Steel forgings for subsea applications - quality management requirements

Transcription

1 RECOMMENDED PRACTICE DNVGL-RP-B202 Edition March 2017 Steel forgings for subsea applications - quality management requirements The electronic pdf version of this document, available free of charge from is the officially binding version.

2 FOREWORD DNV GL recommended practices contain sound engineering practice and guidance. March 2017 Any comments may be sent by to This service document has been prepared based on available knowledge, technology and/or information at the time of issuance of this document. 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 responsibility for loss or damages resulting from any use of this document.

3 CHANGES - CURRENT This is a new document. Changes - current Recommended practice DNVGL-RP-B202. Edition March 2017 Page 3

4 Acknowledgements This recommended practice is developed based on results from a joint industry project (JIP). The following companies, 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 Changes - current Further organisations have participated in the review process. DNV GL is grateful for the valuable cooperations and discussions with individuals in these organisations. Recommended practice DNVGL-RP-B202. Edition March 2017 Page 4

5 CONTENTS Changes - current...3 Acknowledgements...4 Contents Section 1 Introduction General Scope and application Normative and informative references Definitions and abbreviations... 8 Section 2 Requirements for qualifying company and personnel General Qualifying company Material specialist Inspector Section 3 Qualification of manufacturers General Initial technical assessment Technical audit Assessment of existing manufacturer qualifications Maintaining qualified manufacturers...15 Section 4 Manufacturing procedure qualification General Manufacturing procedure specification Inspection and test plan Pre-qualification meeting Manufacture and testing of qualification forging Surveillance Alternative surveillance methods Manufacturing procedure qualification report Assessment of existing forging qualifications...18 Section 5 Production of forgings General Manufacturing procedure specification Inspection and test plan Manufacture and testing of production forging...20 Recommended practice DNVGL-RP-B202. Edition March 2017 Page 5

6 5.5 Surveillance Alternative surveillance methods Certification and documentation...20 Appendix A Pre-audit questionnaire...21 Contents Appendix B Technical audit checklist Appendix C Inspection and test plan qualification of forgings Appendix D Inspection and test plan production of forgings Appendix E Manufacturing procedure qualification record front page Changes - historic...42 Recommended practice DNVGL-RP-B202. Edition March 2017 Page 6

7 SECTION 1 INTRODUCTION 1.1 General This recommended practice (RP) contains criteria, requirements and guidance on quality management of steel forgings for subsea applications. The corresponding technical requirements for such forgings are given in DNVGL-RP The RP has been written for general, world-wide application. Governmental regulations may include requirements 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 informative references, definitions and abbreviations Sec.2 Requirements for qualifying company and personnel: Contains requirements related to competence and experience of qualifying company, material specialist and inspector Sec.3 Qualification of manufacturers: Contains requirements for quality management related to qualification of forging manufacturers and maintaining qualified manufacturers Sec.4 Manufacturing procedure qualification: Contains requirements for quality management and surveillance related to manufacturing procedure qualification (MPQ) Sec.5 Production of forgings: Contains requirements for quality management and surveillance related to production of forgings. 1.2 Scope and application This RP specifies quality management and surveillance requirements applicable to manufacturing of steel forgings in accordance with DNVGL-RP 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 some particular 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 that is outside the scope of this RP. Assessment of financial and commercial viability of potential manufacturers is also outside the scope of this RP. The requirements covered herein come in addition to and not instead of the requirements specified in DNVGL-RP Subject to agreement between contracting parties, this RP may also be used for quality management of forgings intended for other than subsea applications. 1.3 Normative and informative references In the context of this document the term standard shall be understood to cover document types such as codes, 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 in this text, constitute provisions and guidance of this RP. The latest edition applies unless dated references are given. Recommended practice DNVGL-RP-B202. Edition March 2017 Page 7

8 Other recognized standards may be used provided it can be demonstrated that they meet or exceed the requirements of the referenced standards. Any deviations, exceptions and modifications to the standards shall be documented and agreed between the manufacturer and contractor/third party and listed in the forging documentation/mpqr. When performing work for a specific subsea project, company shall be notified of and agree to all deviations, exceptions and modifications. Table 1-1 Normative references Document code DNVGL-RP-0034 ISO 9001 ISO/IEC ISO/IEC Title Steel forgings for subsea applications Quality Management Systems Requirements Conformity assessment General criteria for the operation of various types of bodies performing inspection General requirements for the competence of testing and calibration laboratories Table 1-2 Informative references Document code ISO Title Guidelines for auditing management systems 1.4 Definitions and abbreviations Terms For 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 assessment audit (ISO 9000) special/critical process surveillance technical audit verification (ISO 9000) Definition a process which evaluates activities, facilities, or systems against requirements or expectations systematic, independent, and documented process for obtaining audit evidence and evaluating it objectively to determine the extent to which audit criteria are fulfilled process that includes melting and casting of ingots, forging, heat treatment, material testing and NDT planned assessment and verification to confirm that forgings meet requirements qualifying company audit of potential manufacturer to assess and verify capability to meet technical requirements confirmation through the provision of objective evidence that specified requirements have been fulfilled Recommended practice DNVGL-RP-B202. Edition March 2017 Page 8

9 Table 1-4 Definitions of terms organization and roles Term company contractor manufacturer manufacturer s supplier material specialist inspector third party qualifying company Definition end user of subsea equipment entity that provides subsea equipment to a company or company s main contractor entity that provides steel forgings for components in subsea equipment to contractor entity that provides starting material to manufacturer or provider of sub-contracted manufacturing, testing and NDT/inspection activities for manufacturer person authorized by qualifying company to perform technical assessments, technical audits and surveillance of agreed activities during manufacturing procedure qualification or production person authorized by qualifying company or contractor/third party to perform surveillance of manufacturing procedure qualification or production independent entity hired by contractor or manufacturer to perform material specialist or inspector activities at manufacturer s site entity responsible for qualification of manufacturers and manufacturing procedure qualification Verbal forms For the purpose of this RP, the definitions of verbal forms in Table 1-5 apply. Table 1-5 Definitions of verbal forms Term shall should may Definition verbal form used to indicate requirements strictly to be followed in order to conform to the document verbal form used to indicate that among several possibilities one is recommended as particularly suitable, without mentioning or excluding others, or that a certain course of action is preferred but not necessarily required verbal form used to indicate a course of action permissible within the limits of the document Abbreviations Technical abbreviations used in this RP are listed in Table 1-6. Table 1-6 List of technical abbreviations Abbreviation AUT CE CTOD Description automatic ultrasonic testing carbon equivalent crack tip opening displacement Recommended practice DNVGL-RP-B202. Edition March 2017 Page 9

10 Abbreviation CVN EAF ESR HSE ITP LR MPQ MPQR MPS MT MTR NCR NDT PAUT PPM PQM QMS RP SFC SMYS SPWHT UT VAR VD VT QA QT Description Charpy V-notch electric arc furnace electro slag re-melting health, safety and environment inspection and test plan ladle refining manufacturing procedure qualification manufacturing procedure qualification report manufacturing procedure specification magnetic particle testing material test report non-conformance report non-destructive testing phased array ultrasonic testing pre-production meeting pre-qualification meeting quality management system recommended practice steel forging class specified minimum yield strength simulated post weld heat treatment ultrasonic testing vacuum arc re-melting vacuum degassing visual testing quality assurance quenched and tempered Recommended practice DNVGL-RP-B202. Edition March 2017 Page 10

11 SECTION 2 REQUIREMENTS FOR QUALIFYING COMPANY AND PERSONNEL 2.1 General This section contains requirements related to competence and experience of qualifying company, material specialist and inspector. See also Table Qualifying company The qualifying company shall be a contractor or a third party. The qualifying company shall be independent of the forging manufacturer and shall have an established track record with forged material to the subsea industry. 2.3 Material specialist The 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 Inspector The inspector shall be a person with technical degree or higher and at least two years relevant experience or a 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. Recommended practice DNVGL-RP-B202. Edition March 2017 Page 11

12 SECTION 3 QUALIFICATION OF MANUFACTURERS 3.1 General This section contains requirements for quality management related to qualification of forging manufacturers and maintaining qualified manufacturers. The objective is to obtain and maintain confidence in the capability of a manufacturer. This shall be accomplished by assessing and verifying that the manufacturers have the personnel, competence, procedures, systems/practices, facilities, equipment and experience needed for compliance with requirements in DNVGL-RP 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] Pre-audit questionnaire [Appendix A] Assessment report Proceed? Yes Technical audit [3.3] Technical audit checklist [Appendix B] No Audit report [3.3.5] No Satisfactory? Yes Qualification process stopped SFC 1: Qualified manufacturer SFC 2 and 3: Proceed to MPQ [4] Figure 3-1 Outline of process steps in qualification of new manufacturers Recommended practice DNVGL-RP-B202. Edition March 2017 Page 12

13 3.2 Initial technical assessment An initial technical assessment of the manufacturer shall be performed by the qualifying company. The assessment shall be performed by a material specialist. More disciplines, e.g. quality assurance (QA), may be involved 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-audit questionnaire, see the template in App.A. Qualifying companies may develop and use their own questionnaire formats provided that they are updated or modified as necessary to include the items in App.A. The questionnaire 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 supporting documentation to decide whether to proceed with technical audit. As far as practical, the material specialist should ask follow-up questions and investigate alternative and/or mitigating actions for negative answers to any of the questions in App.A. These alternative and/or mitigating actions shall be explained in the assessment report or memo. Results of the assessment and review shall be documented in a suitable format, e.g. report or memo. The result shall be made available for manufacturer, when requested. 3.3 Technical audit General Following a positive recommendation from the initial technical assessment, the qualifying company shall perform a technical audit at the manufacturer s site(s). The audit shall include the manufacturer s suppliers of any of the following sub-contracted activities: forging heat treatment non-destructive testing (NDT) material testing, if the laboratory is not certified according to ISO Where manufacture of starting material (ingots, blooms or billets) is sub-contracted, these suppliers need not be audited by the qualifying company but shall be audited by the manufacturer. Ingot supplier audit reports shall be made available for qualifying company review Scope of audit The scope of the audit shall include detailed assessment and verification of the following: a) personnel competence relevant to manufacturing and testing activities b) procedures for special/critical processes c) traceability of material throughout the whole process d) process for disposition OF non-conforming material or process failures e) facilities and equipment relevant to manufacturing and testing activities f) routines for maintenance and calibration of equipment relevant to manufacturing and testing activities g) previous experience with relevant materials and products h) systems and procedures for selection and qualification of manufacturer s suppliers. Generic guidance for planning and conducting an audit is given in ISO Audit team and preparation The technical audit shall be performed by a material specialist. Where appropriate, the audit may be performed in cooperation with or supported by a separate QMS audit team. Recommended practice DNVGL-RP-B202. Edition March 2017 Page 13

14 The audit shall be prepared based on information provided in the pre-audit questionnaire including, where relevant, 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 modified as necessary to include the checklist items in App.B Audit execution The 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 by means of appropriate sampling. All information shall be verified. Methods of collecting information include interviews, observations and review of documents. Only verifiable information shall be accepted as audit evidence. 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 Audit report and follow-up Qualifying 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 actions and submit it to qualifying company for approval. Appropriate follow-up actions shall be performed and documented by qualifying company to verify that the corrective actions taken are effective at eliminating the cause of the original audit finding. The audit report, including documentation of follow-up actions to close any audit findings, shall be transmitted to the manufacturer and shall be made available for company, when requested. 3.4 Assessment of existing manufacturer qualifications Manufacturers 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 this RP b) the manufacturer has produced and supplied critical forgings to contractor within the previous five years c) the forgings have a history of acceptable field performance d) 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 of the first edition of this RP. Recommended practice DNVGL-RP-B202. Edition March 2017 Page 14

15 3.5 Maintaining qualified manufacturers General Qualifying 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 Quality performance The manufacturer s quality performance shall be monitored and controlled. This may be in the form of on-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 by the manufacture shall result in a documented performance improvement plan, and/or documented corrective action. Recommended practice DNVGL-RP-B202. Edition March 2017 Page 15

16 SECTION 4 MANUFACTURING PROCEDURE QUALIFICATION 4.1 General This section contains requirements for quality management and surveillance related to manufacturing procedure qualification (MPQ). This is only applicable for steel forging classes SFC 2 and SFC 3, as given in DNVGL-RP The process shall include the steps outlined in Figure 4-1 and as detailed in [4.2] to [4.8]. For assessment of existing forging qualifications, see [4.9]. Techincal audit approved [3] Manufacturer develops MPS and ITP [4.2] and [4.3] ITP template [Appendix C] and DNVGL-RP-0034 No Review of MPS and ITP [4.2] and [4.3] Accepted? Yes Pre-qualification meeting [4.4] No Manufacture and testing incl. surveillance [4.5], [4.6] and [4.7] Results OK? Yes MPQR [4.8] MPQR front page [Appendix E] Qualified forging. Proceed to production [5] Figure 4-1 Outline of process steps in manufacturing procedure qualification Recommended practice DNVGL-RP-B202. Edition March 2017 Page 16

17 4.2 Manufacturing procedure specification Based 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 the information required in DNVGL-RP-0034 including references to applicable procedures/process controls. 4.3 Inspection and test plan Based 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 are updated 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 in DNVGL-RP Qualifying company s own intervention points shall be marked up and shall as a minimum include verification and surveillance as given in App.C. 4.4 Pre-qualification meeting A pre-qualification meeting (PQM) between manufacturer and qualifying company shall be conducted to assess manufacturer s readiness prior to start of the MPQ. Qualifying company s material specialist shall attend the PQM. Surveillance to be performed by qualifying company s material specialist and/or inspector shall be established in the PQM. Qualifying company shall document the PQM, e.g. by meeting minutes. 4.5 Manufacture and testing of qualification forging Manufacture and testing of qualification forging shall be in accordance with the approved MPS and shall meet all applicable requirements in DNVGL-RP Surveillance Qualifying company s material specialist and/or inspector shall perform surveillance during the MPQ as approved in the ITP established in the PQM. Qualifying company shall document surveillance, e.g. by signed off ITP and/or surveillance/inspection reports. 4.7 Alternative surveillance methods As an alternative to on-site inspection, the use of other inspection technique methods such as remote inspection may be considered for acceptance. In such cases the methods applied shall be capable of providing the information normally obtained from an on-site inspection. Use of alternative inspection technique methods shall be documented and agreed between manufacturer and qualifying company in advance of the inspection. Recommended practice DNVGL-RP-B202. Edition March 2017 Page 17

18 4.8 Manufacturing procedure qualification report General On 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 Content of report The MPQR shall contain the following information relevant to manufacture and testing of the qualification forging: a) MPQR front page, see App.E b) approved MPS and ITP c) starting material certificate d) 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, metallographic and 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 Approval and distribution of report Qualifying company shall review the MPQR for completeness and compliance with all applicable requirements in DNVGL-RP-0034 and this RP. On completion of satisfactory review, the qualifying company shall approve the MPQR by signing and stamping the MPQR front page. The signed and stamped MPQR front page shall be transmitted to the manufacturer. The MPQR shall be made available for company, when requested. 4.9 Assessment of existing forging qualifications Forgings with qualification in existence prior to the release of DNVGL-RP-0034 may be acceptable provided that: a) the qualification was reviewed and approved by contractor prior to the release of DNVGL-RP-0034 and the first edition of this RP b) the manufacturer has produced and supplied qualified forgings to contractor within the previous five years c) the forgings have a history of acceptable field performance d) 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 Recommended practice DNVGL-RP-B202. Edition March 2017 Page 18

19 deviations such as a missing test location or direction in qualification are agreed between the contractor and company a plan is developed for upgrading the MPQR to be compliant within five years from the date of release of the first edition of this RP. Recommended practice DNVGL-RP-B202. Edition March 2017 Page 19

20 SECTION 5 PRODUCTION OF FORGINGS 5.1 General This section contains requirements for quality management and surveillance related to production of forgings. 5.2 Manufacturing procedure specification The 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, the MPS 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 plan The manufacturer shall prepare an ITP for production forgings. An ITP template is given in App.D. Other templates or forms may be developed and used provided they are updated or modified as necessary to include the items, including required intervention points, in App.D. Contractor/third party shall review and approve the ITP. The ITP shall contain the information required in DNVGL-RP Contractor s/third party s own intervention points shall be marked up and shall as a minimum include verification and surveillance as given in App.D. 5.4 Manufacture and testing of production forging Manufacture and testing of production forging shall be in accordance with the approved MPS and shall meet all applicable requirements in DNVGL-RP Surveillance A pre-production meeting (PPM) between manufacturer and contractor/third party shall be conducted to assess 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/inspection reports. 5.6 Alternative surveillance methods As an alternative to on-site inspection, use of other inspection technique methods such as remote inspection may be considered for acceptance. In such cases the methods applied shall be capable of providing the information normally obtained from an on-site inspection. Use of alternative inspection technique methods shall be documented and agreed between manufacturer and contractor/third party in advance of the inspection. 5.7 Certification and documentation Contractor/third party shall review manufacturer s certificates with accompanying documentation and records for completeness and compliance with all applicable requirements in DNVGL-RP Any concessions related to products shall be included in the final documentation. Manufacturer s certificates with accompanying documentation and records shall be transmitted for company evaluation, when requested. Recommended practice DNVGL-RP-B202. Edition March 2017 Page 20

21 APPENDIX A PRE-AUDIT QUESTIONNAIRE All items identified in this pre-audit questionnaire shall be completed by the manufacturer for the qualification process to commence. When all sections are completed, please fill in the information below and this document <in format> with applicable supporting documents to <Company/Name>. Manufacturer representative completing this questionnaire Name and title Manufacturer Phone number Signature address Date of submission 1. General information 1.1 Manufacturer information and contacts Manufacturer name Physical address Postal address Phone number Web site Type of ownership Country of registration Registration number Registration year Quality contact Quality HSE contact HSE Additional comments, if any: 1.2 Organization management Position Name address CEO/managing director Marketing/sales manager Procurement manager Production manager Quality assurance manager Quality control manager HSE manager Human resources manager Recommended practice DNVGL-RP-B202. Edition March 2017 Page 21

22 1.1.2 Additional comments, if any: 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) Total (all departments) How many graduate metallurgical engineers are on staff? Name of responsible NDT level State if responsible NDT level 3 is permanently employed or contracted Additional comments, if any: Please attach organization chart 2. Quality management system (QMS) 2.1 QMS certification QMS standard Certificate number Issued by Renewal date Additional comments, if any: Please attach a copy of your QMS certificate(s) Recommended practice DNVGL-RP-B202. Edition March 2017 Page 22

23 2.2 QMS general Do you have a quality policy? Yes No Do you have a quality manual? Yes No Do you have a documentation management system? Yes No Do you have a process/system for non-conformance report (NCR) handling? Yes No Do you provide ISO 10474/EN type 3.1 or 3.2 inspection certificates? Yes No Are permanent records maintained that relate to the products? Yes No How are these records stored? Do you have a system for qualification and training of personnel? Yes No Do you have a system for qualification and evaluation of your suppliers? Yes No Additional comments, if any: 3. Product information and approvals 3.1 Product information List in general all forged products that your company provides: Have you supplied forged products to the subsea industry? Yes No If yes, please list type of forgings, applicable standards/specifications, grades, size and configurations: Specify the forged products you wish to supply to the subsea industry: Do you sub-contract (outsource) manufacturing or testing activities? Yes No If yes, please list sub-contracted activities and supplier names: Additional comments, if any: Please attach your reference list Recommended practice DNVGL-RP-B202. Edition March 2017 Page 23

24 3.2 Product approvals Has your company and products been approved by international oil companies? If yes, please list approvals: Yes No 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? If yes, please list approvals: Yes No List other relevant approvals or qualifications you have, e.g. ASME, API, PED, NORSOK: Additional comments, if any: 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) Total Currently how many shifts are in operation? How many shifts are you capable of running? What is the facility crane capacity limitation? Additional comments, if any: Recommended practice DNVGL-RP-B202. Edition March 2017 Page 24

25 4.2 Steelmaking Do you have in-house melting and casting facilities? Yes No Do you subcontract manufacture of ingots or billets? Yes No If yes, please list names and addresses of manufacturers: Which steelmaking methods are performed? In-house EAF LR VD Subcontracted EAF LR VD ESR VAR Other Specify: ESR VAR Other Specify: Please describe methods/practices for scrap source control, deoxidation, fine grain treatment, inclusion shape control (SFC 3) and heat analysis: Is melting, refining and casting controlled and documented through formal procedure(s)? How is traceability maintained during steelmaking? Yes No Procedure no.: Which records of steelmaking are maintained? How and by whom are these records controlled? Additional comments, if any: 4.3 Forging Which forging methods are performed in-house? Open die Closed die Ring rolling Other Specify: Which steels/materials are forged? Carbon Low alloy Stainless Other Specify: List product forms (rounds, squares etc), max. size and weight of forgings: List annual production capacity: List max. weight of ingots: List type, number and capacity of heating furnaces: Recommended practice DNVGL-RP-B202. Edition March 2017 Page 25

26 4.3.7 List furnace calibrations and means of temperature control: List type, number and capacity of presses/hammers/ ring rolling machines: Is forging controlled and documented through formal procedure(s)? How is traceability maintained during forging? Yes No Procedure no.: How is hot work temperature monitored during forging? Which records of forging are maintained? How and by whom are these records controlled? Additional comments, if any: 4.4 Heat treatment Which heat treatment processes are performed inhouse? Normalizing QT Other Specify: List type, number and capacity of furnaces: Which standards are used for calibration of furnaces/ equipment? List furnace/equipment calibrations and means of temperature control: ISO 10423/API 6A AMS-H-6875 Other Specify: Are preliminary heat treatment and rough machining prior to quality heat treatment performed? Is quality heat treatment controlled and documented through formal procedure(s)? How is traceability maintained during heat treatment? Yes No Procedure no.: Describe furnace loading practices: How are temperatures and soaking times controlled? Recommended practice DNVGL-RP-B202. Edition March 2017 Page 26

27 4.4.9 Describe method(s) of unloading from furnace and max. transfer time to quench tank: List number and size/volume of quench tanks including quenching medium, type of agitation and temperature control: How is surface metal temperature at removal from quench tank controlled and measured? Which records of heat treatment are maintained? How and by whom are these records controlled? Additional comments, if any: 4.5 Testing (excluding non-destructive testing) Which tests are performed in-house? Tensile Grain size CTOD Other CVN Cleanliness Product analysis Specify: Hardness Is the test laboratory QMS conforming to ISO 17025? 4.5.3* Do you have documented system for calibration of test machines and measurement equipment? 4.5.4* Is testing controlled and documented through formal procedure(s)? Which standards/codes are used for performing testing? Yes No Yes No Yes No If certified, please attach a copy of the certificate. Procedure no.: How is traceability maintained during testing? Which records of testing are maintained? How and by whom are these records controlled? Additional comments, if any: * Not applicable for ISO certified laboratories. Recommended practice DNVGL-RP-B202. Edition March 2017 Page 27

28 4.6 Non-destructive testing (NDT) Which tests are performed in-house? UT, conventional UT, AUT/autom. PAUT UT, manual PAUT Is the company conforming to ISO 17020? Yes No MT, fluorescent VT Other (specify) Are personnel responsible for all NDT methods/activities certified to Level 3 in accordance with ISO 9712 or ACCP? Are personnel performing NDT certified to min. Level 2 in accordance with ISO 9712 or ACCP? Do personnel performing VT comply with vision requirements in ISO 9712? Do you have documented system for calibration of NDT equipment? Is NDT controlled and documented through formal procedure(s)? Which standards/codes are used for performing NDT? Yes No Yes No Yes No Yes No Yes No If no, provide details: If no, provide details: If no, provide details: Procedure no.: Which records of NDT are maintained? How and by whom are these records controlled? Additional comments, if any: 5 Final inspection/review 5.1 Is final inspection/review to verify compliance with specified requirements controlled and documented through formal procedure(s)? 5.2 Which records of final inspection/review are maintained? Yes No Procedure no.: 5.3 How and by whom are these records controlled? 5.4 Is preservation, packaging and marking of forgings to be shipped controlled and documented through formal procedure(s)? 5.5 Additional comments, if any: Yes No Procedure no.: Recommended practice DNVGL-RP-B202. Edition March 2017 Page 28

29 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. Recommended practice DNVGL-RP-B202. Edition March 2017 Page 29

30 APPENDIX B TECHNICAL AUDIT CHECKLIST Technical 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 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 material manufacturers performed according to documented procedure/system?procedure/system: Verify procedure/system in place. 1.2 How is specification requirements passed down to manufacturers of starting material? 1.3 How is control of scrap sources for steelmaking managed? 1.4 Is receiving inspection performed according to documented procedure? 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 discard verified? 1.9 How is marking/traceability to certificate checked and visual inspection performed? 1.10 How are particulars in certificate/mtr verified (chemistry etc)? Recommended practice DNVGL-RP-B202. Edition March 2017 Page 30

31 No. Checklist item Yes No N/A Comments/guidance 1.11 What records of receiving inspection are maintained? Verify records are maintained 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 during storage? 1. Starting materials cont. in-house melting, refining and casting 1.15 What are the documented personnel training/qualification procedures for all in-house melting, refining and casting processes performed? Procedure: 1.16 Is melting, refining and casting performed according to documented procedure/system? Procedure/system: Verify training procedures for technical content for each operation. Verify procedure in place. Review procedure How is control of scrap sources for steelmaking managed? 1.18 How and by whom is melting, refining and casting methods, ingot type/size and 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 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 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 and storage? Maintained on traveller or work piece: 2. Forging 2.1 What are the documented personnel training/qualification procedures for all forging processes performed? Procedure: 2.2 Is forging performed according to documented procedures/ instructions? Procedure/instruction: Verify training procedures for technical content for each operation. Verify procedure in place. Review procedure. Recommended practice DNVGL-RP-B202. Edition March 2017 Page 31

32 No. Checklist item Yes No N/A Comments/guidance 2.3 How and by whom is forging method, forging reduction, sequence of forging steps 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: Verify transfer by review. 2.7 How are operators familiarized with the instructions? 2.8 How is satisfactory condition of heating furnaces verified, e.g. size, fuel and temperature 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 are done prior to quality heat treatment? 2.13 What records of forging are maintained? Verify records are maintained Who reviews and approves the records? 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 all heat treatment processes performed? Procedure: 3.2 Is furnace equipment calibration and temperature uniformity surveys performed according to documented procedure? Procedure: Verify training procedures for technical content for each operation. 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 a year. Verify temperature variation from set point within allowed range. 3.5 Are temperature controlling and recording instruments calibrated and within calibration period? Sample and verify that instruments are calibrated at least once every three months. Recommended practice DNVGL-RP-B202. Edition March 2017 Page 32

33 No. Checklist item Yes No N/A Comments/guidance 3.6 Is heat treatment performed according to documented procedures/instructions? Procedure/instruction: Verify procedure in place. Review procedure. 3.7 How and by whom is furnace loading/unloading plan, heat treatment cycles and 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: Verify transfer by review How are operators familiarized with the instructions? 3.11 How is furnace loading controlled and recorded? Observe loading or review records. Verify proper spacing, no stacking, position of sacrificial/ prolongation part, attached thermocouples, etc What is the method of transfer from furnace to quench tank and how is transfer time controlled and recorded? 3.13 How are quench tanks sized and what means of agitation is used to optimize cooling rate? 3.14 How is surface metal temperature at removal from quench tank measured and recorded? Method and record: Observe quenching or review records. Verify max. 90 seconds transfer time. Observe quenching or review records. Verify quench tanks permit complete immersion of parts and proper agitation of quench medium. Verify quench water temperature max 40 C at start and max 50 C at finish of quench. Sample records and review What records of heat treatment are maintained? Verify furnace loading and heat treat charts are maintained 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 Recommended practice DNVGL-RP-B202. Edition March 2017 Page 33

34 No. Checklist item Yes No N/A Comments/guidance 4.1 What are the documented personnel training/qualification procedures for all testing methods performed? Procedure: 4.2 Are procedures available for calibration of test machines/ equipment? Procedure: 4.3 Is testing equipment calibrated and within calibration period? 4.4 Is testing performed according to documented procedures/ instructions including order specific test plans? Procedure/instruction: Verify training procedures for technical content for each operation. Verify personnel qualifications. Verify procedures are available. Verify unique identification of each equipment and current calibration labels/stickers on them. Verify procedures in place. Review procedures. Sample test plan and verify correct number, position and orientation of test specimens. Witness, if possible, sample mechanical and hardness testing. 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/instructions and test plans? 4.7 How are instructions/test plans transferred to testing lab? Job card/traveller or on-line computer: Verify transfer by review. 4.8 How is testing personnel familiarized with the instructions? 4.9 What records of testing are maintained? Verify test plan, mechanical, hardness, chemical and metallographic test records are maintained Who reviews and approves the records? 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 and certification of NDT personnel? Procedure: 5.2 Are personnel responsible for all NDT methods/activities qualified and certified to Level 3? Verify procedures/systems are available. Verify personnel qualifications. Recommended practice DNVGL-RP-B202. Edition March 2017 Page 34

35 No. Checklist item Yes No N/A Comments/guidance 5.3 Are personnel performing NDT qualified and certified to minimum Level 2? 5.4 Are personnel performing VT complying with vision requirements according to documented procedures? 5.5 Are procedures available for calibrations, verifications and checks of NDT equipment? Procedure: Verify personnel qualifications. Verify personnel qualifications. Verify procedures are available. 5.6 Is NDT equipment calibrated and within calibration period? Verify unique identification of each equipment and current calibration labels/stickers on them. 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: Verify transfer by review How is NDT personnel familiarized with the instructions? 5.12 Explain how NDT acceptance criteria are defined, understood and implemented: 5.13 What records of NDT are maintained? 5.14 Who reviews and approves the records? 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 with specified requirements controlled and documented through formal procedure(s)? Procedure: Verify procedures/systems are available. 6.2 What records of final inspection/review are maintained? Sample and review. 6.3 How and by whom are these records controlled? 6.4 Is preservation, packaging and marking of forgings to be shipped controlled and documented through formal procedure(s)? Verify procedures are available. Recommended practice DNVGL-RP-B202. Edition March 2017 Page 35