4.5.3* Do you have documented systemfor calibration of test machines andmeasurement equipment?

Yes __ No __

4.5.4* Is testing controlled and documentedthrough formal procedure(s)?


4.5.5 Which standards/codes are used forperforming testing?

4.5.6 How is traceability maintained duringtesting?

4.5.7 Which records of testing aremaintained?



* Not applicable for ISO 17025 certified laboratories.


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4.6 Non-destructive testing (NDT)

4.6.1 Which tests are performed in-house? UT, conventional __UT, AUT/autom. PAUT __

UT, manual PAUT __

MT, fluorescent __ VT __Other (specify) __

4.6.2 Is the company conforming to ISO 17020? Yes __ No __

4.6.3 Are personnel responsible for all NDTmethods/activities certified to Level 3 inaccordance with ISO 9712 or ACCP?

Yes __ No __ If no, provide details:

4.6.4 Are personnel performing NDT certified tomin. Level 2 in accordance with ISO 9712or ACCP?


4.6.5 Do personnel performing VT comply withvision requirements in ISO 9712?


4.6.6 Do you have documented system forcalibration of NDT equipment?

Yes __ No __

4.6.7 Is NDT controlled and documentedthrough formal procedure(s)?


4.6.8 Which standards/codes are used forperforming NDT?

4.6.9 Which records of NDT are maintained?



5 Final inspection/review

5.1 Is final inspection/review to verify compliance with specifiedrequirements controlled and documented through formal procedure(s)?


5.2 Which records of final inspection/review are maintained?

5.3 How and by whom are these records controlled?

5.4 Is preservation, packaging and marking of forgings to be shippedcontrolled and documented through formal procedure(s)?


5.5 Additional comments, if any:


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6 Manufacturing procedure specification (MPS)/inspection and test plan (ITP)

6.1 Please attach a generic MPS copy.

6.2 Please attach a generic ITP copy.


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APPENDIX B TECHNICAL AUDIT CHECKLISTTechnical audit – general information

Manufacturer name

Physical address

Postal address

Registration number

Qualifying company name

Material specialist name

Audit team member name

Date of audit (YYYY-MM-DD)

Manufacturer personnel contacted or interviewed during audit

Name Title Phone or email

No. Checklist item Yes No N/A Comments/guidance

1. Starting materials – bought-in ingots and receiving inspection

1.1 Is qualification and evaluation of starting materialmanufacturers performed according to documentedprocedure/system?Procedure/system:

Verify procedure/system inplace.

1.2 How is specification requirements passed down to manufacturers of startingmaterial?

1.3 How is control of scrap sources for steelmaking managed?

1.4 Is receiving inspection performed according to documentedprocedure?Procedure:

Verify procedure in place.

1.5 Who is responsible for preparing and approving procedure/instruction?

1.6 Who performs the receiving inspection?

1.7 How are inspectors familiarized with the instructions?

1.8 How is required melting and casting methods including sufficient ingot discardverified?

1.9 How is marking/traceability to certificate checked and visual inspectionperformed?

1.10 How are particulars in certificate/MTR verified (chemistry etc)?


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1.11 What records of receiving inspection are maintained? Verify records are maintained.

1.12 Who reviews the records?

1.13 What actions are taken when defects are found in receiving inspection?

1.14 How is identification and traceability of starting material maintained duringstorage?

1. Starting materials cont. – in-house melting, refining and casting

1.15 What are the documented personnel training/qualification procedures for allin-house melting, refining and casting processes performed?Procedure:

Verify training procedures fortechnical content for eachoperation.

1.16 Is melting, refining and casting performed according todocumented procedure/system?Procedure/system:

Verify procedure in place.Review procedure.

1.17 How is control of scrap sources for steelmaking managed?

1.18 How and by whom is melting, refining and casting methods, ingot type/sizeand ingot discard determined?

1.19 Who is responsible for preparing and approving instructions/procedure?

1.20 How is instruction transferred to manufacturing facility?Job card/traveller or on-line computer

Verify transfer by review.

1.21 How are operators familiarized with the instructions?

1.22 What inspections are performed on ingots?

1.23 How is sufficient ingot discard verified?

1.24 What records of melting, refining and casting are maintained? Verify records are maintained.

1.25 Who reviews and approves the records?

1.26 What actions are taken when deviations from instructions occur?

1.27 How is identification and traceability maintained during manufacture andstorage?Maintained on traveller or work piece:

2. Forging

2.1 What are the documented personnel training/qualification procedures for allforging processes performed?Procedure:


2.2 Is forging performed according to documented procedures/instructions?Procedure/instruction:



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2.3 How and by whom is forging method, forging reduction, sequence of forgingsteps and forging temperature range determined?

2.4 How are heating/re-heating temperatures and holding times determined?

2.5 Who is responsible for preparing and approving forging instructions/procedure?

2.6 How is instruction transferred to manufacturing facility?Job card/traveller or on-line computer:



2.8 How is satisfactory condition of heating furnaces verified, e.g. size, fuel andtemperature range?

2.9 How is hot work temperature monitored during forging?

2.10 What methods are used for cleaning/descaling of forgings?

2.11 What inspections are performed after forging?

2.12 What determines if preliminary heat treatment and/or rough machining aredone prior to quality heat treatment?

2.13 What records of forging are maintained? Verify records are maintained.


2.15 What actions are taken when deviations from forging instructions occur?

2.16 How is identification and traceability maintained during forging?Maintained on traveller or work piece:

3. Heat treatment

3.1 What are the documented personnel training/qualification procedures for allheat treatment processes performed?Procedure:


3.2 Is furnace equipment calibration and temperatureuniformity surveys performed according to documentedprocedure?Procedure:

Verify procedure in place.

3.3 Who reviews and approves temperature uniformity surveys?

3.4 Are surveys of furnaces performed and documented? Verify surveys at least once ayear.Verify temperature variationfrom set point within allowedrange.

3.5 Are temperature controlling and recording instrumentscalibrated and within calibration period?

Sample and verify thatinstruments are calibrated atleast once every three months.


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3.6 Is heat treatment performed according to documentedprocedures/instructions?Procedure/instruction:


3.7 How and by whom is furnace loading/unloading plan, heat treatment cyclesand method of temperature control determined?

3.8 Who is responsible for preparing and approving heat treatment instructions/procedure?

3.9 How are instructions transferred to manufacturing facility?Job card/traveller or on-line computer:



3.11 How is furnace loading controlled and recorded? Observe loading or reviewrecords.Verify proper spacing, nostacking, position of sacrificial/prolongation part, attachedthermocouples, etc.

3.12 What is the method of transfer from furnace to quench tank and how istransfer time controlled and recorded?

Observe quenching or reviewrecords.Verify max. 90 seconds transfertime.

3.13 How are quench tanks sized and what means of agitation is used to optimizecooling rate?

Observe quenching or reviewrecords.Verify quench tanks permitcomplete immersion of partsand proper agitation of quenchmedium.

Verify quench water temperaturemax 40°C at start and max 50°Cat finish of quench.

3.14 How is surface metal temperature at removal from quench tank measuredand recorded?Method and record:

Sample records and review.

3.15 What records of heat treatment are maintained? Verify furnace loading and heattreat charts are maintained.

3.16 Who reviews the records?

3.17 What actions are taken when deviations from heat treat instructions occur?

3.18 How is identification and traceability maintained during heat treatment?Maintained on traveller or work piece:

4. Testing – mechanical, hardness, chemical and metallographic


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4.1 What are the documented personnel training/qualification procedures for alltesting methods performed?Procedure:

Verify training procedures fortechnical content for eachoperation.Verify personnel qualifications.

4.2 Are procedures available for calibration of test machines/equipment?Procedure:

Verify procedures are available.

4.3 Is testing equipment calibrated and within calibrationperiod?

Verify unique identification ofeach equipment and currentcalibration labels/stickers onthem.

4.4 Is testing performed according to documented procedures/instructions including order specific test plans?Procedure/instruction:

Verify procedures in place.Review procedures.

Sample test plan and verifycorrect number, position andorientation of test specimens.

Witness, if possible, samplemechanical and hardnesstesting.

4.5 How and by whom is test method/standard, extent of testing and position/orientation of test specimens determined?

4.6 Who is responsible for preparing and approving test procedures/instructionsand test plans?

4.7 How are instructions/test plans transferred to testing lab?Job card/traveller or on-line computer:


4.8 How is testing personnel familiarized with the instructions?

4.9 What records of testing are maintained? Verify test plan, mechanical,hardness, chemical andmetallographic test records aremaintained.


4.11 What actions are taken when deviations from testing instructions occur?

4.12 How is identification and traceability maintained during testing?Maintained on traveller or work piece:

5. Non-destructive testing

5.1 Are procedures/systems available for qualification andcertification of NDT personnel?Procedure:

Verify procedures/systems areavailable.

5.2 Are personnel responsible for all NDT methods/activitiesqualified and certified to Level 3?

Verify personnel qualifications.


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5.3 Are personnel performing NDT qualified and certified tominimum Level 2?


5.4 Are personnel performing VT complying with visionrequirements according to documented procedures?


5.5 Are procedures available for calibrations, verifications andchecks of NDT equipment?Procedure:


5.6 Is NDT equipment calibrated and within calibration period? Verify unique identification ofeach equipment and currentcalibration labels/stickers onthem.

5.7 Is NDT performed according to documented procedures/instructions?Procedure/instruction:

Verify procedures in place.Review procedures.

5.8 How and by whom is test method, extent of testing, scan plan, etc.determined?

5.9 Who is responsible for preparing and approving testing instructions/procedure?

5.10 How are instructions transferred to NDT facility?Job card/traveller or on-line computer:


5.11 How is NDT personnel familiarized with the instructions?

5.12 Explain how NDT acceptance criteria are defined, understood andimplemented:

5.13 What records of NDT are maintained?


5.15 What actions are taken when deviations from NDT instructions occur?

5.16 How is identification and traceability maintained during NDT?Maintained on traveller or work piece:

6. Final inspection/review

6.1 Is final inspection/review to verify compliance withspecified requirements controlled and documented throughformal procedure(s)?Procedure:

Verify procedures/systems areavailable.

6.2 What records of final inspection/review are maintained? Sample and review.


6.4 Is preservation, packaging and marking of forgings tobe shipped controlled and documented through formalprocedure(s)?



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7. Control of non-conforming product

7.1 Is non-conforming product controlled and documentedthrough formal procedure(s)?Procedure:

Verify procedures/systems are inplace.

7.2 What are the controls and related responsibilities and authorities foraddressing non-conforming product?

7.3 Who raises and who closes out non-conformance?

7.4 How are non-conforming products identified, segregated and dispositioned?

7.5 How are customers notified of non-conforming products and eventualconcessions obtained?

7.6 How are causes of non-conforming products analysed?

7.7 What records of non-conforming product and subsequent actions aremaintained?

Sample and review.



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APPENDIX C INSPECTION AND TEST PLAN QUALIFICATION OFFORGINGS

Inspection and test planManufacturing procedure qualification of steel forgings

Process activityControllingdocument

with revision no.

Acceptancecriteria

Verifyingdocument

Verification/surveillance method 1)

No. Description Location Manu-facturer

Qualifyingcompany

Preliminary activities

1.1 Qualified manufacturer R

1.2 MPS R

1.3 Pre-qualification meeting H

Manufacturing, testing and inspection activities

2.1 Starting materialverification

W

2.2 Ingot heating W

2.3 Forging W

2.4 Preliminary inspection W

2.5 Preliminary heattreatment, if used

W

2.6 Rough machining M

2.7 Dimensional verification R

2.8 Furnace loading,austenitizing (start ofoperation)

H

2.9 Quenching W

2.10 Furnace loading,tempering

W

2.11 Surface hardness testing W

2.12 Cleaning, sand blasting

2.13 Visual testing W

2.14 Magnetic particle testing W

2.15 Ultrasonic testing W

2.16 Test sampling and testprogram

H

2.17 Product analysis W


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Inspection and test planManufacturing procedure qualification of steel forgings

Process activityControllingdocument

with revision no.

Acceptancecriteria

Verifyingdocument

Verification/surveillance method 1)

No. Description Location Manu-facturer

Qualifyingcompany

2.18 Tensile and CVN impacttesting

W

2.19 Hardness testing; throughcross section

W

2.20 SPWHT testing, ifapplicable; tensile andCVN impact testing

W

2.21 Metallographicexamination; austenitegrain size, cleanliness andmacro-etch

W

2.22 CTOD testing for SFC 3 W

Completion activities

3.1 Certification anddocumentation

R

3.2 Final MPQ reportapproval; release forproduction

H

1)

Code Term Description

H hold point The qualifying company shall be notified in advance of the activity. The activity shall notcommence without the presence of, or written instruction from, the qualifying company.

M monitor point Activity proceeds as scheduled, without advance notification, but the qualifying company choosesto observe on a random basis.

R review point Activity proceeds as scheduled, without advance notification, but the qualifying company shallreview documentation at an agreed time after completion of the activity.

W witness point The qualifying company shall be notified in advance of the activity. Following the agreednotification period, the activity may commence as planned with or without the presence of thequalifying company. Waiving a witness point shall be documented and the reason for waivingstated. If the qualifying company is not present, the activity shall be verified by the qualifyingcompany by document review at a later date.


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APPENDIX D INSPECTION AND TEST PLAN PRODUCTION OFFORGINGS

Process activity Verification/surveillance method 1)

No. Description Location

Controllingdocument with

revision no.

Acceptancecriteria

Verifyingdocument Manu-

facturer

Contractor/thirdparty

Preliminary activities

1.1 MPQ R

1.2 MPS R

1.3 Pre-production meeting H

Manufacturing, testing and inspection activities

2.1 Starting materialverification

2.2 Forging

2.3 Preliminary heattreatment

2.4 Quality heat treatment W

2.5 Test material marking/cutting

W

2.6 Product analysis

2.7 Mechanical testing

2.8 Metallographicexamination

2.9 Non-destructive testing W

2.10 Dimensional inspection

2.11 Marking

Completion activities

3.1 Certification anddocumentation

R

3.2 Final inspection H

3.3 Packing and preservation


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1)

Code Term Description

H hold point The contractor/third party shall be notified in advance of the activity. The activity shall notcommence without the presence of, or written instruction from, the contractor/third party.

M monitorpoint

Activity proceeds as scheduled, without advance notification, but the contractor/third partychooses to observe on a random basis.

R review point Activity proceeds as scheduled, without advance notification, but the contractor/third party shallreview documentation at an agreed time after completion of the activity.

W witnesspoint

The contractor/third party shall be notified in advance of the activity. Following the agreednotification period, the activity may commence as planned with or without the presence of thecontractor/third party. Waiving a witness point shall be documented and the reason for waivingstated. If the contractor/third party is not present, the activity shall be verified by the contractor/third party by document review at a later date.


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APPENDIX E MANUFACTURING PROCEDURE QUALIFICATIONRECORD FRONT PAGE

Cha

nges

- h

isto

ric


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CHANGES - HISTORICThere are currently no historical changes for this document.

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