1、Manufacture of Structural Steel Castings for Primary Offshore ApplicationsAPI SPECIFICATION 2SCFIRST EDITION, SEPTEMBER 2009EFFECTIVE DATE: MARCH 1, 2010REAFFIRMED, JUNE 2015Manufacture of Structural Steel Castings for Primary Offshore ApplicationsUpstream SegmentAPI SPECIFICATION 2SCFIRST EDITION,
2、SEPTEMBER 2009EFFECTIVE DATE: MARCH 1, 2010REAFFIRMED, JUNE 2015Special NotesAPI publications necessarily address problems of a general nature. With respect to particular circumstances, local, state, and federal laws and regulations should be reviewed.Neither API nor any of APIs employees, subcontra
3、ctors, consultants, committees, or other assignees make any warranty or representation, either express or implied, with respect to the accuracy, completeness, or usefulness of the information contained herein, or assume any liability or responsibility for any use, or the results of such use, of any
4、information or process disclosed in this publication. Neither API nor any of APIs employees, subcontractors, consultants, or other assignees represent that use of this publication would not infringe upon privately owned rights.API publications may be used by anyone desiring to do so. Every effort ha
5、s been made by the Institute to assure the accuracy and reliability of the data contained in them; however, the Institute makes no representation, warranty, or guarantee in connection with this publication and hereby expressly disclaims any liability or responsibility for loss or damage resulting fr
6、om its use or for the violation of any authorities having jurisdiction with which this publication may conflict.API publications are published to facilitate the broad availability of proven, sound engineering and operating practices. These publications are not intended to obviate the need for applyi
7、ng sound engineering judgment regarding when and where these publications should be utilized. The formulation and publication of API publications is not intended in any way to inhibit anyone from using any other practices.Any manufacturer marking equipment or materials in conformance with the markin
8、g requirements of an API standard is solely responsible for complying with all the applicable requirements of that standard. API does not represent, warrant, or guarantee that such products do in fact conform to the applicable API standard.All rights reserved. No part of this work may be reproduced,
9、 translated, stored in a retrieval system, or transmitted by any means, electronic, mechanical, photocopying, recording, or otherwise, without prior written permission from the publisher. Contact the Publisher, API Publishing Services, 1220 L Street, NW, Washington, DC 20005.Copyright 2009 American
10、Petroleum InstituteForewordThis specification is based on the experience acquired during the design, construction, operation and maintenance of offshore processing units and permanent facilities, as supplemented with the experience of operating companies with topsides, fixed platforms, floating stru
11、ctures (e.g. TLPs, spars, and the like), and their tendons and risers. Castings in these applications tend to be limited production components, with relatively few replications, and receive more intense scrutiny than routine mass production runs. Where appropriate, this specification is based on, or
12、 reference is made to, international, regional, national and industry standards.This is a manufacturing specification for the casting itself. It is anticipated that geometric design for both service requirements and casting feasibility will have been agreed collectively between the contractor, manuf
13、acturer, and purchaser before this specification is invoked. Attendant issues regarding system reliability, geometric design, incorporation into the overall construction, operation, and maintenance are not addressed here. Those electing to use this specification as a reference for their needed level
14、 of performance quality should carefully consider all these attendant issues.When contractors or manufacturers/suppliers use this specification they should be solely responsible for the quality of work and the attainment of the required design and engineering standards. In particular, for those requ
15、irements not specifically covered, the purchaser will expect them to follow those design and engineering practices which will achieve the same level of integrity as reflected in their best production. If in doubt, the contractor or manufacturer/supplier should, without detracting from his own respon
16、sibility, consult the purchaser or its technical advisor. The purchaser may then negotiate with the authorities concerned with the object of obtaining agreement to follow this specification as closely as possible.Nothing contained in any API publication is to be construed as granting any right, by i
17、mplication or otherwise, for the manufacture, sale, or use of any method, apparatus, or product covered by letters patent. Neither should anything contained in the publication be construed as insuring anyone against liability for infringement of letters patent.This document was produced under API st
18、andardization procedures that ensure appropriate notification and participation in the developmental process and is designated as an API standard. Questions concerning the interpretation of the content of this publication or comments and questions concerning the procedures under which this publicati
19、on was developed should be directed in writing to the Director of Standards, American Petroleum Institute, 1220 L Street, NW, Washington, DC 20005. Requests for permission to reproduce or translate all or any part of the material published herein should also be addressed to the director.Generally, A
20、PI standards are reviewed and revised, reaffirmed, or withdrawn at least every five years. A one-time extension of up to two years may be added to this review cycle. Status of the publication can be ascertained from the API Standards Department, telephone (202) 682-8000. A catalog of API publication
21、s and materials is published annually by API, 1220 L Street, NW, Washington, DC 20005.Suggested revisions are invited and should be submitted to the Standards Department, API, 1220 L Street, NW, Washington, DC 20005, standardsapi.org.iiiContentsPage1 Scope . . . . . . . . . . . . . . . . . . . . . .
22、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Normative References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Terms, Definiti
23、ons, and Acronyms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.1 Term and Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24、23.2 Acronyms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Quality Requirements, Quality Plan (QP), and Manufacturing Procedure Specification (MPS). . . . . . . . . 44.1 General . . .
25、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.2 Procurement Specification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26、. . . . . . . . 44.3 Lowest Anticipated Service Temperature (LAST) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.4 Service Categories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27、 . . . . . . . . . . . . 44.5 Critical Sections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54.6 Underlying Industry Standard Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
28、 . . . . . . . . . . . . . . . . . . . . . 54.7 Traceability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54.8 Information to be Supplied to the Casting Manufacturer . . . . . . . . . . . .
29、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54.9 Document Requiring Approval by the Purchaser and Contractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64.10 Preproduction Meeting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30、. . . . . . . . . . . . . . . . . . . . . . . . 74.11 Post-job Production Histograms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74.12 Certificates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
31、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Process of Manufacture and Chemical Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
32、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75.2 Chemical Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Heat Treatment. . . . . . . . . . . . . . . . .
33、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96.1 Heat Treatment Process Control Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96.2 Quenching . . . . . . . . . . . . .
34、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96.3 Heat-treatment Furnace Records or Charts, Temperatures and Cycle Times . . . . . . . . . . . . . . . . . . . . . . . 97 Qualification Test Sample (QTS) . . . . . .
35、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97.1 Castings Represented by QTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97.2 QTS Dimensional Requirements .
36、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107.3 QTS Heat Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107.4 Partial Severin
37、g of Quality Test Samples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 Mechanical Properties and Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118.1 Tensile Tes
38、ts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118.2 Hardness Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
39、 . . . . . . . . . . 118.3 Charpy V-notch Impact Tests (CVN Tests) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128.4 Drop-weight or Pellini Test (DWT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
40、 . . . . . . . . . . . . 129 Repair Welding of Castings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139.1 Approval of Repair Welding WPSs and PQRs and Code Compliance . . . . . . . . . . . . . . . . . . . . . . . . . .
41、 . . 139.2 Allowable Welding Processes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139.3 PWHT of Major Weld Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
42、. . . . . . . . . 139.4 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149.5 Records of Welder and Welding Operator Qualification Test Results . . . . . . . . . . . . . . . . . . . .
43、 . . . . . . . . 149.6 Welding Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149.7 Welding Procedure Specification (WPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
44、 . . . . . . . . . . . . 159.8 Repair Weld Procedure Qualification Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169.9 Repair Weld Workmanship and Technique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
45、 . . . . 19vPage9.10 NDT of Repair Welds Made During Production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209.11 Repair Weld Charts and Maximum Allowable Repair Weld Volume and Surface Area . . . . . . . . . . . . . . 2110 NDT of Castings. . . . . .
46、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2110.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
47、 . . . 2110.2 VT of Castings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2110.3 NDT of Castings for Surface Defects. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
48、 . . . . . . . . . . . . . 2210.4 NDT of Castings for Subsurface Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2310.5 Documentation of NDT results. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
49、. . . . . . . . . . . . . . 2411 Dimensional Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2412 MTR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Annex A (informative) Use of the API Monogram by Licensees . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Bibliography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
