Subsea

Ver. Status Issue date Made by Checked by Approved by

PARANJAPE, OTERKJÆR, DAG LY, HANS

05 Re-issued Constr 2013.04.15
PARAG ARNE CHRISTIAN
PARANJAPE,
Originator:
PARAG RAVINDRA

MAT SPEC, ASTM A 694 F65

LOW ALLOY STEEL
FORGINGS

10000109350-PDC-000

This document contains Aker Subsea legal entity proprietary and confidential information that is legally privileged and is intended only
for the person or entity to which it is addressed and any unauthorised use is strictly prohibited. It is provided for limited purpose and
shall not be reproduced, stored electronically, transferred to other documents, disseminated or disclosed to any third parties without
the prior written consent of the relevant Aker Subsea legal entity. Any attachments are subject to the specific restrictions and
confidentiality regulations stated therein and shall be treated accordingly. The document is to be returned upon request and in all
events upon completion of use for which it was provided.
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LOW ALLOY STEEL Issue date: 2010-08-23
FORGINGS Page: 2 of 14

TABLE OF CONTENTS
1. SCOPE ............................................................................................................................................ 4

2. REFERENCE DOCUMENTATION ................................................................................................. 4

2.1. ASTM Standards ............................................................................................................................. 4
2.2. Industry Standards ........................................................................................................................... 4
2.3. Aker Solutions Documents .............................................................................................................. 5
2.4. Abbreviations ................................................................................................................................... 5

3. CHEMICAL COMPOSITION ........................................................................................................... 5

4. ALLOWABLE MELTING PRACTICES ........................................................................................... 6

5. HOT WORKING PRACTICES......................................................................................................... 6

6. HEAT TREATMENT FURNACE ..................................................................................................... 6

6.1. Equipment Qualification / Calibration .............................................................................................. 6
6.2. Furnace Loading .............................................................................................................................. 7
6.3. Instrumentation ................................................................................................................................ 7

7. HEAT TREATMENT ........................................................................................................................ 7

8. HARDEN-ABILITY .......................................................................................................................... 8

9. EXTENT OF TESTING .................................................................................................................... 8

10. TENSILE PROPERTIES ................................................................................................................. 8

11. HARDNESS TESTING ON PROLONGATION / SACRIFICIAL PART .......................................... 9

12. IMPACT TESTING .......................................................................................................................... 9

13. MICRO-STRUCTURAL EXAMINATION ....................................................................................... 10

14. CORROSION TEST ...................................................................................................................... 10

15. NON DESTRUCTIVE EXAMINATION (NDE) ............................................................................... 10

15.1. General .......................................................................................................................................... 10
15.2. Visual Inspection (VT) .................................................................................................................... 11
15.3. Ultrasonic inspection ...................................................................................................................... 11
15.4. Magnetic Testing ........................................................................................................................... 11
15.5. Hardness Testing of Parts ............................................................................................................. 12

16. WELD REPAIR .............................................................................................................................. 12

17. CERTIFICATION - DOCUMENTATION ........................................................................................ 12

17.1. Final Documentation ...................................................................................................................... 13
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18. IDENTIFICATION AND MARKING ............................................................................................... 13

19. CHANGES ..................................................................................................................................... 13

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MAT SPEC, ASTM A 694 F65 Version: 05 - Re-issued Constr
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1. SCOPE
This specification defines the requirements for low carbon low alloy steel for
manufacturing 450MPa (65 ksi) forging components. In general the forgings shall be
manufactured according to ASTM A694 with modifications as specified in this
specification.

Supplier shall submit Manufacturing procedure specification and Inspection Test plan for
approval prior to start of work according to this document. Any significant changes to the
manufacturing procedure specification shall call for re-qualification.

Manufacturing procedure shall be qualified either

By destructive testing as per Aker Solutions document 10000639576
or
By documentation of previous experience with manufacture of similar forgings in
the same type of material.

Manufacturing procedure specification shall as a minimum include chemistry

composition limits, mechanical testing details specifying number, location, method
(prolongation or sacrificial), test procedures and acceptance criteria along with sketch
showing dimensions, heat treatment, non-destructive testing and forging procedure.

2. REFERENCE DOCUMENTATION
2.1. ASTM Standards

ASTM A255 Standard test methods for Determining Hardenability of Steel

Standard test methods and Definitiions for Mechanical testig of steel
ASTM A 370
products
ASTM A 388 Standard practice for Ultrasonic Esamination of Steel Forgings
Standard specification for Carbon and Alloy steel forgings for pipe
ASTM A694
flanges, fittings, valves and parts for high pressure transmission service
ASTM E 10 Standard test method for Brinell Hardness of metallic materials
Standard test method for Rockwell Hardness and Rockwell superficial
ASTM E18
hardness of metallic materials
ASTM E 112 Standard test methods for Determining Average Grain size

2.2. Industry Standards

DNV OS F101 Submarine Pipeline systems

EN 10204 Metallic products Types of inspection documents
Non-destructive testing- Wualification and certification of NDT personnel-
EN 473
General principles
ISO 9712 Non-destructive testing- Wualification and certification of NDT personnel
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ISO 10423 (API Petroleum and natural gas industries Drilling and production equipment
6A) Wellhead and Christmas tree equipment
ISO 15156 Petroleum and natural gas industries Materials for use in H2S-
(NACE MR0175) containing environments in oil and gas production all parts

2.3. Aker Solutions Documents

10000108841 Traceability Specification for Suppliers

10000639576 Qualification Program for Heavy forgings

2.4. Abbreviations
AISI American Iron and Steel Institute
API American Petroleum Institute
ASNT American Society for Non-destructive Testing
ASTM American Society for Testing of Materials
Cev Carbon Equivalent
Elong Elongation
EN European Norm
ER Equivalent Round
HB Brinell Hardness
ISO International Standards Organization
LAS Low Alloy Steel
NACE National Association of Corrosion Engineers
NDE Non-destructive Examination
PSL Product Specification Level
QTC Qualification Test Coupon
RA Reduction of Area
SDRL Supplier Documents Requirement List
VT Visual Testing
UT Ultrasonic Testing
3. CHEMICAL COMPOSITION
The chemical composition shall be selected to ensure an acceptable balance between
hardenability, toughness and weldability. The chemical elements shall be within the limits
as specified in the Table below (wt %):

C Mn Si Ni Cr Mo Al S P Nb V N2 H O2
Min - 1.10 0.20 0.5 0.10 0.20 0.02 - - - 0.02 - - -
120 2.0 20
Max 0.12 1.40 0.45 0.99 0.50 0.50 0.06 0.01 0.015 0.04 0.05
ppm ppm ppm

Notes:
The total sum of the unspecified residual elements plus Vanadium, Aluminium, and
Niobium must not exceed 1.00 %. Furthermore, the supplier shall furnish a
certified chemical analysis of each heat including all elements listed above along
with Copper, Calcium and Titanium contents.
Cev = C + Mn/6 + (Cr+Mo+V)/5 + (Ni+Cu)/15
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Cev= 0.40-0.43 %
Other elements: Cu < 0.3 %, Ca < 0.002 %, Ti < 0.03; Nb+Ti+V < 0.10 %
For sour service S < 0.003 %.
4. ALLOWABLE MELTING PRACTICES
Material shall be produced via an electric furnace melting practice followed by
Vacuum Degassing (VD), Argon-stirred Degassing, Argon Oxygen Decarburization
(AOD), Electro slag Re-melting (ESR) or Vacuum Arc Re-melting (VAR).
Material shall be fully killed and melted to a fine grain practice using standard
deoxidizing/grain refining elements to complete deoxidization and to refine the
grain size.
Supplier shall identify and document the specific melting practices that are used.

5. HOT WORKING PRACTICES

1. Material shall be of pressure vessel quality and shall have a wrought structure
throughout. Grain size, texture and orientation shall be documented.
2. The supplier must identify and document the specific hot working practice used
and report the hot working ratio. The minimum acceptable hot work ratio (it is
defined as the product of the ratios of area reduction relative to ingot size) shall be
4 to 1, demonstrated in manufacturing procedure specification.
3. Materials shall be forged according to a written procedure specified by the forging
supplier. Procedure shall specify minimum forging temperature and ways to
monitor the same during forging operation.

6. HEAT TREATMENT FURNACE

6.1. Equipment Qualification / Calibration
Heat treatment equipment (furnaces) shall be calibrated / qualified in accordance
with requirements from ASTM A991 and ISO 10423 (API 6A) annex M as described
hereon.

For batch furnaces, temperature shall be controlled to within +/-8°C (+/-15°F) for
sub-critical treatments and +/-14°C (+/-25°F ) for super-critical treatments relative to
the set point temperature. Controlling and recording equipment shall be calibrated
every 3 months and shall be accurate to 1% of full scale; calibrating equipment to
0.
determined prior to initial use and after each
repair/rebuild.

This furnace survey shall be conducted at the max. and min. operating temperatures
across the whole of the working zone volume. Where this exceeds 0.28 m3 (10 ft3); a
- the remainder evenly
around the periphery. With much larger volumes, 1 T/C per 3.5 m 3 (125 ft3), up to a

variance limit.

Temperature readings shall be taken regularly:

Every 3 minutes as the temperature approaches the set point.
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Every 2 minutes after reaching the set point for a minimum of 10 minutes.
Every 5 minutes thereafter for 30 minutes minimum to determine furnace
stability.
Survey records shall be maintained for a minimum of 2 years.

Tempering temperature shall be sufficiently high to allow post weld heat treatment if
required.

6.2. Furnace Loading

The material shall be loaded into the heat treatment equipment such that the presence
of one part does not adversely affect the heat treatment response of any other part in the
same heat treatment load. Stacking of parts is not allowed; only single layer loading is
acceptable.
6.3. Instrumentation
Only automatic controlling and recording instruments shall be used. Controlling
thermocouples shall be located in the working zone of the furnace.
7. HEAT TREATMENT
Heat treatment of forgings shall include normalizing, austenitizing, quenching, and
tempering as specified below:

1. Normalizing shall be performed at a minimum of 28°C (50°F) above the

austenitizing temperature. Hold time to be minimum 30 minutes per inch of
heaviest cross section followed by air cool or cool in protective atmosphere as
required.
2. Austenitizing shall be performed in the range of 900°C - 930°C (1652°F - 1688°F ).
Hold time to be minimum 30 minutes per inch of maximum cross section.
Maximum time to be 90 minutes per inch of maximum cross section. Hold time
shall start after the contact thermocouple reaches the set point temperature.
3. Quenching: Forgings shall be quenched in water, oil or polymer. Water is the
preferred media. Qualification is required with proposed media for a given
component in question. Once qualification has been made for a given component,
no change in media can be made without re-qualification. Where the quench tank
is not directly associated with the furnace, the maximum transfer time for the
forging shall be specified and not exceed 90 seconds from the time furnace doors
are opened.

a. If quenched in water, the temperature of the quenchant shall not exceed 40 °C

(100°F) at the start of the quench, nor exceed 50°C (120°F) at the completion
of the quench.

b. If quenched in polymer (such as, synthetic oil) the operating temperature range

documented evidence of through thickness properties shall be provided. Once

qualification has been made using a given polymer for a given component, no
change in concentration can be made without re-qualification.

c. Forgings shall be cooled to below 204°C (400°F) prior to removal from the
quench media.
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Quench water temperature shall be monitored during quenching operation, start

and end temperatures shall be reported.

4. Tempering shall be performed at minimum 540°C (986oF). Hold time shall be for
a minimum of 60 minutes per inch of maximum cross section thickness or one
hour minimum, whichever is greater with maximum of 90 minutes per inch of
maximum cross section.

Contact thermocouples shall be used to monitor time subsequent to equilibrium being

achieved. To have redundancy, minimum 2 thermocouples shall be in contact with actual
components. Component with contact thermocouples shall be located in the center of
the furnace. If several baskets are used, each basket shall be monitored. Location of all
thermocouples including contact thermocouples shall be clearly mentioned in the
furnace loading sketch.
8. HARDEN-ABILITY
The harden-ability limit representative for the manufacturing procedure within specified
chemical and process limits shall be tested and reported as part of the material
certificate. The harden-ability shall be tested by Jominy End Quench test as per ASTM
A255.
9. EXTENT OF TESTING
All testing shall be carried out after final heat treatment.

A lot is defined as forgings with same size from same heat and heat treatment batch.
Testing shall be on a prolongation on the actual component or a sacrificial forging of the
same shape and size, processed according to the same procedures as the actual
forgings it shall represent from the same lot. A test lot shall not exceed 2000Kg
(4400Ibs) for forgings with an as-forged weight of
(11000Ibs) for forgings with an as-forged weight of >50Kg (>110lbs).

The prolongation shall be subjected to the same degree of forging and heat treatment
cycle as the component which it qualifies. The prolongation shall remain attached to the
component until the heat treatment cycle is completed. The prolongation shall be
associated with / represent the critical area(s) of the forging, i.e., those areas where
stress calculations have previously shown the necessity for specific minimum
mechanical properties as well as the thickest sections. Responsibility for prolongation
location acceptance lies with Aker Solutions.

10. TENSILE PROPERTIES

Tensile testing shall be conducted in accordance with ASTM A370 at room temperature,
with requirements as per Table 2 below.

Table 2: Tensile Properties

Yield ksi (MPa) Tensile ksi (MPa) Elong (%) min RA (%) min Hardness
min min (4D) HB
450 (65) 535 (77) 20 35 235 max
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. If the size of
forging does not allow taking standard specimen for testing, a sub-size specimen may be
taken with prior approval from Aker Solutions.

From each lot (of same heat and heat treatment) one piece of forging shall be tested as
follows:
Transverse direction at ¼ T (T is thickness of thickest section) from internal
surface: 1 specimen
Transverse direction at ½ T (T is thickness of thickest section): 1 specimen
Longitudinal direction at ½ T (T is thickness of area with highest utilization, e.g.
the weld neck area): 1 specimen
Transverse direction at ½ T (T is thickness of area with highest utilization, e.g.
the weld neck area): 1 specimen, total 4 test specimens
Supplier shall submit sketches detailing location of test specimens for approval
For thickness T 50 mm, the test specimens shall be taken such that the
mid-length shall be at least 50 mm from any second surface. For test pieces
(components) having maximum section thickness, T > 50 mm, the test
specimens shall be at least T or 100 mm, whichever is less, from any second
surface.

Maximum yield to tensile ratio shall be 0.9.

11. HARDNESS TESTING ON PROLONGATION / SACRIFICIAL PART

Surface hardness testing shall be conducted on a prepared specimen by either the static
Brinell method, as per ASTM E 10 using a 3000 kg load and a 10 mm dia. Tungsten
-18. Testing per the Brinell
method is the preferred technique. Location for hardness testing same as for charpy
impact testing. A minimum of 3 hardness measurements shall be taken on each sample.

12. IMPACT TESTING

Impact values shall comply with following requirements.
Table 3: Impact Requirements
Direction Test Temperature Impact Value Min. Impact Value Min.
°C / (°F) Avg. (J) Ind. (J)
Longitudinal -46/ (-50 ) 68 57
Transverse -46/ (-50 ) 45 38

Minimum average shear area requirement is 80% with single minimum value of 60% and
shall be reported.

Material shall be Charpy impact tested per ASTM A370, one forged piece from each lot
as follows:
One set is of 3 specimens
Transverse direction at ¼ T (T is thickness of thickest section): 1 set
Transverse direction at ½ T (T is thickness of thickest section): 1 set
Transverse direction at ½ T (T is thickness of area with highest utilization, e.g.
the weld neck area) : 1 set
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Longitudinal direction at ½ T (T is thickness of area with highest utilization, e.g.

the weld neck area): 1 set
For component with thickest section T greater than or equal to 25mm (when
applicable), one set taken in the tangential direction at 2 mm below the internal
surface
For thickness T 50 mm, the test specimens shall be taken such that the
mid-length shall be at least 50 mm from any second surface. For test pieces
(components) having maximum section thickness, T > 50 mm, the test
specimens shall be at least T or 100 mm, whichever is less, from any second
surface.
Supplier shall submit sketches detailing location of test specimens for approval

The specimen shall be of standard size of 10mm x 10mm x 55mm. If the size of forging
does not allow taking standard specimen for testing, a sub-size specimen may be taken
with prior approval from Aker Solutions. Reduction factors of energy requirements for
sub-size specimens shall be 5/6 for 7.5 mm specimen thickness and 2/3 for 5 mm
specimens.

13. MICRO-STRUCTURAL EXAMINATION

A metallographic sample shall be taken at charpy specimen positions and a
corresponding description of the microstructure shall be given in the report to be
enclosed the material certificate. Prior austenite grain size for material in the quenched
and tempered condition shall be 5 and finer as defined by ASTM E 112. Grain size
needs to be reported by supplier along with the content of different phases of alloy
matrix (with microphotograph at 400X magnification).

14. CORROSION TEST

Purchase order shall specify the requirement of Hydrogen Induced cracking (HIC)
testing and Sulphide stress cracking (SSC) testing, when required.

15. NON DESTRUCTIVE EXAMINATION (NDE)

15.1. General
NDE shall be carried out after final heat treatment.
1. All NDE procedures shall be approved by a Level III inspector certified per the
appropriate NDE method.
2. All NDE examination shall be performed by a Level II or level III inspector qualified
in accordance with EN 473 / ISO 9712, PCN, ASNT Central Certification Program
(ACCP).
3. Components received by Aker Solutions may be subjected to NDE examination as
described in this section.
4. Forgings are subject to (dye) penetrant testing (PT) examination prior to final
acceptance, so forging suppliers should be aware that all accessible wetted and
sealing surfaces of each finished part shall be so inspected after final machining
operations.
5. Failure of any forgings to pass the NDE examination(s) requested by Aker Solutions
shall be grounds for rejection.
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15.2. Visual Inspection (VT)

Forgings shall be VT inspected for 100% surface coverage as per DNV OS F101 app D
clause C400 as below:
Visual examination shall be carried out in a sufficiently illuminated area; minimum 1000
lx. If required to obtain good contrast and relief effect between imperfections and
background additional light sources shall be used.
For direct examination the access shall generally permit placing the eye within 600 mm
of the surface to be examined and at an angle of not less than approximately 30°. If this
is not possible then the use of mirrors, boroscopes, fiber optics or cameras shall be
considered.
A sufficient amount of tools, gauges, measuring equipment and other devices shall be
available at the place of examination.
The objects to be examined shall be cleaned to remove all scale and processing
compounds prior to examination. The cleaning process shall not injure the surface finish
or mask possible imperfections.
Acceptance criteria:
All accessible surfaces shall be free from visible laps, cracks, cold shuts, porosity, slag,
scale, and other surface imperfections. The results of all VT inspections shall be
reported on the documentation package.
15.3. Ultrasonic inspection
Forgings shall be 100% volumetric UT examined after all manufacturing and heat
treatment processes have been completed.
For quenched and tempered products, the volumetric inspection shall be performed after
heat treatment for mechanical properties exclusive of stress relief treatments or re-
tempering to reduce hardness.
Methods:
In accordance with DNV-OS-F101 Appendix D section D200

Acceptance criteria:
In accordance with DNV-OS-F101 Appendix D, section D500 as below
Straight beam testing
No single indication shall be larger than the indication received from the flat bottom
holes in the reference block required in D200.
Angle beam testing
No single indication shall exceed a DAC curve established using the notches in the
reference block required in D200.

Procedures:
Procedures for the examination shall be established in accordance with DNV-OS-F101
Appendix D, section D100.

15.4. Magnetic Testing

Machining vendor shall perform 100% Magnetic particle examination after final
machining. It will include inspection of machined surface & unmachined or forge surface
as well if any.

Methods:
In accordance with DNV-OS-F101 Appendix D section D200.
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Acceptance criteria:
In accordance with DNV-OS-F101 Appendix D, section D500 as below

A Crack-like indications: not permitted

Linear indications with length more than 2 mm or three times the width: not
B permitted.
Linear indications with length < 1.5 mm may be deemed irrelevant
Rounded indications: Diameter < 3 mm, accumulated diameters in any 100 -
C
150 mm area < 8 mm

Procedures:
Procedures for the examination shall be established in accordance with DNV-OS-F101
Appendix D, section D100.
15.5. Hardness Testing of Parts
Unless otherwise specified, all parts shall be surface hardness tested by supplier on
surface of each piece of forged material.

In addition to surface hardness, hardness testing may be required on specific items, in

which case the purchase order shall state it as an additional requirement. When such
testing is specified, hardness tests shall be conducted at a minimum of 3 test locations,
viz., near ID, near OD; and at the mid-wall of hollow cylindrical shapes: and the centre,
the OD and at the half-radius locations of round bars.

If impractical to perform testing by the static Brinell method (due to size restrictions),
parts may be tested by a King Brinell portable hardness tester. Use of Equotip type of
hardness testing equipment is not permitted without prior written approval from Aker
Solutions.
16. WELD REPAIR
No weld repair shall be permitted on any forgings.
17. CERTIFICATION - DOCUMENTATION
Documentation must be provided to Aker Solutions with each shipment of material as
described in the appropriate Supplier Documentation Requirement List (SDRL) for the
part required. Additionally, there must be a statement of compliance to ISO 15156-2
(NACE MR0175).

Test certificate shall be as per EN 10204 Type 3.2 with content complying with DNV-
OS-F101 Section 8, H100.

For 3.2 certification, following activities as a minimum need to be witnessed by

independent inspector:
Non-destructive testing
Test specimen sampling
Mechanical testing
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authorized inspection representative or the inspector designated by the official

regulations.

17.1. Final Documentation

Following documents shall be submitted
o Manufacturing procedure specification (prior to production start, for approval)
o Heat treatment procedure with furnace loading sketch (prior to production start, for
approval)
o NDT procedures (prior to production start, for approval)
o Material certificates including chemical analysis on product and NDE reports
o Heat treatment records including photos of furnace loading for respective batch
o Certificate of conformance to this specification
o Dimensional inspection reports

18. IDENTIFICATION AND MARKING

Each piece of raw material and the test coupon shall be identified in accordance with
section 5 of Aker Solutions document 10000108841, which shall accompany the
Purchase Order.

19. CHANGES

Version Changes
00 First version
01 Format changed
02 Minor changes

Ca, Ti, O 2 & N2 added to chemical composition. Magnetic partial testing

03

Tensile & Impact test sampling location change for distance from second
04
surface.
Mid-thickness testing for thickest section added, contact thermocouple
05
requirements added, some other minor changes made
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APPENDIX A GUIDANCE FOR SAMPLING OF TEST SPECIMEN

GUIDANCE FOR SAMPLING OF TEST SPECIMEN FOR HUB FORGING

Weld neck
side
PROLONGATION

PROLONGATION

T HUB FORGING
T

T = thickest section
Side

Prolongation = suitable size to be able to take specified number of standard specimens.

NOTE! This is exemplary sketch. Supplier needs to submit similar sketch with actual
dimensions showing location and direction of specimen sampling.