Manufacture of Duplex Stainless Steel Fittings and Components

Document No.
GP 18-04
Applicability Group
Date 29 August 2007
GP 18-04
Manufacture of Duplex Stainless Steel

Fittings and Components
Group Practice
BP GROUP
ENGINEERING TECHNICAL PRACTICES
29 August 2007 GP 18-04
Manufacture of Duplex Stainless Steel Fittings and Components
Foreword
This is the first issue of Engineering Technical Practice (ETP) BP GP 18-04.
Copyright  2007, BP Group. All rights reserved. The information contained in this
document is subject to the terms and conditions of the agreement or contract under which
the document was supplied to the recipient’s organisation. None of the information
contained in this document shall be disclosed outside the recipient’s own organisation
without the prior written permission of BP Group, unless the terms of such agreement or
contract expressly allow.
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The latest update of this document is located in the BP ETP and Projects Library
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29 August 2007 GP 18-04
Table of Contents
Page
Foreword ........................................................................................................................................ 2
Introduction ..................................................................................................................................... 4
1. Scope .................................................................................................................................... 5
2. Normative references............................................................................................................. 5
3. Terms and definitions............................................................................................................. 6
4. Symbols and abbreviations .................................................................................................... 6
5. Background ........................................................................................................................... 6
6. Metallurgical considerations................................................................................................... 7
7. Material selection, application, and fabrication ....................................................................... 8
8. Qualification of manufacturing and testing laboratory facilities ............................................... 8
9. Audit and technical appraisal ................................................................................................. 9
9.1. Audit team................................................................................................................... 9
9.2. Review and confirmation........................................................................................... 10
10. Purchase specification ......................................................................................................... 11
10.1. General..................................................................................................................... 11
10.2. Manufacturing Procedure Qualification Testing ......................................................... 11
10.3. Production test sampling........................................................................................... 12
10.4. Scope of production testing....................................................................................... 12
10.5. BP rights of inspection .............................................................................................. 14
10.6. Certification............................................................................................................... 14
10.7. Marking..................................................................................................................... 14
10.8. Packaging................................................................................................................. 14
11. Preproduction meeting......................................................................................................... 14
12. Production monitoring and inspection .................................................................................. 14
13. Final inspection and release ................................................................................................ 15
14. Positive material identification.............................................................................................. 16
Bibliography .................................................................................................................................. 17

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29 August 2007 GP 18-04
Introduction
This Group Practice (GP) covers selection of manufacturers and the QA and QC associated with the
specification and manufacture of fittings and components in all grades of duplex stainless steel.
This GP draws attention to important issues that shall be addressed by BP when purchasing items in
this range of alloys.
This GP has been written against a background in which many duplex stainless steel components of
poor metallurgical quality have been certified and dispatched by manufacturers. These manufacturers
have invariably been ISO 9001 certified and usually NORSOK M-650 qualified, but have,
nevertheless, fallen short in terms of manufacturing controls.

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29 August 2007 GP 18-04
1. Scope
a. This GP specifies requirements for the selection and qualification of manufacturers and the
associated manufacturing QA and QC measures for the purchase, manufacture, and
production monitoring of fittings and components manufactured in all grades of duplex
stainless steel.
b. This GP covers the manufacture of cast, forged, and hot isostatically pressed fittings and
components.
Manufacture of OCTG (see GIS 02-206), linepipe (see GIS 43-315) and small
diameter tubing for use in subsea control umbilicals are not within the scope of this
GP.
Fabrication of process pipework systems, linepipe materials, and new pressure
vessels is not within the scope of this GP (see GIS 42-102, GIS 43-334, and
GIS 46-010).
2. Normative references
The following normative documents contain requirements that, through reference in this text,
constitute requirements of this technical practice. For dated references, subsequent amendments to, or
revisions of, any of these publications do not apply. However, parties to agreements based on this
technical practice are encouraged to investigate the possibility of applying the most recent editions of
the normative documents indicated below. For undated references, the latest edition of the normative
document referred to applies.
BP
GIS 18-011 Welded Fabrication and Construction.
GIS 42-102 Fabrication, Assembly, Erection, and Inspection of Austenitic and Duplex
Stainless Steel, Cupro-Nickel based Alloys, and Titanium and Zirconium
Pipe work (ASME B31.3).
GN 36-016 Piping Materials Data Sheets.
American Petroleum Institute (API)

API Q1 Specification for Quality Programs for the Petroleum, Petrochemical and
Natural gas Industry.
American Society for Testing and Materials (ASTM)

ASTM E562 Standard Test Method for Determining Volume Fraction by Systematic
Manual Point Counting.
British Standards Institute (BSI)

BS EN 10204 Metallic products. Types of inspection documents.
International Organization for Standardization (ISO)

ISO 3834-1 Quality requirements for the fusion welding of metallic materials. Part 1:
Criteria for the selection of the appropriate level of quality requirements.
ISO 3834-2 Quality requirements for the fusion welding of metallic materials. Part 2:
Comprehensive quality requirements.
ISO 9001 Quality management systems - Requirements.
ISO 10474 Steel and Steel Products - Inspection Documents.
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29 August 2007 GP 18-04
ISO TS 29001 Petroleum, petrochemical and natural gas industries - Sector specific
quality management systems requirements for product and service supply
organizations.
Norsk Sokkels Konkuranseposisjon (NORSOK)

M-650 Qualification of manufacturers of special materials.
3. Terms and definitions
For the purposes of this GP, the following terms and definitions apply:
22% Cr duplex
Ferritic/austenitic stainless steel alloy with 22% Cr and PREw greater than or equal to 34.
25% Cr duplex
Ferritic/austenitic stainless steel alloy with 25% Cr and PRE w greater than or equal to 38.
25%Cr super duplex

Ferritic/austenitic stainless steel alloy with 25% Cr and PRE w greater than or equal to 40.
PREw
Pitting resistance equivalent number (PREw = % Cr + 3,3% (Mo + 0,5% W) + 16% N).
4. Symbols and abbreviations
For the purpose of this GP, the following symbols and abbreviations apply:
HAZ Heat affected zone.
MPQT Manufacturing procedure qualification test.
OCTG Oil country tubular goods.
PREw Pitting resistance equivalent number.
QA Quality assurance.
QC Quality control.
QMS Quality management system
5. Background
Quality management standards (ISO TS 29001/ISO 9001) require manufacturers to

validate any process used in production where the conformity of the resulting
product can not be readily or economically verified by subsequent monitoring or
measurement. Such processes are often termed special processes. The forming,
fabrication and thermal processing of duplex stainless steels is considered to be a
series of special processes. NORSOK M-650 establishes a set of qualification
requirements to verify that manufacturers have sufficient competence, experience
and the necessary facilities to manage such special processes. Therefore, it might be
reasonably anticipated that manufacturers possessing both IS0 9001 and
NORSOK M-650 qualifications would consistently produce duplex stainless steel
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components of adequate metallurgical quality. Industry experience in this respect is

variable and a number of recent BP projects have had particularly poor experience
(GN 18-004). Consequently, this GP directs projects to assure themselves that
manufacturers maintain their production competence and consistently apply the
anticipated manufacturing procedures and controls. Assurance is based on
prequalification by audit/technical appraisal, together with production monitoring
and inspection release.
6. Metallurgical considerations
Technical and inspection personnel involved in the specification of materials, vendor audits,
procurement, manufacturing control, and inspection of fittings and components in duplex stainless
steels shall have an understanding of the metallurgical issues associated with these alloys.
Duplex and super duplex stainless steels are a group of corrosion resistant alloys
that possess a two phase microstructure of ferrite and austenite. This group of alloys
has achieved widespread application in the oil and gas industry due, in part, to an
attractive combination of higher strength and improved stress corrosion cracking
resistance compared with austenitic stainless steels. Typical 0,2% proof strengths
are the order of 450 MPa (65 ksi) for duplex grades and 550 MPa (80 ksi) for
superduplex grades. In addition, these stainless steels have a favourable
combination of toughness and weldability. Specific alloys are sometimes described
by their chromium content as either 22% Cr “duplex” or 25% Cr “super duplex”
grades, although a stricter definition of the latter category is those alloys with a
PREw greater than 40. Some 25% Cr grades, by this definition, are not “super
duplex”.
The properties of duplex stainless steels are maintained by careful attention to the
microstructural phase balance. Steel makers will aim, by the combined control of
alloying elements and heat treatment, to achieve a phase balance of approximately
50% ferrite and 50% austenite. To achieve the correct phase balance in wrought
products, the material is subjected to a solution annealing heat treatment (typically
1 050°C [1 922°F]) followed by a rapid quench, usually a water quench. If the
cooling rate is too slow or the material is incorrectly heat treated at a soaking
temperature in the range 550°C to 900°C (1 022°F to 1 652°F), harmful
intermetallic phase precipitates are formed. These tertiary phases include “sigma”
and “chi”. Such phases are detrimental to both mechanical and corrosion
resistance properties, even in very small quantities (less than 1% volume fraction).
Furnace control and quench rate are important considerations in avoiding
precipitate formation during manufacture. However, it can be difficult to achieve the
necessary quench rate in the centre of thick section castings and forgings (typically
those greater than 50 mm [2 in]), and these require special attention, since the
absence of intermetallic phase precipitates cannot be guaranteed. Rough machining
of such components prior to final heat treatment should be considered. Welding of
thin wall products requires special consideration due to their inability to conduct
heat away from the weld at a sufficient rate. This may result in the formation of
intermetallic phases. With such components, strict interpass temperature control
needs to be applied.
Because of the risk of intermetallic phase formation and the general desire to avoid
post weld heat treatment during the fabrication of process systems, the weld metal
phase balance is controlled by alloying elements in the welding consumable.
Specifically, the nickel content is higher than that in the base steel to promote
austenite formation during cooling. The HAZ phase balance is affected by the
welding process, and to avoid excessive ferrite formation, duplex stainless steels are
also alloyed with nitrogen to promote austenite formation in the HAZ. The pitting
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corrosion resistance of these alloys is improved predominantly through alloying

with molybdenum and nitrogen, although tungsten is also being used in certain
alloys. Autogenous welds tend to have a high volume fraction of the ferrite phase
with consequential poor properties and are best avoided.
There are a number of areas of concern with these alloys that require attention
during fitting and component manufacture. For example:
• Control of the thermal profile of all manufacturing processes to achieve a
satisfactory microstructure.
• Welding design and qualification to ensure that a satisfactory ferrite/austenite
phase balance is achieved in the weld zones and that precipitation of tertiary
phases, such as nitrides and intermetallics, is avoided or at least minimised.
Careful control is required if welded components are subject to solution anneal
and water quench.
• Dimensional stability of heavy section components during machining due to
“cold creep” at locations of high residual stress.
Further information on the metallurgy of duplex stainless steels may be found in
“Duplex Stainless Steels” by Gunn, Abington Publishing, Cambridge.
7. Material selection, application, and fabrication
a. Items shall be solution heat treated and water quenched.

b. Dimensional tolerances shall not be corrected by thermal treatment or local cold working.
Guidance on the selection, application, and fabrication of duplex stainless steels is
provided in a number of ETPs: GP 18-03, GP 36-10, GP 36-15, GP 36-20, and
GIS 42-102.
More general guidance can be found in:
• “Use of duplex stainless steels in the oil refining industry”, API Technical
Report 938C.
• “Practical guidelines for the fabrication of duplex stainless steels”,
International Molybdenum Association publication.
• “How to Perform Welding in Duplex Stainless Steels to Obtain Optimum Weld
Metal Properties”, Outokumpu publication.
• Welding guide for Sandvik duplex stainless steels, Sandvik.
• Arc welding duplex stainless steels - a guide to best practice, www.twi.co.uk.
8. Qualification of manufacturing and testing laboratory facilities
a. Manufacturers shall be prequalified prior to placement on a bid list.

b. Prequalification shall ensure that potential manufacturers comply with the following
requirements:
1. Manufacturers shall operate a QMS certified in accordance with ISO TS 29001
(API Q1), ISO 9001, or BP approved equivalent and shall ensure that the QMS of any
subcontractors is also certified.
2. Manufacturers shall demonstrate compliance with the requirements of
NORSOK M-650 and shall ensure that any subcontractors are also working in
compliance with NORSOK M-650.

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29 August 2007 GP 18-04
3. Manufacturers using welding in the production of fittings or components shall

demonstrate that their shop floor manufacturing and fabrication activities are in
compliance with ISO 3834, Parts 1 and 2 and ensure that subcontractors’ activities are
also compliant.
4. Test laboratories shall operate a QMS in accordance with ISO TS 29001 (API Q1),
ISO 9001, or BP approved equivalent.
5. Test laboratories that are part of or are owned by the manufacturer shall be governed
by the QMS of the manufacturer.
6. Test laboratories shall be accredited by an International Laboratory Accreditation
Cooperation (ILAC) member organisation (e.g., United Kingdom Accreditation
Service [UKAS], American Association for Lab Accreditation [A2LA], another
member of the European network for Accreditation [EA]), or by an alternative
scheme subject to BP approval.
c. Manufacturers (including all manufacturing locations), subcontractors, and test
laboratories shall have:
1. Been subject to a documented audit/technical assessment performed either by BP or
on behalf of BP, within the 12 months immediately preceding the expected date of
order placement. In the absence of a documented report a further review shall be
undertaken and reported.
And/Or:
2. Successfully delivered a BP order of components of similar type and physical
dimensions fully in accordance with specification requirements within the 12 months
immediately preceding the expected date of order placement.
d. Changes to technical management structure
1. If manufacturer, subcontractor, or test laboratory technical and/or quality
management structure or personnel have substantially changed since the last BP
audit/technical appraisal or successful delivery, a new audit/technical appraisal shall
be performed.
2. BP shall be notified regarding full details of any changes to the technical management
structure and/or personnel such that BP may determine if a new audit is required.
Changes in the senior and technical management structure can alter the competency
of key personnel as well as the approach taken by the company in applying
manufacturing controls.
3. If orders are to be placed through a stockist or handling agent, procurement shall not
proceed until it has been verified that manufacturers, subcontractors, and test
laboratories in the supply chain comply with this GP.
e. Stockists and handling agents shall operate a QMS certified in accordance with
ISO TS 29001 (API Q1), ISO 9001, or an equivalent approved by BP.
9. Audit and technical appraisal
9.1. Audit team

Audit/technical appraisal teams shall, as a minimum, consist of a metallurgist and QA/QC
inspector.

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9.2. Review and confirmation

The object of the audit is to confirm the validity of the ISO QMS certification together with
NORSOK M-650 compliance and, if appropriate, ISO 3834 compliance. In undertaking this
audit/technical appraisal the team shall review and confirm the following:
a. Technical and quality management understand the manufacturing processes in use and the
implications related to the control of those processes for all relevant grades of duplex
stainless steel.
b. Verification/accreditation
1. Verification/accreditation is up to date and valid for the duration of the potential
order.
2. If certification/accreditation expires prior to completion of the order, measures shall
be in place to ensure timely renewal.
c. Elevated temperature processing
1. Manufacturing processes involving elevated temperatures (greater than 300°C
[572°F]) are documented with appropriate working instructions available on the shop
floor to ensure consistent application.
2. Adequate precautions are in place to ensure that the thermal profile (heating rate,
holding temperatures, and cooling rate) associated with each stage of manufacture
will not promote the formation of any deleterious tertiary phase, such as intermetallic
compounds, nitrides, or carbides, in the alloy being processed.
Once tertiary phases (particularly intermetallics, such as sigma phase) form in
duplex stainless steel alloys, it can be extremely difficult to take these phases back
into solution during the final solution heat treatment. Consequently, it is essential to
avoid tertiary phase formation during each stage of manufacture.
d. Welding procedures
1. Qualification, control, and application of welding procedures shall comply with
GIS 18-011 and GIS 42-102.
e. Furnace calibration/charging
1. Furnace calibration records shall be reviewed.
2. Furnace charging procedures and thermocouple locations shall be reviewed.
3. Furnaces shall be calibrated annually. As a minimum, calibration shall comply with
the requirements of NORSOK M-650.
4. Re-calibration is required following any significant modifications to the furnace.
f. Furnace loading procedures and charging patterns shall be reviewed, with particular
attention to the placement of components in the calibrated zone and the location of the
furnace control and charge monitoring thermocouples. Additionally,
1. Basket charging of large and uncontrolled numbers of small components shall not be
acceptable.
2. If basket charging procedures are used:
a) The maximum number and weight of components per basket shall be controlled.
b) Qualification testing shall clearly demonstrate that adequate heating rates and
soak temperatures/times and are achieved in all regions of the basket charge.
3. If items are bundled for heat treatment:
a) The maximum number and weight of components per bundle shall be controlled.

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29 August 2007 GP 18-04
b) Qualification testing shall clearly demonstrate that adequate heating rates and
soak temperatures/times are achieved in all regions of the bundle.
g. Furnace discharge procedures.
h. Furnace temperature profile during discharge shall be available.
i. Time taken for components to be transferred from furnace to quench bath shall be
reviewed.
j. Quenching procedures, including full details of water temperature control, flow rates, and
component agitation, shall be reviewed as follows:
1. Quenching procedures involving basket / bundle quenching shall demonstrate that
adequate quench rates are achieved in all regions of the basket/bundle.
2. Quenching procedures relating to quenching of pierced or hollow components shall
demonstrate that all regions of components are adequately quenched and that steam
bubbles do not become entrapped.
k. Manufacturing summaries (NORSOK M-650 paragraph 7.2) specific to components in the
potential order shall be reviewed and associated qualification test records shall be
examined.
l. Audit/technical appraisal shall include witness of manufacture of typical components.
m. Laboratory audit/technical appraisal shall:
1. Review competence of laboratory personnel.
2. Review the experience of point counting microstructures of duplex stainless steels.
3. Review equipment and associated procedures relevant to tests being performed for
manufacture of components ordered.
n. Audit/technical appraisals shall be reported for each of the items a-m, with a clear
recommendation concerning the competence and capability of the manufacturer,
subcontractor, or laboratory concerned.
o. At the close of the audit, deficiencies identified shall be communicated and confirmed in
writing to manufacturer, subcontractor, or laboratory concerned. The criticality of the
deficiencies shall be judged by the audit team.
p. Critical deficiencies shall be rectified before placement of an order.
10. Purchase specification
10.1. General
a. Purchase specification shall be prepared for each duplex stainless steel order.
b. Suitable specification data sheets are in GN 36-016.
c. Specifications shall include all requirements identified in the data sheets in GN 36-016.
10.2. Manufacturing Procedure Qualification Testing

a. A MPQT shall be specified for each order.
b. At the discretion of the BP metallurgist the MPQT may be performed on a component
from the first production heat treatment batch of any given component. The item for test
should be selected at random by the BP inspector.
c. A MPQT shall be performed for each component type and size in the order.

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d. Test groupings in terms of component size/weight and manufacturing process may be

established by the BP metallurgist.
e. MPQT component
1. Component selected for MPQT shall initially be inspected and non-destructively
examined as required by the purchase specification.
2. Component shall then be subject to the full range of mechanical, toughness, and
corrosion tests (including microstructural assessment) required by purchase
specification.
3. Test pieces shall be taken from all critical areas of the component, including the
regions of maximum and minimum thickness and, where appropriate, the normal
production test prolongation.
4. The weld seam and HAZ of welded components shall be included in evaluation.
5. The results of the MPQT shall comply with the specified properties and, where
appropriate, shall demonstrate that the results of testing in the prolongation are
representative of the overall component properties.
10.3. Production test sampling

a. Routine production sampling shall be performed at the frequency specified in the material
data sheet in GN 36-016.
b. Production test sampling for small items (where prolongations are not appropriate) shall
use sacrificial components.
c. Representative prolongations may be used for larger components following successful
MPQT.
d. Furnace location of samples containing prolongations shall be subject to approval by BP
inspector.
e. Small samples for testing shall be selected at random by BP inspector.
f. Location of specimens taken for production testing shall be documented and subject to BP
approval.
Production test sampling involves the selection of one or, perhaps two components
for examination and testing to demonstrate the compliance of all components in a
material heat/furnace load. Depending on the size of the components relative to the
size of the furnace, the furnace charge may be one item, two items, or perhaps 100
or more items. Thus, any unexpected temperature gradients in the furnace that may
affect component properties may not be identified by production testing. Production
testing also provides a demonstration of the effectiveness of the quenching
operation. Accordingly, items for testing should be carefully selected. Occurrence of
processing variations will be minimised by careful manufacturing control, but
variations may still, and often do, occur.
Consequently, testing of each component as detailed in section 13 is imperative to
ensure a consistent metallurgical quality across an entire production run.
10.4. Scope of production testing
10.4.1. General
The specified scope of production testing shall comply with the data sheets in GN 36-016.

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29 August 2007 GP 18-04
10.4.2. Prolongations
a. Prolongations shall be designed (where practicable) to be representative of maximum
thicknesses of the component.
b. If welding has been performed during manufacture, prolongations shall include weld
regions.
c. For components where prolongations are used they shall be identical in design and size to
those used for the MPQT.
10.4.3. Metallographic assessment

a. The location of specimens for metallographic assessment shall be agreed by the BP
metallurgist.
b. Specimens for metallographic assessment shall be polished to 1 micron (4 x 10-5 in)
surface finish prior to etching.
c. Etchants shall be subject to agreement by the BP metallurgist.
Suitable etchants are:
• For determining austenite/ferrite phase balance: 40% KOH or 40% NaOH
(electrolytic).
• For examination of intermetallic phases: 20% sulphuric acid + 0,1 g/l
ammonium thiocyanate.
d. Microstructure shall:
1. Be suitably etched.
2. Be examined at 400x magnification.
3. Have grain boundaries with no continuous precipitates.
e. Nitrides, and carbides shall not exceed 1% total.
f. Intermetallic phases, e.g. Sigma phase shall not be present. The acceptance of components
containing limited amounts of intermetallics up to a maximum of 0,5% shall be at the
discretion of the BP metallurgist taking factors such as the overall material production
route, the location of the intermetallics and the final application of the component into
consideration.
g. Ferrite content shall be determined by point counting in accordance with ASTM E562 and
shall in be in the range 40-60% for parent materials.
h. If welding has been utilised in the manufacture of the fitting or component weld seams and
associated HAZs shall be included in the assessment. The ferrite content shall be 35-65%.
i. Digital photographic records (400x) of the microstructures shall be retained and presented
with the certification.
10.4.4. Corrosion testing

The value of testing duplex stainless steel components in ferric chloride in
accordance with ASTM G48, Method A, is debatable in that it gives little
information on the suitability of the material for the intended service conditions in
terms of corrosion resistance. However, a ‘pass’ in this test provides additional
confidence that the material has been correctly thermally processed during
manufacture and the benefit of specifying this test should be assessed when
preparing product data sheets.

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10.5. BP rights of inspection

a. Purchase specification shall establish right of BP designated personnel to monitor, witness,
and inspect all stages of component manufacture.
b. BP personnel shall have safe access to manufacturing plant, subcontractor works, and test
laboratory facilities at all reasonable times.
c. Provision of office accommodation and communication facilities for BP inspector shall be
dealt with in purchase specification.
10.6. Certification
Product certification shall comply with BS EN 10204, Type 3.1 (formerly 3.1.B), or ISO 10474,
Type 3.1.B.
10.7. Marking
Marking shall comply with project requirements.
10.8. Packaging
a. Unless otherwise specified packing shall be responsibility of Vendor.
b. Packaging shall be such as to ensure that items are not damaged during transportation and
are sealed to prevent ingress of water.
c. Particular attention shall be paid to adequate protection of bevelled ends and sealing faces.
d. If size permits, items shall be shrink wrapped and supplied on pallets or in wooden boxes.
A plastic barrier shall be placed between the duplex stainless steel components and the
pallet or box.
e. If pallets and shrink wrap are not possible, adequate protection, such as end protectors and
wooden blocks, shall be used, with a plastic barrier between the wood and the duplex
stainless steel components.
f. Duplex stainless steel items shall be packed separately from carbon steel items to avoid
contamination.
g. Duplex stainless steel items shall be packed using plastic banding.
h. Carbon steel banding shall not be used.
11. Preproduction meeting
a. Following placement of the order and prior to beginning any production, a preproduction
meeting shall be held at each manufacturing location.
b. The objectives of preproduction meeting shall be to ensure that manufacturer fully
understands requirements of the order, agreement of the quality plan together with the
inspection/test plan.
c. Attendees at this meeting shall include the BP metallurgist, BP QA representative, and BP
inspector.
d. Manufacturers, subcontractors, and test laboratory QA and technical/production personnel,
as appropriate, shall also attend.
12. Production monitoring and inspection
a. BP shall maintain a presence at manufacturer and subcontractor production facilities for

the duration of the order.
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29 August 2007 GP 18-04
b. While it is desirable that BP should have a full time presence, it is recognised that this
level of attendance may be impractical. Nevertheless, a presence greater than that needed
to comply with the quality/inspection and test plan requirements shall be maintained.
c. Manufacturer shall provide timely notice when witnessing at specified hold points is
required.
Experience demonstrates that if BP takes an interest in manufacture and regularly
attends the manufacturing facilities, the manufacturer invariably takes a greater
level of interest in the product than if BP does not attend.
13. Final inspection and release
a. BP inspector shall be present at all final inspections to enable release.

b. Feritscope inspection
1. As part of the final inspection process, every component shall be tested using a
Fischer Feritscope (MP30E) or an equivalent BP approved instrument in accordance
with a BP approved procedure.
2. Multiple locations (minimum of four) on the inside and outside of each component,
including thick and thin sections, shall be examined.
3. Each weld seam in any fabricated component shall be examined at multiple locations
(minimum of four).
4. Calibration of Feritscope or other BP approved instrument shall be performed prior to
examination of each batch of components and shall be regularly checked at least once
per hour during examination.
5. Each calibration event shall be recorded.
6. If instrument calibration needs correction, all components examined since the
previous calibration shall be re-examined.
c. A series of material samples of known microstructural composition, with varying levels of
austenite/ferrite contents shall be available for reference purposes.
Standards are available from National Institute of Standards and Technology
(USA). However, manufacturers have the option of producing material samples of
different microstructural compositions (validated by point counting) themselves.
Although the Feritscope cannot directly measure the presence of intermetallic
phases, such as sigma, it will provide an assessment of the austenite/ferrite phase
balance. If this balance is destroyed (usually by poor thermal processing), low
ferrite readings are likely to be indicative of the presence of sigma or other
unacceptable intermetallic compounds.
d. Verifying proper phase balance
1. Feritscope will establish a characteristic value for austenite/ferrite phase balance in
components being examined.
2. Anomalous ferrite values that deviate from the trend of values obtained in the
production run shall be investigated.
3. If phase balance is outside the specified range, components shall be confirmed to be
free from intermetallics by metallographic sampling.
4. Direct metallographic examination is preferred, but if this is impractical, BP may
agree to replica metallography.
5. Procedures for metallographic examination shall be subject to BP approval.
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29 August 2007 GP 18-04
e. Components containing intermetallic compounds shall be rejected, and processing failures

leading to development of such intermetallic phases in the microstructure shall be
investigated by manufacturer to the satisfaction of BP.
f. Processing failures shall be rectified before further production occurs.
14. Positive material identification
Projects should consider the need to establish the chemical analysis of critical individual items (parent
material and, where appropriate, weld metal).

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Bibliography
BP
[1] GIS 02-206, Specification for Duplex and Super Duplex 25% Chrome Stainless Steel Pipe.
[2] GIS 43-315, Manufacture of 22% Cr and 25% Cr Duplex Stainless Steel Seamless Linepipe.
[3] GIS 43-334, Welding of CRA, Internally Clad, and Mechanically Lined Pipe.
[4] GIS 46-010, Pressure Vessels.
[5] GP 18-03, Heat Exchanger Tube End Fixing.
[6] GP 36-10, Metallic Material Selection.
[7] GP 36-15, Materials Selection for Surface (Topsides) Equipment in Oil and Gas Production Facilities.
[8] GP 36-20, Materials Selection for Subsea Equipment.
American Petroleum Institute (API)

[9] API Technical Report 938-C: First Edition, May, 2005, Use of Duplex Stainless Steels in the Oil
Refining Industry.
American Society for Testing and Materials (ASTM)

[10] ASTM G48, Standard Test Methods for Pitting and Crevice Corrosion Resistance of Stainless Steels
and Related Alloys by use of Ferric Chloride Solution.
Other
[11] Robert N. Gunn, Abington Publishing, Cambridge, England, 1997, Duplex Stainless Steels,
Microstructure, Properties and Applications.
[12] Björn Holmberg, How to Perform Welding in Duplex Stainless Steels to Obtain Optimum Weld Metal
Properties, (www.Outokumpu.com - Document acom, 1997, Ed. 3).
[13] International Molybdenum Association, Practical guidelines for the fabrication of duplex stainless
steels. Also available from Nickel Development Institute (www.nidi.org – Document No. 16000).
[14] Sandvik, Welding guide for Sandvik duplex stainless steels.
[15] TWI, Arc welding duplex stainless steels - a guide to best practice. www.twi.co.uk (available to
industrial members of TWI).

Page 17 of 17

Manufacture of Duplex Stainless Steel Fittings and Components

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Document No.

Manufacture of Duplex Stainless Steel

This is the first issue of Engineering Technical Practice (ETP) BP GP 18-04.

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American Petroleum Institute (API)

American Society for Testing and Materials (ASTM)

British Standards Institute (BSI)

International Organization for Standardization (ISO)

Norsk Sokkels Konkuranseposisjon (NORSOK)

3. Terms and definitions

25%Cr super duplex

4. Symbols and abbreviations

HAZ Heat affected zone.

MPQT Manufacturing procedure qualification test.

OCTG Oil country tubular goods.

PREw Pitting resistance equivalent number.

QMS Quality management system

Quality management standards (ISO TS 29001/ISO 9001) require manufacturers to

components of adequate metallurgical quality. Industry experience in this respect is

corrosion resistance of these alloys is improved predominantly through alloying

7. Material selection, application, and fabrication

a. Items shall be solution heat treated and water quenched.

8. Qualification of manufacturing and testing laboratory facilities

a. Manufacturers shall be prequalified prior to placement on a bid list.

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3. Manufacturers using welding in the production of fittings or components shall

9. Audit and technical appraisal

9.1. Audit team

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9.2. Review and confirmation

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10. Purchase specification

10.2. Manufacturing Procedure Qualification Testing

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d. Test groupings in terms of component size/weight and manufacturing process may be

10.3. Production test sampling

10.4. Scope of production testing

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10.4.3. Metallographic assessment

10.4.4. Corrosion testing

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10.5. BP rights of inspection

11. Preproduction meeting

12. Production monitoring and inspection

a. BP shall maintain a presence at manufacturer and subcontractor production facilities for

13. Final inspection and release

a. BP inspector shall be present at all final inspections to enable release.

e. Components containing intermetallic compounds shall be rejected, and processing failures

14. Positive material identification

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[4] GIS 46-010, Pressure Vessels.

[5] GP 18-03, Heat Exchanger Tube End Fixing.

[6] GP 36-10, Metallic Material Selection.

[8] GP 36-20, Materials Selection for Subsea Equipment.

American Petroleum Institute (API)

American Society for Testing and Materials (ASTM)

[14] Sandvik, Welding guide for Sandvik duplex stainless steels.