ships construction gl-materials and welding

Rules for Classification and Construction II Materials and Welding

1 Metallic Materials

1 Principles and Test Procedures

Edition 2009

The following Rules come into force on April 1st, 2009

Alterations to the preceding Edition are marked by beams at the text margin.

Germanischer Lloyd Aktiengesellschaft

Head Office Vorsetzen 35, 20459 Hamburg, Germany

Phone: +49 40 36149-0 Fax: +49 40 36149-200

[email protected]

www.gl-group.com

"General Terms and Conditions" of the respective latest edition will be applicable (see Rules for Classification and Construction, I - Ship Technology, Part 0 - Classification and Surveys).

Reproduction by printing or photostatic means is only permissible with the consent of Germanischer Lloyd Aktiengesellschaft.

Published by: Germanischer Lloyd Aktiengesellschaft, Hamburg Printed by: Gebrüder Braasch GmbH, Hamburg

Table of Contents

Section 1 Principles Covering the Manufacture and Testing of Materials

A. Scope .......................................................................................................................................... 1- 1

B. Other Relevant Specifications and Documents .......................................................................... 1- 1

C. Requirements Applied to Manufacturing Works ........................................................................ 1- 1

D. General Requirements Relating to the Manufacture and Properties of Materials ....................... 1- 2

E. General Test Conditions ............................................................................................................. 1- 3

F. Identification and Marking of Products ...................................................................................... 1- 4

G. Test Documents .......................................................................................................................... 1- 4

H. Certificates ................................................................................................................................. 1- 5

Section 2 Mechanical and Technological Tests

A. Scope .......................................................................................................................................... 2- 1

B. Testing Machines and Personnel ................................................................................................ 2- 1

C. Sampling and Specimen Preparation .......................................................................................... 2- 1

D. Tensile Tests .............................................................................................................................. 2- 2

E. Notched Bar Impact Tests .......................................................................................................... 2- 5

F. Technological Tests on Pipes ..................................................................................................... 2- 7

G. Instructions for the Bend Test, Hardness Test and Drop Weight Test ....................................... 2- 9

H. Retests ........................................................................................................................................ 2- 10

Section 3 Non-Destructive Testings

A. General Items ............................................................................................................................. 3- 1

B. Standards and Regulations ......................................................................................................... 3- 1

C. Requirements Applicable to the Inspection Body ...................................................................... 3- 1

D. Inspection Personnel, Supervisors .............................................................................................. 3- 1

E. Test Methods, Equipment and Test Media ................................................................................. 3- 1

F. Preparation and Performance of Tests ........................................................................................ 3- 2

G. Certification of Test Results ....................................................................................................... 3- 2

H. Visual Testing (VT) ................................................................................................................... 3- 2

I. Magnetic Particle Testing (MT) ................................................................................................. 3- 3

J. Penetrant Testing ........................................................................................................................ 3- 4

K. Ultrasonic Testing (UT) ............................................................................................................. 3- 5

L. Radiographic Testing ................................................................................................................. 3- 7

II - Part 1 GL 2009

Table of Contents Chapter 1

Section 1

Principles Covering the Manufacture and Testing of Materials

A. Scope

1. The Rules for Materials apply to materials and products which are intended for the construction, repair and equipping of ships, offshore installations and other structures which are classified by Ger-manischer Lloyd (GL) or whose classification has been applied for.

2. The scope of these Rules includes all those materials and products whose use is referred to in the Rules for Construction. GL reserve the right to extend the scope of these Rules to materials and products not specifically mentioned in the Rules for Construction.

3. Where there are special grounds for so doing, GL reserve the right to impose more comprehensive requirements with respect to the manufacture, proper-ties and testing of materials and products, where these appear necessary in the light of more recent research or operational experience, and GL likewise reserve the right to sanction departures from the Rules, where these are technically justified.

4. This Section contains principles governing metallic materials and the forms in which these are produced, e.g. plate, strip, sections, rod, pipes, for-gings and castings, as well as propellers and anchoring and mooring components, which are to be applied in the course of manufacture and testing. These general principles are to be implemented in conjunction with the specific rules prescribed in the following Sections in reference to the particular products.

B. Other Relevant Specifications and Docu-ments

1. The properties of products not covered by requirements specified in these Rules are subject to the standards applicable to the product in question or, where appropriate, to the material specifications or conditions of supply which have to be complied with by the manufacturer of the material.

2. Materials or products to national or interna-tional standards or to special material specifications may be permitted by GL, if their properties are recog-nized by it as equivalent to those of the products specified in these Rules for Materials, or where GL has given special approval for their use. In these cir-cumstances, the relevant standards or specifications are considered to be an integral part of these Rules.

3. Subject to the conditions mentioned in 2., GL may sanction the supply of products conforming ex-clusively to the relevant standard or material specifica-tions.

4. Should differences exist between these Rules and the relevant standards or specifications with re-gard to their requirements, the tests shall take account of the more stringent requirements.

C. Requirements Applied to Manufacturing Works

1. The materials and products covered by these Rules may only be manufactured in works approved by GL for this purpose. To be approved, works shall satisfy at least the following conditions, proof of which shall be furnished to GL during a factory in-spection and by submission of relevant documents prior to the commencement of manufacture:

1.1 They shall be equipped with plant enabling the materials to be expertly manufactured and worked in accordance with modern technical practice.

1.2 They shall have the necessary testing equip-ment and the skilled staff required for its operation in order to perform expertly the tests specified in these Rules for Materials and in the relevant documents. Where, in exceptional cases, individual tests have to be carried out by outside bodies, such tasks shall be entrusted by the manufacturer only to those firms or institutes which also meet the aforementioned condi-tions and have been approved by GL.

1.3 The works shall, by their own quality control arrangements, ensure that the products are expertly manufactured and processed and that they meet the specified requirements. Testing carried out by GL shall not exonerate the manufacturer from this liabil-ity. Where internal quality control departments are established for the performance of these functions, this shall be independent of the management of the pro-duction and processing departments.

1.4 As part of their own internal quality control system, works shall keep a constant record of the manufacture and testing of materials and products.

1.5 Where called for in D., works shall demon-strate the properties of their products by preliminary testing of the procedure an/or the product suitability.

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Section 1 Principles Covering the Manufacture and Testing of Materials Chapter 1Page 1–1

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2. Manufacturers shall apply in writing to GL for approval. Applications are required to contain the following information:

– Materials and products for which approval is sought, including the method of manufacture, guide values for the chemical composition, con-dition in which the materials and products are to be supplied, properties and dimensions.

– A list of the manufacturing plant and testing equipment used together with descriptions of the quality control system and details of the persons responsible for quality control. Where tests are performed by outside bodies, the addresses of these and their testing facilities are also to be stated. Such testing bodies are subject to GL ap-proval. This condition is deemed satisfied if the testing body is accredited by an authorized insti-tution.

3. If the assessment by GL yields that the re-quirements of 1. and 2. are met, the manufacturer will be approved by GL. The approval normally remains valid for 3 years. The manufacturer receives a certifi-cate of approval and will be included in the list of approved material manufacturers, which also contains the scope of approval and the area of validity. The validity may thereafter be extended for a further 3 years where it is demonstrated by repeat testing that the conditions under which the first approval was issued continue to be fulfilled.

4. During the validity period the following cases may give rise to a new decision regarding mainte-nance of the approval:

– damages during operation due to the quality of the product

– discrepancies of the product established between manufacture and assembly

– ascertained deficiencies in the quality system of the manufacturer

– changes regarding approval matters carried out by the manufacturer, which have not been agreed with GL

– indications for major discrepancies during test-ing of the products

D. General Requirements Relating to the Manufacture and Properties of Materials

1. Manufacture

1.1 All materials shall be manufactured by suffi-ciently well proven techniques, which ensure that the required properties are achieved. Where new proc-esses are to be employed, preliminary proof of their suitability is to be submitted to GL. According to the

decision of GL, this shall take the form of special procedure tests and/or the presentation of works documentation of tests performed or of expert assess-ments by independent testing bodies.

1.2 In the case of steel, the well proven tech-niques referred to in 1.1 include basic oxygen or elec-tric furnace steel-making and continuous, ingot and mould casting.

2. Chemical composition and required prop-erties

Materials and products shall satisfy the requirements relating to chemical composition and properties speci-fied in these Rules for Materials or, where applicable, in the relevant documents. As a rule, the chemical composition is that of the melt.

3. Condition of supply and heat treatment

3.1 Products are to be supplied in the prescribed heat-treated condition. Where the final heat treatment is to be performed by the steel user, the condition in which the material is supplied shall be clearly stated in the relevant certificates.

3.2 All heat treatments are to be carried out in suitable furnaces, which shall be efficiently main-tained. The furnaces shall be provided with devices for controlling and indicating the temperature; these de-vices are to be checked at regular intervals.

3.3 If it is intended to apply other treatments in place of the prescribed heat treatments such as nor-malising or quenching and tempering, the manufac-turer shall first prove to GL that, when these other processes are used, the mechanical properties of the products meet the requirements.

4. Freedom from defects

4.1 All materials and products shall be free from defects which have more than an insignificant adverse effect on their use or appropriate further working.

Insignificant surface defects may be removed me-chanically provided that the dimensional tolerances permitted for these products are not exceeded.

4.2 Defects in the material may be repaired by welding only where this is permitted by the specifica-tions relating to the product in question, the Surveyor has given his consent and the welding technique has been approved by GL.

5. Weldability

Materials intended for the manufacture of welded structures shall be weldable by standard workshop techniques. Where welding is possible only in special conditions, these shall be determined in agreement with GL and shall be validated by a procedure test.

Chapter 1 Page 1–2

Section 1 Principles Covering the Manufacture and Testing of Materials II - Part 1GL 2009

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6. Approval of materials and products

6.1 The manufacturer shall first prove that the properties of the materials and products made by him fulfil the stipulated requirements. As a rule, this calls for a test of suitability performed on selected products, the scope of which shall be decided by GL in each case. With the consent of GL, account may be taken for this purpose of the reports of other independent testing bodies.

6.2 In the case of standardized materials men-tioned in these Rules which correspond to EN or DIN standards, to the iron and steel specifications of the VDEh (Association of German Metallurgists) or to national or international standards of equivalent stand-ing, a test of product suitability may, with the consent of GL, be dispensed with. Materials for the loading and processing equipment of gas tankers, with the exception of austenitic steels, are excluded from this Rule.

E. General Test Conditions

1. Acceptance tests shall normally be performed in the manufacturing works in the presence of the Surveyor. For this purpose, the manufacturer shall give the Surveyor access to the manufacturing and testing departments concerned and shall make avail-able to him all the records relating to quality control, in so far as this is necessary for the proper discharge of his duties. The Surveyor is also entitled to witness the manufacturing process, although this shall not interfere with the manufacturing flow.

2. For the testing of mechanical and technolo-gical properties, use shall be made of the general methods and test specimens mentioned in Section 2. Test requirements and results shall be stated in SI units. Tests not referred to in Section 2 are to be carried out in accordance with national or international standards, unless otherwise agreed.

3. Where non-destructive tests are specified for the various product types, these shall be performed by the manufacturer and the results together with details of the test method are to be evaluated according to recognized criteria of acceptability and documented in a certificate. The Surveyor is entitled to be present at the tests. Where tests are to be performed by GL, special agreements shall be reached concerning these.

3.1 For acceptance tests according to the GL Rules only materials and products included in the scope of approval shall be submitted.

4. The chemical composition of materials shall normally be demonstrated by the manufacturer by melt analyses, and these shall cover all those elements for which limited values are prescribed in these Rules for Materials or in the other relevant documents, or

which are added in order to guarantee the required mechanical properties. The certificate of the manufac-turer is generally recognized as proof of the chemical composition. Where doubts exist as to the composi-tion, GL may also require the performance of product analyses. Possible deviations between the melt and product analyses shall conform to the relevant stan-dards or specifications.

5. All products are to be checked by the manu-facturer for compliance with the specified dimensions. They shall also be inspected by him for possible de-fects and shall, when this is called for, be presented to the Surveyor.

For this purpose, the products shall normally be in the prescribed "as delivered" or heat-treated condition and shall have a clean surface, prepared for testing, which is free from coatings or other protective media which impair the detection of defects.

Unless otherwise specified in the following Sections or specially agreed, the Surveyor shall perform a ran-dom test of the dimensions and surface finish as he sees fit.

Products which do not meet the requirements shall be set aside by the manufacturer beforehand.

6. Where in exceptional cases testing cannot be carried out in accordance with the methods stated in these Rules for technical reasons, other equivalent test methods or techniques may, with the consent of GL, be applied.

7. Where products are manufactured in large runs by series-manufacturing techniques and/or using continuous processes with constant, monitored condi-tions, GL may entrust the manufacturer with the per-formance of some or all of the tests. This is inter alia subject to the condition that the manufacturer has established and maintains a quality assurance system, e.g. in accordance with ISO 9001, and furnishes proof thereof by a certificate bearing the certifier's mark of accreditation. Furthermore it is amongst others to be demonstrated that the requirements for the product have already been satisfied for several years. Approval of testing on the manufacturer's responsibility is to be applied for in writing to GL Head Office and can only be granted after close examination.

8. If there is reasonable doubt as to the quality of a product, the Surveyor may require additional tests to be performed.

9. GL gives no guarantee that products which have been subjected to testing to the prescribed extent, either individually or grouped together in test batches, fulfil in all respects the requirements contained in these Rules for Materials or in other relevant docu-ments.

Products which prove defective in the course of sub-sequent application or processing may be rejected despite satisfactory previous testing.

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F. Identification and Marking of Products

1. Retraceability

The manufacturer shall introduce a system which enables the product to be identified after every stage of the manufacturing process and be traced back to the heat. This system shall be demonstrated to the Sur-veyor if he so requests.

2. Marking

2.1 Prior to acceptance testing, products shall be provided by the manufacturer at least at one position with the necessary marking as described in the follow-ing Sections. The marking shall agree with the details given in the works certificates or delivery documents.

2.2 The marking shall normally be impressed with a punch, unless such marking is precluded by materials with a sensitive surface or which are too thin. In such cases marking may be done with low-stress stamps, paint, rubber stamps, adhesive stickers or electroengraving.

2.3 All marks shall be so applied that their legi-bility cannot be impaired by the transportation or storage of the products. Where the further processing of the products entails the removal of existing marks, the manufacturer concerned shall apply these to a different spot and shall arrange for the transfer of the GL stamp, unless another solution is adopted.

2.4 As a general rule, every product shall be marked. In the case of small parts of the same type and size which are securely packed in crates, drums or similar containers, and also in the case of steel rods and sections weighing up to 25 kg/m and packed to-gether in bundles, marking of the uppermost unit is sufficient or by a securely fastened, strong tag.

2.5 Wherever possible, marks should be enclosed by a painted surface. In the case of forgings and cast-ings, the area to be marked should be bright machined.

3. Use of the GL stamps

3.1 Specimens and the product from which specimens have been taken are to be marked with the "specimen stamp", unless otherwise agreed in accor-dance with 4.:

–

3.2 Products for which individual tests of some kind, e.g. tests of mechanical properties and surface finish, in-ternal pressure test and non-destructive testing, are spe-cified are to be marked with the "anchor stamp", provided that all requirements of the GL Rules have been satisfied:

–

As an exception, shipbuilding steels of grades E and F which are subject to individual testing as well as the non-alloy pipes R 360, R 410 and R 490 may also be stamped in accordance with 3.3.

3.3 Plates, sections and rods of steel which are grouped into test batches for testing, are to be marked with the "batch stamp", provided that all the require-ments have been satisfied:

–

This stamp may be applied by approved materials manufacturers and suppliers themselves.

In exceptional cases, e.g. series-produced steel cast-ings, the letters "GL" may be either cast or stamped in after agreement with GL.

3.4 Products which have to be tested in accor-dance with other specifications or supply conditions, i.e. which shall not be used within the scope of Classi-fication, are to be marked, irrespective of the extent of the tests prescribed, with the "broad anchor stamp" in the presence of the Surveyor, provided that, when tested, the products have met the requirements stipu-lated in the specifications or supply conditions:

–

3.5 Should it be shown during subsequent tests or during further processing of the tested products that these have defects or in some way no longer meet the requirements, the GL stamping shall be cancelled in a suitable manner.

4. Stamping of specimens by the works

Manufacturers of materials who have an independent quality control department in accordance with C.1.3 may, with the consent of the GL inspection office, allow members of this department to apply the speci-men stamp. The Surveyor shall be notified of the names of the persons authorized for stamping and of the marks identifying their personal stamps.

In case of automated production facilities for speci-men selection the stamping may be dispensed with, provided the responsible Inspection Office verified the continuous retraceability of specimen marking.

G. Test Documents

For testing purposes, the manufacturer shall submit to the Surveyor documents referring to the materials or products to be tested. These documents shall contain at least the following information:

– name of purchaser together with order number

– newbuilding and project number respectively, where known

– item numbers and quantities

– dimension and indication of product

– material grade, type and specification

– application and drawing number, where necessary

– weight of products



G

H. Certificates

The type of required certificate is specified in the Rules.

1. Certificates of the manufacturer

Where, in accordance with the Rules or special agree-ments, the task of material testing is left to the manu-facturer, the latter shall issue a relevant certificate. In case testing yields that the prescribed requirements are met, the result will be certified by the manufacturer.

1.1 Test report of the manufacturer (C-type Certificate)

Where, in accordance with the Rules or special agreements, a certificate of the manufacturer, inde-pendent of the material/product at hand, is required, the manufacturer shall issue a relevant test report (e.g. 2.2 according to EN 10204). The manufacturer shall be approved for the material/product.

Besides the information listed in G., the test report shall also specify the following:

– manufacturing process

– condition of supply

– details of heat treatment, where necessary

– marking

– results of non-specific material testing of current production

1.2 Manufacturer’s inspection certificate (B-type Certificate)

Where, in accordance with the Rules or special arrange-ments, a certificate of the manufacturer for the material at hand and product respectively is required, the manu-facturer shall issue a relevant inspection certificate (e.g. 3.1 according to EN 10204). Also in such cases the ma-nufacturer shall be approved for the material/product.

Besides the information listed in G., the inspection certificate shall also specify the following:


– heat number and chemical composition



– test pressures, where necessary

– results of special tests to be undertaken, where necessary

– results of mechanical tests of the delivery at hand

2. GL Certificates

Where, in accordance with the Rules or special ar-rangements, material testing under survey of GL is required, a relevant GL Certificate will be issued.

In case testing yields that the prescribed requirements are met, the result will be certified by the Surveyor.

2.1 Material certificate according to GL Rules (A-type Certificate)

Materials and products intended for use within the scope of Classification have to be delivered with a material certificate according to GL Rules, see A.2.

To obtain this material certificate the GL Rules rele-vant for the material/product shall be satisfied. The manufacturer shall be approved by GL for the mate-rial/product. The GL Rules shall be named as test procedure. Normally, stamps are the "anchor stamp" as well as the "batch stamp" .

Besides the information listed in G., the certificate shall also specify the following:


– heat number and chemical composition



– test pressures, where necessary

– results of special tests to be undertaken, where necessary

– results of mechanical tests of the delivery at hand

2.2 Material certificate according to other rules

For materials and products which are not to be tested according to GL Rules but to other rules a material certificate may be issued. In this case GL will carry out an acceptance test on behalf of the orderer as neu-tral third party.

The rules which are to be met for the acceptance test have to be named in the material certificate, whereat here the GL Rules shall not be named. If the test re-quirements are fulfilled a material certificate with the "broad anchor stamp" will be issued.

Materials and products with this certificate shall not be used within the scope of Classification.

3. Alternative verification (A-type Certifi-cate)

By agreement, the results may also be attested using the following alternatives:

3.1 Confirmation of the test results on a com-monly issued certificate of manufacturer and GL (e.g. inspection certificate 3.2 according to EN 10204).

3.2 In the case of products produced in large quantities and subjected to testing by heat or batch, by confirmation of the Surveyor who appends his stamp and signature to the manufacturer's certificate in token that the tests carried out on the consignment in accor-dance with the Rules have satisfied the requirements. In addition, the manufacturer shall add by printing in the certificate an appropriate remark and shall also con

II - Part 1 GL 2009


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firm that the products listed in the documents have been manufactured in accordance with GL Rules.

4. Issuing of test certificates by a material user or a merchant

If a product is supplied by a material user or a mer-chant, he shall put the manufacturer's certificates 1 at the disposal of the purchaser without amendment.

–––––––––––––– 1 See standard EN 10204

These manufacturer's certificates shall be accompa-nied by a suitable means of identifying the product, so as to ensure that product and certificates can be clearly matched up.

If the material user or the merchant has modified the condition or dimensions of the product in any way, these particular new properties shall be confirmed in an additional certificate.

The same applies to special requirements in the order which are not shown in the manufacturer's certificates.



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Section 2

Mechanical and Technological Tests

A. Scope

1. This Section contains general Rules for the mechanical and technological test methods for metal-lic materials and for the necessary test specimen shapes which are to be used for materials testing.

2. It is a fundamental requirement that all tests shall be performed in accordance with established national and/or international standards and in confor-mity with these Rules.

3. Departures from the prescribed test specimen shapes or from the conditions governing sampling and specimen preparation are permitted only in excep-tional, technically justified cases where this enables the materials to be subjected to equivalent tests and where GL has given its consent to the change.

B. Testing Machines and Personnel

1. All tests shall be performed by trained per-sonnel using calibrated testing machines. The testing machines shall be maintained by the owners in a good working condition and shall be calibrated at regular intervals by a testing authority acknowledged by GL. The calibration records shall be kept available for inspection in the test laboratory.

2. Tensile testing machines are subject to the calibration periods and permitted indication errors shown in Table 2.1. Tensile testing machines shall be calibrated in accordance with ISO 7500-1 or another commonly accepted standard.

Table 2.1 Indication errors and calibration periods for tensile testing machines

Type of tensile testing

machines

Test class (ISO

7500-1)

Permitted indication

error, max.

Calibration period

Multi-purpose testing 1 1 % 1 year

Testing ma-chines for equipment

components

3 3 % 2 years

3. For pendulum impact testing machines, the total friction with the full swing of the pendulum may not exceed 0,5 % of the available energy. On request, compliance with this value shall be demonstrated to the Surveyor before the machine is used. Pendulum impact testing machines shall be recalibrated at yearly intervals. The calibration of pendulum impact testing machines shall be performed in accordance with ISO 148-2 or another commonly accepted standard.

4. Hardness testing equipment shall be cali-brated at yearly intervals. It is to be verified that the acceptable tolerances for the equipment parameters and the indicating accuracy are complied with in ac-cordance with the appropriate standards.

5. Compliance with the above requirements may also be evidenced by the testing laboratory's certificate of accreditation, provided that the accreditation was granted by an accredited institution and the test meth-ods in question are stated in the certificate of accredi-tation.

C. Sampling and Specimen Preparation

1. Definitions

1.1 Sample

"Sample" is the term applied to the product, e.g. the plate or pipe, which is selected from the unit test quan-tity for the purpose of taking specimens.

1.2 Unit test quantity/test batch

"Unit test quantity" or "test batch" is the term describ-ing that portion of a consignment to which the result of the test refers.

The term may be applied, for example, to a specific number of products of the same shape and dimensions originating from one melt, or to a length of rolled material (plate or strip) or to a single product (a large forging or casting).

1.3 Test section

The term "test section" describes a section of material (e.g. a strip of plate) which is taken from the sample and which serves for the preparation of one or more test specimens.

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Section 2 Mechanical and Technological Tests Chapter 1Page 2–1

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1.4 Test specimen

"Test specimen" is the term applied to a piece taken from the test section which, in the machined or un-machined condition, has prescribed dimensions and is subjected to the test in question.

2. Marking of test sections and test specimens

2.1 Test sections and test specimens shall be representative of the sample; see 3.1.

2.2 Test sections and test specimens shall be so marked that, after their removal and preparation, it is still clear from which sample they were taken and how they were positioned and orientated in the sample. Where, during the preparation of test sections and test specimens, it is impossible to avoid erasing the origi-nal markings, these shall be previously reapplied in another position.

2.3 As a general rule, test sections and test speci-mens shall be marked by the Surveyor with the test stamp before they are removed from the sample unless some other arrangement has been made with the manu-facturing works in accordance with Section 1, F.4.

3. Removal and dimensions of test sections

3.1 Test sections are to be removed from the sam-ple at specified positions. They shall be large enough to provide material for the test specimens prescribed for the performance of the tests together with the addi-tional test specimens required for possible retests.

3.2 In general, test sections may be removed from the sample only after completion of all the me-chanical and/or heat treatments to be applied to the product prior to delivery. In this context, heat treat-ments which cause no changes in the mechanical properties may be disregarded.

3.3 If, in exceptional cases, the test section cannot remain attached to the sample until the end of the manu-facturing process, e.g. where products are machined to their final dimensions before annealing, then the test section shall undergo the same mechanical and/or heat treatments which are applied to the sample itself. Fur-thermore, the consent of the Surveyor shall be obtained in cases of premature removal of the test sections.

4. Removal and dimensions of test specimens

The longitudinal axes of test specimens are to be ori-entated in relation to the main direction of deforma-tion in the manner prescribed in the following sec-tions. Notwithstanding this, the manufacturer may, in order to save test material and after agreement with the Surveyor, take transverse instead of longitudinal test specimens, provided that corresponding require-ments are specified for transverse test specimens or the requirements applicable to longitudinal specimens can be satisfied by this means.

The tolerances applicable to the specimen shall be in accordance with ISO 6892-98 or another standard accepted by GL.

5. Preparation of test specimens

5.1 All test specimens shall be machined to the prescribed dimensions. Exceptions to this requirement are those test sections, e.g. those of small-diameter pipes and rods, which may be subjected to tensile testing in their entirety.

5.2 When removing test sections or test speci-mens, deformations and heating up of the material are to be avoided as far as possible. Where test sections or test specimens are removed by thermal cutting or shearing from the sample, a sufficient allowance shall be provided to be removed by machining.

5.3 Machining defects, e.g. notches, grooves and burrs, which occur during the preparation of test specimens and which may affect the test results are to be removed, and the execution of this operation shall respect the dimensional and geometrical tolerances applicable to the specimen shape concerned.

5.4 Where test sections have to be straightened before test specimens are taken, e.g. in the case of transverse specimens from pipes, the straightening operation shall normally be performed in the cold state and shall not significantly affect the mechanical prop-erties of the material. If this is not possible, the test specimens shall be taken in such a way that straighten-ing is unnecessary. Tensile specimens taken from the pipe wall in the longitudinal direction may not be pressed flat between the gauge marks.

D. Tensile Tests

1. Specimen shapes

The following notation is used to specify the dimen-sions of test specimens.

1.1 Notation

A = elongation determined in tensile test for gauge length Lo for short proportional test specimens [%]

Ar = elongation required due to conversion for other gauge lengths [%]

do = diameter of round specimen [mm]

a = thickness of flat specimen [mm]

b = width of flat specimen [mm]

Lo = initial gauge length [mm]

Lc = test length [mm]


Section 2 Mechanical and Technological Tests II - Part 1GL 2009

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So = initial cross-section within test length [mm2]

Su = smallest specimen cross section after fracture [mm2]

r = shoulder radius at end of specimen [mm]

D = outside diameter of pipe [mm]

t = thickness of product [mm]

1.2 Dimensional tolerances

The dimensional tolerances shall be those specified in the relevant standards, e.g. EN 10002, Part 1 or ISO 6892.

1.3 Dimensions

1.3.1 Use should preferably be made of short pro-portional test specimens with an initial gauge length of

o oL 5,65 S=

or Lo = 5 do, respectively, as the requirements relating to elongation specified in the following sections refer to this gauge length.

The test length Lo shall be preferably larger than 20 mm.

The gauge length Lo may be rounded to the nearest 5 mm provided that the difference between this gauge length and Lo is less than 10 % of Lo.

1.3.2 For forgings and castings, with the exception of grey cast iron, cylindrical specimens conforming to EN 10002, Part 1 or as shown in Figure 2.1 are to be used.

Specimen shape A should be preferred. If this is not possible, the alternative dimensions should be deter-mined as specified for shape B with the specimen diameter do selected being between 10 and 20 mm.

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1.3.3 For hot-rolled rods and products of similar shape, the specimen shapes prescribed in 1.3.2 are to be used.

In the case of bars with a smaller section, suitable lengths may also be tested in their entirety, i.e. without machining the cross-section.

1.3.4 For plates, strips and sections, flat tensile specimens conforming to EN 10002, Part 1 or as shown in Figure 2.2 are to be used by preference. In these cases the rolled surface of the metal shall be preserved. Where, in testing heavy plate thicknesses, the tensile loading capacity of the machine is insufficient, the thickness of the specimens may be reduced by machin-ing one side to not less than ½ of the product thickness.

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Fig. 2.2 Flat tensile specimens

Otherwise round tensile specimens conforming to Fig. 2.1 are to be used, for which the following is to be observed:

In the case of products with a thickness of > 40 mm, round tensile specimens as prescribed in 1.3.2 may also be used. The specimens shall then be taken from the sample in such a way that their axis is located at 1/4 of the product thickness measured from one face or as close as possible to this position.

1.3.5 In the case of pipes, the tensile test may be performed on a sufficiently long section of the entire pipe. To enable the specimen to be secured in the test machine, mandrels have to be inserted into the pipe ends, cf. Figure 2.3, specimen shape E, or the pipe ends have to be pressed flat. Where the pipe diameter pre-cludes testing a length of the entire pipe, tensile speci-mens of shape F are to be taken from the pipe wall.

Where the wall thickness of the pipe is sufficient, cylindrical specimens as prescribed in 1.3.2 may also be used. The specimens shall then be taken from the sample in such a way that their axis is located at the mid-point of the wall thickness.

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D

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Fig. 2.3 Tensile specimens for pipes

In the case of large pipe diameters, flat or cylindrical specimens perpendicular to the pipe axis may also be taken.

To this end the test length may not be pressed flat, but the wider ends may be pressed flat to enable the speci-men to be secured in the specimen device of the test-ing machine-

1.3.6 For grey cast iron, test specimens as shown in Figure 2.4 are to be used. These shall be taken from a separately cast cylindrical test bar with a casting di-ameter of 30 mm.

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Fig. 2.4 Tensile specimen for grey cast iron

1.3.7 Tensile specimens which have their axes vertical to the product face (Z-specimens) are to be prepared as described in Chapter 2 – Steel and Iron Materials, Section 1, I.3.

1.3.8 Aluminium alloys

For aluminium alloys with product thickness including 12,5 mm flat tensile specimens are to be used. The specimens shall be prepared in such a way that both rolled/pressed surfaces shall be preserved. For product thicknesses exceeding 12,5 mm round tensile speci-mens may be used. For product thicknesses up to and including 40 mm the longitudinal axis of the round tensile specimen shall be located at ½ of the product thickness measured from face. For product thickness measured from on face. For product thicknesses ex-ceeding 40 mm the longitudinal axis of the round tensile specimen shall be located at ¼ of the product thickness measured from one face.

1.3.9 Tensile specimens for wire ropes, single wires and strands are to be performed in accordance with Chapter 4 – Equipment, Section 3, E. Specimens containing the entire section and the following dimen-sions are to be tested:

o

c o

L 200 mm

L L 50 mm

=

= +

1.4 Tolerances

The manufacturing tolerances for specimens shall meet the requirements of ISO 6892-84 or other recognised standard.

2. Performance of tests

Tests shall be performed in accordance with estab-lished standards. This category includes, for example:

EN 10002, Part 1 Tensile Testing

3. Determination of test results

Using the symbols and units of measurement stated below, the test results shall be determined as fol-lows:

3.1 Yield strength ReH

Generally, the upper yield point ReH [N/mm2] 1 has to be determined. This corresponds to the maximum stress preceding the initial drop in tensile load as the elongation increases. For determining the yield point at room temperature, the rate at which the stress is increased shall be not be less than 6 N/mm2 per

–––––––––––––– 1 [N/mm2] = [MPa]



D

second and may not exceed 30 N/mm2 per second for steel. For non-ferrous metals the rate at which the stress is increased shall not be less than 2 N/mm2 per second and may not exceed 10N/mm2 per second. The test result shall be stated accurate to 1 N/mm2.

3.2 Proof stress Rp

In the case of materials without a marked yield point, the proof stress Rp [N/mm2] shall be determined. Gen-erally, the 0,2 % proof stress Rp 0,2 shall be specified. For austenitic steels as well as austenitc-ferritic (= duplex) steels, the 1 % proof stress Rp 1,0 may be stated instead of, or in addition to, Rp 0,2. The rate of loading and the indication of the results shall be as stated in 3.1.

3.3 Tensile strength Rm

In determining the tensile strength Rm [N/mm2], the rate of elongation, once the yield point or proof stress has been passed, shall not with ductile materials ex-ceed a maximum of 40 % per min.. With brittle mate-rials, e.g. grey cast iron, the rate of stress increase may not exceed 2,5 N/mm2 per second. The test result shall be stated accurate to 1 N/mm2.

3.4 Elongation A

It not otherwise stated, this relates to short propor-tional test specimens with Lo = 5,65 oS and then is

named as A [%]. For test specimens whose gauge length bears a different relationship to the cross-section of the test specimen, the required elongation Ar shall comply either with the minimum values specified for the products in question (e.g. for a gauge length Lo = 200 mm), or with the minimum value calculated by applying the following formula:

2 5o

ro

SA 2 A

L

⎛ ⎞⎜ ⎟= ⋅ ⋅⎜ ⎟⎝ ⎠

This conversion formula may only be used for ferritic steels with a strength of ≤ 700 N/mm2 which have not been cold formed, cf. also ISO 2566.

The value for the elongation is valid if the distance of the fracture from the gauge marks is at least 1,25 times the diameter for round tensile specimens or at least the sum of the width and the thickness in the case of flat tensile specimens.

The result of the test shall be stated to an accuracy of 0,5 %. If the elongation is not determined using short proportional test specimens, then the gauge length [mm] shall be stated in the test certificate, e. g. A200 mm = elongation for initial gauge length Lo = 200 mm.

3.5 Reduction in area Z

The reduction in area at fracture Z [%] shall be deter-mined only where this is called for in the following sections of the Rules for Materials.

[ ]o u

o

S SZ 100 %

S

⎛ ⎞−= ⋅⎜ ⎟

⎝ ⎠

The test result shall be stated to an accuracy of 1 %.

E. Notched Bar Impact Tests

1. General

1.1 As specified for the product in question, notched bar impact tests are to be performed either on Charpy V-notch specimens to ISO 148 (EN 10045 Part 1), or on Charpy U-notch specimens to ISO 83 (EN 10045 Part 1), see Figures 2.5 and 2.6.

1.2 Unless otherwise agreed, for products with a thickness of < 10 mm smaller dimension specimens with a specimen width of 7,5 or 5 mm are to be tested. In the case of products with thicknesses of < 6 mm, the notched bar impact test is generally not required.

The longitudinal axis of the notch shall be made per-pendicular to the surface of the product.

2. Dimensions of test specimens

Test specimens shall be machined to the dimensions shown in Figure 2.5 or 2.6 and those stated in Table 2.2.

The data given in Table 2.2 should be regarded as being the permitted tolerances for the specimen di-mensions.

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Fig. 2.5 Charpy V-notch specimen

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Fig. 2.6 Charpy U-notch specimen

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Table 2.2 Permitted tolerances of specimen dimensions

V-notch specimen U-notch specimen Dimensions

Normal size Tolerance Normal size Tolerance

Length of specimen Thickness of specimen

55 mm 10 mm

± 0,60 mm ± 0,06 mm

55 mm 10 mm

± 0,60 mm ± 0,11 mm

Width of specimen:

– Normal specimen – Sub-size specimen – Sub-size specimen

10 mm 7,5 mm 5 mm

± 0,11 mm ± 0,11 mm ± 0,06 mm

10 mm –– ––

± 0,11 mm –– ––

Notch angle 45° ± 2° –– ––

Thickness at base of notch 8 mm ± 0,06 mm 5 mm ± 0,09 mm

Notch radius 0,25 mm ± 0,025 mm 1 mm ± 0,07 mm

Distance of notch centre from ends of specimen 1 27,5 mm ± 0,42 mm 27,5 mm ± 0,42 mm

Angle between plane of symmetry of notch and longitudinal axis

90° ± 2° 90° ± 2°

Angle between adjacent longitudinal faces 90° ± 2° 90° ± 2°

1 For pendulum impact testing machines which have automatic specimen positioning, a tolerance of ± 0,165 is recommended rather than ± 0,42.

3. Test machine

Wherever possible, use shall be made of a pendu-lum impact testing machine with an impact energy of 450 J or 300 J (in any case not less than 150 J) and an impact velocity of 5 to 5,5 m/s. The test ar-rangement is shown in Figure 2.7, with the character-istic quantities of the test machine being given in Table 2.3.

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Fig. 2.7 Notched bar impact test

Table 2.3 Characteristic quantities of test machine

Dimension Requirement

Clear spacing between supports ( )0,2040 mm+

Radius of curvature of supports ( )0,501 mm+

Undercut of supports 11 1° ± °

Angle of peen wedge 30 1° ± °

Radius of curvature of peen cutter ( )0,5

02 mm+

Maximum thickness of pendulum face

18 mm

Striking velocity of pendulum 5 to 5,5 m/s 1

Angle between supports and bearing 90° ± 0,1°

1 For pendulum impact test machines built before 1983 a value of 4,5 to 7 m/s may be agreed.



E

4. Performance of test

4.1 Impact tests using U-notch specimens should

generally be performed at room temperature (23 ± 5) °C. Impact tests on V-notch specimens shall be performed at room temperature or at a lower test temperature, accord-ing to specification. With test temperatures below room

temperature, the temperatures of the specimens are to be

carefully checked. At the moment of fracture they may

not vary from the prescribed test temperature by more

than ± 2 °C. If the specimens are cooled by placing them

in a bath, they shall remain there for at least ten minutes.

4.2 A test is regarded as being performed under normal conditions when the working capacity of the pendulum impact test machine is (300 ± 10) J and when a standard specimen is used. The following abbreviations are assigned to the notch impact energy value which is established under these conditions:

– KV for a V-notch specimen

– KU for a U-notch specimen

5. Determination of test results

5.1 Using the symbols shown below, the energy absorbed by the impact shall be normally stated in joules (J), accurately rounded to 1 J.

Where the test is conducted other than at room tem-perature, this shall also be stated.

5.2 If required, the crystalline proportion of the fracture surface and/or the lateral expansion at the point of fracture shall also be determined.

The crystalline proportion of the fracture surface shall then be estimated and expressed as a percentage of the total area of the fracture. The lateral expansion shall be measured to an accuracy of 0,01 mm on the side oppo-site the notch (cf. also DIN 50115 and ASTM A 370).

F. Technological Tests on Pipes

1. Pipe flattening test

1.1 To perform this test, a section of pipe equal in length to 1,5 times the pipe diameter, but not less than 10 mm and not more than 100 mm, is flattened between two plates to the prescribed distance H, see Chapter 2 – Steel and Iron Materials, Section 2, A.8.5 or until fracture occurs, see Figure 2.8. In the case of welded pipes, the specimen shall be placed in the press in such a manner that the seam is set at 90° to the direction of the pressure, unless agreed otherwise.

1.2 After the test, the specimens shall be thor-oughly examined for defects with normal visual acu-ity. The test shall be satisfactory if the specimen, hav-ing been flattened to the prescribed distance, is free from cracks and did not fracture.

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Fig. 2.8 Pipe flattening test

The dimensions of the pipe section, the distance H between the flattening plates as well as the position of the welding joint are to be stated.

Examples of applicable standards:

EN 10233 Pipe Flattening Test or ISO 8492

2. Ring expanding test

2.1 To perform this test, sections of pipe measur-ing 10 to 16 mm in length L are expanded to the pre-scribed diameter C or until fracture occurs using a drift with a taper of about 1:5. Where necessary, more than one test shall be performed with drifts of increasing dia-meter. The superimposition of several specimens of the same size and steel grade is permitted, see Figure 2.9.

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Fig. 2.9 Ring expanding test

The intrusion rate of the mandrel may not exceed 30 mm/s.

C = Diameter after the the prescribed expansion

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The dimensions of the pipe sections, the outer diame-ter C of the expanded part of the pipe section or the relative expansion [%], as well as the ratio of the taper (if not 1:5) are to be stated.

Examples of standards to be applied:

EN 10236 Ring Expanding Test on Pipes or ISO 8495

2.2 After the test, the specimens shall be thor-oughly examined for defects with normal visual acu-ity, and the ductility of the pipes shall be assessed by reference to the expansion achieved and, where appli-cable, to the appearance of the fracture surface.

The test shall be satisfactory if the specimen reveals no unacceptable defects such as scabs, laps, cracks, grooves or laminations and if the prescribed expansion has been reached.

3. Ring tensile test

3.1 The sections of pipe measuring about 15 mm in length shall have plane and smoothed ends and shall be at right angle to the pipe axis. To perform this test, the pipe sections are stretched in a tensile testing ma-chine until fracture occurs using two pins with a di-ameter equal to at least three times the wall thickness of the pipe, see Figure 2.10. In the case of welded pipes, the specimen shall be placed in the tensile test-ing device in such a way that the welded seam lies at 90° to the direction of the tensile load.

The rate of the pins may not exceed 5 mm/s.

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Fig. 2.10 Ring tensile test

3.2 After the test, the specimens shall be thor-oughly examined for defects with normal visual acuity.

The test shall be satisfactory if the specimen reveals no unacceptable defects such as scabs, laps, cracks, grooves or laminations and if visible deformation has occurred at the point of fracture.

The dimensions of the pipe sections are to be stated.

Example of standards to be applied:

EN 10237 Ring Tensile Test on Pipes or ISO 8496

4. Drift expanding test

4.1 To perform this test, a tapered drift is forced into the specimen until the outside diameter has in-creased to the prescribed value C for the product in question, see Figure 2.11. The length of the specimen and the taper angle β of the drift shall be as shown in the following Table. The intrusion rate of the taper may not exceed 50 mm/s.

4.2 After the test, the specimens shall be thor-oughly examined for defects with normal visual acu-ity. The test shall be satisfactory if the prescribed expansion has been effected without cracks.

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Fig. 2.11 Drift expanding test

C = Diameter after the prescribed expansion

The dimensions of the pipe section, the outer diameter C of the expanded part of the pipe section or the rela-tive expansion [%], as well as the taper angle are to be stated.


EN 10234 Drift Expanding Test on Pipes or ISO 8493

5. Flanging test

5.1 To perform this test, a sample of pipe with a length L = 1,5 D is worked into a flange in the device shown in Figure 2.12 until the outer diameter C of the flange attains the value prescribed for the product.

The radius r shall match that prescribed for the product.

The intrusion rate of the tool may not exceed 50 mm/min.



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Fig. 2.12 Flanging test

5.2 The test shall be satisfactory if the flange has no apparent cracks. Minor defects on the edges can be disregarded.

The dimensions of the pipe section, the outer diameter C of the expanded part of the pipe section or the rela-tive expansion [%], as well as the edge radius of the forming tool r are to be stated.


EN 10235 Flanging Test on Pipes or ISO 8494

G. Instructions for the Bend Test, Hardness Test and Drop Weight Test

1. Technological bend test

1.1 For this test, specimens with thickness a and width b are to be prepared, the edges of which may be rounded on the tension side to a radius of 1 – 2 mm. For plates and sections the specimen thickness a is equal to the product thickness t. For product thick-

nesses t exceeding 25 mm the thickness may be re-duced by machining the compression side of the bend specimen to not less than 25 mm.

For product widths smaller than or equal to 30 mm the specimen width b shall be equal to the product width. For product widths exceeding 30 mm the specimen width b = 30 – 50 mm.

For forgings, castings and semi-finished products the specimen thickness shall be a = 20 mm and the speci-men width b = 25 mm.

1.2 For butt-welded joints the bend specimens at right angle to the weld joint shall have the following dimensions for verification of the final pass and the root pass:

– a = t

– b = 30 – 50 mm

For side bend specimens the following dimensions do apply:

– a = 10 mm

– b = t

For t ≥ 40 mm the side bend specimen may be split, with the width of each part being at least 20 mm.

For bend specimens with longitudinal direction to the joint the dimensions shall be in accordance with gen-erally accepted standards.

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Fig. 2.13 Technological bend test

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1.3 To perform this test, the test specimen is bent in a continuous operation as shown in Figure 2.13 and using a mandrel of specified radius D/2 until the pre-scribed bending angle α is reached or the initial in-cipient fracture occurs. For normal strength steels D/2 = 2 ⋅ a, for higher strength steels D/2 = 3 ⋅ a. The test shall be satisfactory if the prescribed bending angle is achieved without incipient fracture. If, when the specimen is unclamped, it springs back, the bend-ing operation need not be repeated.

Example of standard to be applied:

ISO 7438 Metallic materials - Bend Test

2. Hardness tests

2.1 The tests are to be performed, according to specification, to determine the Brinell, Vickers or Rockwell hardness using standardized methods, see for example:

ISO 6506 Brinell Hardness Test

ISO 6507 Vickers Hardness Test

ISO 6508 Rockwell Hardness Test

2.2 Hardness tests shall not be considered a substi-tute for the tensile test. Brinell hardness tests may, how-ever, be permitted for the purpose of comparing me-chanical properties provided that, of several products of the same shape, grade of material and heat treatment, at least one has been subjected to the tensile test.

3. Pellini drop weight test

3.1 This test shall be performed in accordance with Stahl-Eisen-Prüfblatt 1325 (Iron and Steel Test Specification 1325), EN 10274, or ASTM-E208 on

steels with product thicknesses of ≥ 16 mm. The specimen shape will be chosen which most closely matches the product thickness accordingly to Table 2.4.

Table 2.4 Specimen dimensions for drop weight test

Specimen shape Dimensions

[mm]

P1

P2

P3

360 × 90 × 25

130 × 50 × 19

130 × 50 × 16

The correct specimen thickness shall be achieved by machining one side.

The long sides of the test specimens shall be made with a saw cut or, in the case of specimens obtained by thermal cutting, shall be machined with a machin-ing allowance of at least 25 mm.

3.2 At least 2 test specimens shall be prepared from the sample. The position of the longitudinal axis

of the specimens in relation to the main direction of deformation of the product is optional, but shall be the same for the set of specimens. Where the testing is performed by heats, specimens shall be taken from the thickest product.

3.3 Specimens shall be tested at the specified test temperature. The test shall be considered satisfactory if neither of the two specimens is fractured or if incipient cracks starting from the weld bead terminate in the parent metal and do not extend to one or both edges.

Where one or both specimens fail to satisfy the afore-mentioned conditions, a retest may be carried out in accordance with H.4.

3.4 Where drop weight tests are to be performed on products other than those specified in 3.1 or as part of approval tests, the scope of the test shall be spe-cially agreed with GL.

H. Retests

1. General

1.1 If the test sections or specimens specified for a test are not properly taken and prepared, the test results obtained with them shall be invalid. The tests shall then be repeated on properly prepared test specimens.

1.2 If, in a properly performed test, the require-ments are not met, then, before the corresponding unit test quantities are rejected, retests may be carried out subject to the conditions stated below. Retests are not allowed if it is suspected that the wrong material is concerned.

1.3 If the unsatisfactory result of a test is due to obvious defects in the execution of the test or to a nar-rowly defined fault in the test specimen, the result shall be disregarded and the test in question shall be repeated on a test specimen of the same type which shall be taken from the same test section. This also applies to tensile specimens which, when tested, fracture outside the valid measuring length as defined in D.3.4.

1.4 If the unsatisfactory result of a test is attribut-able to improper heat treatment of the products, they may be resubjected to heat treatment. Subsequently the entire test shall be repeated, and the original test result shall be disregarded.

1.5 The manufacturer may also follow the proce-dure described in 1.4 in the case of those products which, according to the specifications, may be sup-plied without heat treatment but which have failed to meet the requirements in this condition.

1.6 If, under test, a large proportion of the prod-ucts fails because of constantly recurring manufactur-ing defects, the entire delivery may be rejected.



H

2. Unsatisfactory tensile test specimens (ex-cluding pipes)

2.1 Individual tests

For each unsatisfactory tensile specimen, two substi-tute specimens shall be tested, which shall be taken from the same test section as the original specimen, or from the same sample. In every case, both specimens shall satisfy the requirements.

2.2 Testing by heats or batches

The manufacturer shall have the option of separating the sample which has yielded unsatisfactory results or of continuing to treat it as part of the unit test quantity.

If the sample in question is separated, then, for each unsatisfactory tensile specimen, two substitute speci-mens shall be tested which shall be taken from differ-ent samples of the unit test quantity.

If the sample in question continues to be treated as part of the unit test quantity, one of the retests shall be performed on this sample and the other on a different sample.

Both retests shall satisfy the requirements.

3. Unsatisfactory impact test specimens (ex-cluding pipes)


If the average value of 3 impact test specimens fails to satisfy the requirements or if a single value is less than 70 % of the stipulated average value, 3 substitute specimens shall be taken from the same test section and tested. The average value of the 6 individual tests shall then meet the requirements. However, of the 6 individual values only 2 may be below the required average value, of which only one individual value may be less than 70 % of the prescribed average value, failing which the sample in question shall be rejected.

3.2 Testing by heats or batches

If the average value of 3 impact test specimens fails to satisfy the requirements or if a single value is less than 70 % of the stipulated average value, then the procedure described in 3.1 shall be applied initially.

If the retest also produces an unsatisfactory result, the sample tested shall be rejected and two further sam-ples, of the same or the next smaller thickness, from the same unit test quantity shall be tested.

If, again, one of the samples fails to satisfy the re-quirements, then the entire unit test quantity shall be

rejected. With the consent of the Surveyor, the re-maining sample quantities in the unit test quantity may, however, be subjected to testing piece by piece.

4. Unsatisfactory drop weight test specimens


If one or both of the two test specimens fail(s), two similar substitute specimens may be taken from the same sample and tested. Both substitute specimens shall satisfy the requirements. If they fail to do so, the relevant sample shall be rejected.

4.2 Testing by heats

If one or both of the two test specimens to be taken from the thickest sample of the heat fail(s), then, from the same sample and from a different sample of the same thickness - or, if not available, from the next smaller thickness - two specimens of the same type each shall be taken and tested. All four specimens shall satisfy the requirements. If they fail to do so, then the relevant heat shall be rejected.

With the consent of the Surveyor, the remaining sam-ple quantities in the rejected heat may, however, be subjected to individual testing.

5. Unsatisfactory results in the testing of pipes

5.1 Testing by batches

If, when subjected to the tensile test, the ring test or the notched bar impact test, pipes fail to satisfy the requirements, the test which has produced the unsatis-factory results shall be repeated on the same end of the pipe selected for the test. If the new test fails to satisfy the requirements, the pipe in question shall be dis-carded. In its place two further pipes shall be taken from the batch concerned and shall be subjected to the full range of tests. If, during testing, one of the re-quirements is not met, then the entire batch shall be deemed unacceptable.

However, with the consent of the Surveyor, the char-acteristic which failed to meet the requirements may be checked on each individual pipe.

6. Retesting specified in standards

Where a national or international standard specifies a wider scope for the performance of repeat tests; this shall take precedence over the retests described in 5.1.

II - Part 1 GL 2009


H

Section 3

Non-Destructive Testings

A. General Items

1. This Section contains general Rules applica-ble to the performance of non-destructive tests at semi-finished products and components intended for the installation in ships classed with GL.

2. Type and scope of the non-destructive testings prescribed for the individual products are stated in the appropriate sections.

B. Standards and Regulations

1. The standards and regulations indicated in the specific sections are integral part of these Rules and have to be observed when performing the non-destructive testing.

2. Testings according to other comparable stan-dards or regulations require prior consent of GL. For this they shall be submitted to GL for assessment and approval before starting the testing.

3. The manufacturer or purchaser shall state all details of the testing in a testing instruction or specifi-cation and deliver it to the GL-Surveyor before start-ing the testing.

C. Requirements Applicable to the Inspection Body

1. For performing non-destructive testings the manufacturer shall set up a qualified inspection body which is independent of the manufacturing depart-ments and part of a manufacturing site certified ac-cording to ISO 9001, or which is accredited according to ISO/IEC 17025.

2. The inspection body shall have available the necessary regulations, testing specifications, testing equipment, accessories and, if required, comparators for the surface finish of castings.

3. If the manufacturer has no inspection body available, he shall demonstrate which external inspec-tion body will perform the testings on his behalf if necessary.

This external inspection body shall be accredited ac-cording to ISO/IEC 17025 or shall be part of a manu-facturing site certified according to ISO 9001.

D. Inspection Personnel, Supervisors

1. Inspection personnel

1.1 The inspection personnel charged with the non-destructive testing shall be familiar with the test method concerned and shall be qualified and certified to EN 473.

1.2 For the evaluation of results of non-destructive tests only such inspection personnel shall be charged that holds level-2 certificates for the test method concerned which were issued:

– by an independent certification authority accord-ing to EN 473 or ISO 9712

– by the employer of the inspection personnel according to ASNT "Recommended Practice No. SNT-TC-1A"

2. Inspection supervisors

For scheduling and monitoring the testings and for evaluating the results an inspection supervisor quali-fied at least according to 1.2 shall be available.

The inspection supervisor shall hold as far as possible a level-3 certificate for the test method concerned according to the Rules indicated in 1.2.

E. Test Methods, Equipment and Test Media

1. Test methods

For detecting surface and/or volumetric discontinuities in the components indicated in A.1. the test methods from Table 3.1 or combinations of them shall be em-ployed in dependence of the material, the geometry of the component, the expected service condition and the possible flaw position.

II - Part 1 GL 2009

Section 3 Non-Destructive Testings Chapter 1Page 3–1

E

Table 3.1 Test methods

Testing of Method Short name 1

Visual testing VT

Magnetic particle testing MT

Eddy current testing ET

external condition

Penetrant testing PT

Ultrasonic testing UT

Radiographic testing RT internal

condition

Leakage testing LT

1 Definition according to DIN EN 473.

2. Equipment and test media

2.1 The equipment and test media used shall conform to the state of art and the relevant standards and shall be in perfect, serviceable condition.

The Surveyor shall be presented by request proof of internal and/or external monitoring of the equipment and the test media.

2.2 If testing facilities, equipment and inspection personnel of external inspection bodies are engaged the workshop in question has to ensure that the condi-tions according to C. and D. are fulfilled.

F. Preparation and Performance of Tests

1. Preparation of tests

The surfaces that will be tested shall be free of rem-nants of the moulding material, scale, grease, dirt, protective coatings and other contaminations which may affect the indication sensitivity of the specific test methods.


2.1 As a rule the prescribed tests shall be per-formed by the inspection personnel of the inspection body of the manufacturer or of the external body charged with the inspection.

The specific components that will be tested shall be subjected to the Surveyor in final machined condition for the visual testing.

2.2 In case ultrasonic (UT) and or surface crack detecting (MT, PT) shall be performed by the GL Surveyor a special agreement is required.

2.3 The Surveyor shall be informed by the manu-facturer of the works performing the further process-ing about the planned non-destructive testings in time. He will attend the testings in his discretion.

G. Certification of Test Results

1. Inspection reports shall be prepared on all performed tests, and these shall be submitted to the Surveyor together with the further documentation (e. g. NDT plans, film position plans, radiographs).

The inspection reports shall contain all the necessary details according to I. to L. relating to the particular test method used, the position at which the test was performed and the results obtained.

2. The inspection department shall attest the test results by means of inspection certificate according to EN 10204-3.1.

H. Visual Testing (VT)

1. The surfaces of the components that shall be subjected to testing shall be at least in the condition specified in F.1. or in the final machined condition.

2. Of the components that shall be tested the entire surfaces shall be visually tested. In doing so internal surfaces such as e.g. bore holes shall be in-cluded in the tests.

3. For performing visual testing optical magni-fying devices, endoscopes or surface comparators shall be employed if necessary.

Specifications concerning testing criteria are contained in the appropriate specific sections of Chapter 2 to 5.

4. The manufacturer or the company performing further processing shall arrange that testing can be performed with adequate illumination.

The viewing conditions shall be in accordance with the requirements of ISO 3059 or EN 13018.

Light and surface reflections shall be avoided by ap-propriate means.


Section 3 Non-Destructive Testings II - Part 1GL 2009

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I. Magnetic Particle Testing (MT)

1. Magnetization equipment and method

1.1 The surfaces of the components that shall be subjected to testing shall be at least in the condition specified in F.1. or in the final machined condition.

1.2 The stationary or portable equipment for magnetic particle testing shall be in accordance with the state of art for testing and with the standards ISO 9934-1, ISO 9934-2 and ISO 9934-3 or with other standards which are equivalent to these standards.

1.3 The choice of the method of magnetization and of the current for magnetization depends on the geometry of the component and on the type of surface defect to be detected (cracks, inclusions that are lying open towards the surface or inclusions close towards the surface).

1.4 If possible, magnetization shall be effected by passing a current through the workpiece and/or by yoke magnetization using alternating or direct current.

1.5 Where a current is passed through the work-piece, alternating, direct, impulse or surge current may be used. A combination of the aforementioned methods for the detection of variously orientated defects is allowed.

2. Test media

2.1 Suspensions consisting of a carrier liquid (test oils or water with inhibitors) and dispersed mag-netic particles (black or fluorescent) shall be used as test media.

Only such test media shall be used that conform to the requirements of ISO 9934-2.

2.2 Before magnetic particle testing is com-menced the inspector shall verify the test media by means of suitable reference blocks according to ISO 9934-2 and shall prove this to the Surveyor by request.

Note

– Reference blocks 1 and 2 according to ISO 9934-2

– JIS-test block according to JIS Z 2343

3. Performance of magnetic particle testing

3.1 Manual testing

In order to reveal variously orientated defects the magnetization shall be effected in a crosswise manner in two different directions. The angle of the both di-rections for magnetization should be in the range from 60° to 90°. The magnetizing field strength (effective tangential field strength) should be at least 2 kA/m but should not exceed 6 kA/m.

3.2 Mechanized testing

When mechanized testing is performed the conditions stated in 3.1 shall be provided by an adequate choice or combination of magnetization currents and meth-ods.

3.3 When burn marks on final machined surfaces have to be avoided then for the magnetization by means of prods with alternating current only fusible supply electrodes made of tin-aluminium alloys shall be employed.

3.4 Testing of machinery components in the final machined condition shall preferably be performed by stationary appliances. The appliances for magnetizing employed for this shall fulfil the requirements of ISO 9934-3 or another equivalent standard. On demand of the Surveyor the parameters of magnetization stated in 3.1 shall be proved by the manufacturer by means of measurement of the effective tangential field strength or by means of "Berthold" test blocks.

4. Applying of test media, magnetization

The suspension containing the magnetic particles shall be applied on the surface to be tested by spraying or wetting. When doing so the magnetization shall last at least that long as the surface to be tested is sprayed with the magnetic particle suspension; subsequently magnetization shall be performed (at least 5 seconds) until no movement of the magnetic particle suspension can be detected. Testing when remanence is present (residual magnetism in the component) is not allowed.

5. Illumination of testing surfaces

In order to obtain an adequate contrast of test surface and indication the following requirements according to ISO 3059 for the light intensity and the UV inten-sity shall be fulfilled and shall be proved on the test surface with adequate and verified measuring devices, e.g. luxmeter or UV intensity meter.

The UV intensity on the test surface shall be not less than 10 W/m2, the maximum ambient light intensity shall be 20 Lux.

6. Certification of testing results

The manufacturer or the inspection body charged by him shall issue a certificate concerning the performed magnetic particle test containing at least the following information:

– name and address of the inspection body (for external inspection bodies)

– details concerning the accreditation or the ap-proval of the inspection body

– testing specification to be applied and/or testing instructions

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– details of the component such as:

– order no.

– material designation

– heat no.

– specimen no.

– machining condition

– surface condition

– testing scope, inspection zones, severity levels

– type of magnetization, e.g. according to ISO 9934-3

– test equipment, test media, test blocks

– proof of the magnetization by means of meas-urement of the effective tangential field strength

– declaration of the inspection zones and accep-tance criteria

– time of testing

– evaluation of test results

– place and date of testing

– name of the inspector, the inspection supervisor and their qualifications

The aforementioned details may also be certified by means of works instructions of the manufacturer.

They above and the test certificate shall be submitted to the Surveyor together for assessment and acknowl-edgement.

Specifications for the aforementioned acceptance and assessment criteria are contained in the appropriate specific sections of Chapter 2 to 5.

J. Penetrant Testing

1. Testing is to be performed with a testing agent system consisting of penetrant remover, pene-trant and developer in accordance with EN 571-1 or other recognized standards. The employed equipment for this shall fulfil the criteria of ISO 3452-4.

2. Test media and their verification

2.1 The testing agent system required for pene-trant testing shall fulfil the requirements of ISO 3452-4 or of another recognized standard.

2.2 Before penetrant testing is commenced the suitability of the testing agent system is to be verified by means of test blocks e.g. according to ISO 3452-4 and is to be proven on demand to the Surveyor.

3. Performing penetrant testing

3.1 Before testing is commenced the manufac-turer or orderer shall submit to the Surveyor test in-structions fulfilling at least the requirements listed in the following.

3.2 Pre cleaning of test surface

The surface to be tested shall correspond to the re-quirements specified in F.1. and shall be cleaned com-pletely with a cleaner adequate for the testing agent system before testing is commenced.

Specifications concerning the surface areas for which testing is required are contained in the appropriate specific sections of Chapter 2 to 5.

3.3 Testing temperature

As a rule the temperature of the surfaces to be tested shall be between + 5 °C and + 50 °C. For lower tem-peratures pre heating of the test area shall be per-formed on an extensive surface by which the test area achieves the permitted temperature range from + 5 °C and + 50 °C.

3.4 Applying the penetrant

The penetrant may be applied by spraying, brushing or electrostatic spraying depending on the shape and size of the surface or of the geometry of the component to be tested. The test surface shall be completely wetted throughout the entire penetration time.

3.5 Penetration time

The penetration time depends on the properties of the penetrant, testing temperature, the material of the component to be tested and the type of discontinuities that are to be detected and should last from 5 to 60 minutes.

3.6 Intermediate cleaning

Following penetration, the surplus penetrant shall be completely removed in an appropriate manner from the test surface in such a way as to leave behind the penetrant lodged in any defects present.

3.7 Developing process

The developer is to be applied evenly and as thinly as possible immediately after intermediate cleaning and drying. The test surface should just be completely covered.

The developing time should be at least of the same as the time allowed for penetration.

The evaluation of the indications shall not start before the developing time has expired.



J

4. Illumination of the test surfaces

The test surfaces shall be illuminated adequately and reflection of light from already machined surfaces are to be avoided.

Precondition for an adequate evaluation of the indica-tions are the requirements for illumination specified in I.5.

5. Testing criteria, evaluation of indications

Discontinuities exceeding the prescribed acceptance criteria by size and quantity as well as cracks of every type are not permitted.

Specifications for the evaluation of indications are contained in the appropriate specific sections of Chap-ter 2 to 5.

6. Cleaning of the test surfaces

After completion of penetrant testing any residuals of the test media shall be removed of the test surfaces. For this a cleaning agent shall be used that corre-sponds to the prior employed testing agent system and which will not have any effect on the further process-ing of the component.

7. Certification of test results

The manufacturer or the inspection body charged by him shall issue a certificate concerning the performed penetrant test containing at least the following infor-mation:



– testing specification to be applied and/or testing instructions


– order no.


– heat no.

– specimen no.

– machining condition

– surface condition

– testing scope, testing areas, severity levels

– employed testing agent systems according to EN 571-1, test blocks according to ISO 3452-3

– declaration of the inspection zones and accep-tance criteria

– time of testing

– evaluation of test results



The aforementioned details may also be certified by means of works instructions of the manufacturer.

They and the test certificate shall be submitted to the Surveyor together for assessment and acknowledge-ment.

K. Ultrasonic Testing (UT)

1. Methods

1.1 Ultrasonic testing is to be performed with the impulse echo technique in accordance with recognized standards. Such are e.g. EN 12223, EN 27963, EN 12668-3, EN 583-1, EN 10228-3, EN 10160 and EN 12680-1.

Other national or international standards may be ap-plied if they provide an equivalent method.

1.2 The methods described here relate to the testing of components and machinery constructions made of ferritic steels. For testing of components made of austenitic or austenitic-ferritic steels special agreements are to be made.

1.3 Alternatively ultrasonic testing may be per-formed according to the test instructions of the manu-facturer or of the orderer on condition that an equiva-lent test can be achieved.

2. Test specification

2.1 The manufacturer or the orderer shall prepare a test specification which shall contain at least the following information:

– state of machining for pre and final testing

– test method, type of test equipment, type of probes, testing frequencies

– calibration of equipment

– surface condition depending on the manufactur-ing stage, surface roughness (if necessary)

– position of incidences, if necessary explained by means of sketches

– heat treatment condition depending on the manufacturing stage

– determination of testing areas in accordance with the requirements specified in Chapter 2 – Steel and Iron Materials, Section 3 or 4

– evaluation criteria for the specific testing areas and severity levels, respectively

– indication of other applicable standards and regulations

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3. Test appliances and accessories

Ultrasonic testing appliances and probes shall comply with the state of the art and with recognized stan-dards 1 and shall fulfil at least the following require-ments:

3.1 Requirements for the test equipment

– The ranges of adjustment shall enable the range of at least 20 mm up to 2 m without any inter-vening gap for longitudinal and transverse waves in steel.

– The amplification shall be adjustable for a range up to at least 80 dB with switching stages of 2 dB, the accuracy shall be 1 dB.

– The linearity of the time sweep and the vertical linearity shall be better than 5 % of the adjust-ment range or of the screen.

– The test equipment shall be applicable for probes from 1 to 6 MHz nominal frequency for impulse echo technique with straight or SE (twin transducer) probes.

3.2 Requirements for the probes

3.2.1 The selection of the probes concerning the nominal frequency and the transducer size depends on the size of the disc-shaped reflector to be detected, the sound path travel distance and the sound attenuation of the material to be tested.

3.2.2 Depending on the geometry of the component and the type and position of discontinuity to be de-tected straight beam probes and/or angle probes are to be employed; for testing of regions close to the surface SE straight beam probes shall be employed.

3.2.3 For oblique scanning probes with angle of incidence between 35° and 70° shall be employed. Their nominal frequency shall be between 1 and 6 MHz.

4. Calibration blocks

For verification of the inspection system calibration blocks type 1 according to DIN EN 12223 and calibra-tion blocks type 2 according to DIN EN 27963 or other adequate calibration blocks with reference re-flectors are to be used.

5. Coupling media

For inspection the oils, greases or other adequate cou-pling media recommended by the manufacturer of the equipment shall be used preferably.

For calibration of the equipment the same coupling medium shall be used.

–––––––––––––– 1 Recognized standards are e.g. EN 12668-1, EN 12668-2 and

EN 12668-3.

6. Performing ultrasonic testing

Ultrasonic testing of machinery parts is to be per-formed in accordance with the method, standards and regulations specified in 1.1 and/or according to speci-fications of the manufacturer or the orderer.

6.1 Calibration of the inspection system

6.1.1 Calibration of the distance

The calibration of the distance is to be performed at the calibration block type 1 in accordance with EN 12223 or at the component.

The inspection range shall be selected in such a way that the back wall echo of the component thickness to be tested will appear at 80 % of the screen width.

6.1.2 Calibration of sensitivity

Calibration of sensitivity shall be adjusted in such a way that indications to be registered are not smaller than 2/5 of the screen height at the end of the inspec-tion range.

The signal-to-noise ratio based on the registration level shall be at least 6 dB.

Deviations of these specifications may be agreed on by the orderer and/or manufacturer and GL in techni-cally justified exceptional cases.

6.2 Scanning of the test area and testing veloc-ity

6.2.1 Scanning of the test area

In case scanning of test surfaces without any interven-ing gap is required, e.g. in case of 100 % volumetric inspection, the test paths shall overlay each other with at least 15 %.

6.2.2 Testing velocity

If ultrasonic testing is performed manually then with regard to optimal localisation of the indications the testing velocity shall not exceed 100 mm/s.

7. Evaluation of indications

7.1 Indications without extension

The evaluation of indications without extension is to be performed according to the AVG-method (=DGS method = distance gain size method). In doing so the reference reflector size shall be specified as diameter of the equivalent disc shaped reflector (KSR) [mm].

7.2 Indication with extension

If not otherwise agreed, the determination of the re-flector extension shall be performed according to the half-amplitude technique.



K

Specifications concerning the afore mentioned evalua-tion and acceptance criteria are contained in Section 3, G. and Section 4, G. of Chapter 2 – Steel and Iron Materials.

8. Certification of test results

The manufacturer or the inspection body charged by him shall compile a report concerning the test which shall contain at least the following information:



– testing standards to be applied and/or testing specifications


– material

– dimensions

– component no.

– heat no.

– drawing no.


– time of testing, testing scope, inspection zones, severity levels

– the manufacturer and type of the employed testing equipment

– manufacturer, type, nominal frequency and angle of incidence of the employed probes

– type of calibration of distance and sensitivity

– specifications concerning the suitability for ultrasonic testing, surface preparation, correc-tion, values (transfer correction and sound at-tenuation) coupling media

– description of the position of reflectors to be recorded by means of sketches, the size of KSR, its extension in length, width and depth as well as the back-wall echo attenuation



L. Radiographic Testing

1. Method

1.1 If necessary radiographic testing is to be performed in addition to ultrasonic testing in case doubts exist concerning the evaluation of indications of ultrasonic testing.

Radiographic testing can be performed depending on the type of the component to be inspected, its material grade and wall thickness, either with x-rays or gamma rays.

1.2 As a rule radiographic testing is to be per-formed in accordance with recognized standards such as EN 444, EN 1435 for the radiographic examination of welded joints or EN 12681 for the testing of cast components.

2. Scope of validity

The following specifications apply for radiographic testing of components indicated in Chapter 2 – Steel and Iron Materials, Section 4.

3. Performing radiographic testing

As a rule radiographic testing is to be performed in accordance with EN 12681, test category A. Thereby the image quality category A according to EN 462-3 shall be fulfilled.

Testing in accordance with other national or interna-tional standards may be agreed on with GL on condi-tion that the conditions of the standards indicated in 1.2 will be fulfilled.

4. Testing specification

4.1 The orderer or the manufacturer shall prepare a testing specification which shall contain the test method and all relevant details. Especially the follow-ing information shall be specified:

– radiation source, focal spot size or dimensions of the employed gamma-ray source

– radiation energy

– film system class and screens

– test category

– thickness range to be penetrated

– type and position of the image quality indicator

– distances between the film and the focal point

– image quality, density

– test arrangement explained by means of sketches or drawings

4.2 For cast components where a large amount of radiographing is required the manufacturer shall pre-pare a film position plan.

The specification as well as the film position plan shall be submitted to GL for evaluation.

5. Selection of radiation source

The selection of the radiation source depends on the thickness ω of the tested component to be penetrated, the required test category and the selected radio-graphic arrangement according to EN 12681.

II - Part 1 GL 2009


L

6. Selection of film system and intensifying screens

6.1 The selection of the film class depends on the test category and the thickness to be penetrated. The selection of the intensifying screens depends on the maximum permissible tube voltage of the X-rays or the type of isotopes, see Table 3.2.

In case intensifying screens are used close contact between film and screen has to be ensured.

6.2 For the selection of the film class EN 444 is to be observed. A comparison of comparable interna-tional standards for film system classes is contained in Table 3.3.

7. Film density

7.1 The parameters for the exposure shall be selected in such a way that in the entire region to be evaluated the density S of the radiographs according to EN 444 is larger than S ≥ 2,0 for test category A and larger than S ≥ 2,3 for test category B.

Reduction of the minimum required density to 1,5 for test category A or to 2,0 for test category B is only permitted on condition that an appropriate agreement between the orderer and the manufacturer is made and that the multiple film technique is employed. This agreement is to be submitted to GL.

7.2 The upper limit for density depends on the brightness of the film illuminator which is employed for the evaluation.

7.3 In order to depict different wall thickness regimes of cast components without loss of quality within the density limits specified in 7.1 on one screen, the procedures for multiple film technique as indicated in EN 12681 shall be employed.

7.4 For evaluation of radiographs the density shall be verified with a densitometer.

8. Verification of image quality

8.1 The image quality is to be verified by means of image quality indicators such as e.g. wire indicators in accordance with EN 462-1.

In case image quality indicators cannot be positioned conforming to standards, i.e. away from the film, the image quality value shall be verified at least once by means of comparative radiographs prepared under the corresponding conditions.

8.2 In general, for steel castings of test category A, the image quality class A and for test category B the image quality class B according to EN 462-3 shall be achieved.

9. Evaluation of radiographs, evaluation criteria

The inspection department shall submit to the Sur-veyor for evaluation all radiographs and evaluation reports prepared by the inspector. It is up to the Sur-veyor to evaluate all radiographs or only a specific number of them.

The radiographs evaluated by him are to be stamped by him.

The testing and acceptance criteria applicable for the evaluation of the radiographs are contained in Chapter 2 – Steel and Iron Materials, Section 4, G.9.

10. Certification of the test results

The manufacturer shall compile a report concerning the evaluation of the radiographs which shall contain at least the following information:



– details of the cast component such as:

– material

– heat no.

– pattern no.

– drawing no.


– number and name of the testing specification

– testing standards to be applied and regulations

– method of radiographing and test categories

– film position plans, method of marking

– type of radiation source: tube/isotope, size of focal spot or of the radiation source, respectively

– tube voltage and anode current or activity of the radiation source

– exposure time and distance between radiation source and film

– selected film systems, screens and filters

– type and position of image quality indicator

– film density





L

Table 3.2 Film System classes and metal screens in accordance with EN 444 and EN 12681

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II - Part 1 GL 2009


L

Table 3.3 Comparison of international comparable recognized film system classes (examples)

Manufacturer / film type ASTM 1 DIN 4 EN 4 ISO 2 RCC-M 5 BS 3

AGFA 6

Structurix D2 special G1 C1 G I 1 A

Structurix D3 1 G1 C2 G I 1 A

Structurix D3 s.c. 1 G1 C2 G I 2 A


Structurix D5 1 G2 C4 G II 3 – 4 A

Structurix D7 2 G3 C5 G III 4 B


Fuji 6

IX 25 1 G2 C3 G I 3 A

IX 50 special G1 C1 G I 1 A

IX 80 1 G2 C3 G I 3 A

IX 100 1 G2 C4 G II 3 – 4 A

IX 150 2 G4 C6 G III 4 – 5 B

Kodak 6

DR special G1 C1 G I

M 1 G1 C2 G I

MX125 1 G2 C3 G I

T200 1 G2 C4 G II

AA400 2 G3 C5 G III

CX 3 G4 C6 G III

B W-B G III

1 ASTM E 94-93 / ASTM E 94-84 A 2 ISO 5579 3 BS 2600: type A: high contrast - very fine grain type B: high contrast - fine grain 4 classification according to DIN EN 584-1 in comparison to the replaced standard DIN 54117 T1 5 French standard 6 Equivalent film types from other manufacturers may also be considered, provided that appropriate proof has been

furnished.



L


1 Metallic Materials

2 Steel and Iron Materials

Edition 2009

The following Rules come into force on April 1st, 2009




Phone: +49 40 36149-0 Fax: +49 40 36149-200

[email protected]

www.gl-group.com




Table of Contents

Section 1 Steel Plates, Strips, Sections and Bars

A. General Rules ............................................................................................................................. 1- 1

B. Normal and Higher Strength Hull Structural Steels ................................................................... 1- 5

C. Unalloyed Steels for Welded Structures ..................................................................................... 1- 16

D. High-Strength Steels for Welded Structures ............................................................................... 1- 17

E. Steels for Steam Boilers and Pressure Vessels .......................................................................... 1- 21

F. Steels for Cargo Tanks ............................................................................................................... 1- 23

G. Stainless Steels ........................................................................................................................... 1- 28

H. Clad Plates ................................................................................................................................. 1- 30

I. Steels with Through Thickness Properties ................................................................................. 1- 32

J. Steel-Aluminium Welding Joints ............................................................................................... 1- 34

Section 2 Steel Pipes

A. General Rules ............................................................................................................................. 2- 1

B. Pipes for General Purpose .......................................................................................................... 2- 5

C. High-Temperature Steel Pipes .................................................................................................... 2- 7

D. Pipes Tough at Sub-Zero Temperatures ..................................................................................... 2- 10

E. Stainless Steel Pipes ................................................................................................................... 2- 14

Section 3 Forgings

A. General Rules ............................................................................................................................. 3- 1

B. Forgings for Machine Construction and Shipbuilding ................................................................ 3- 5

C. Forgings for Crankshafts ............................................................................................................ 3- 6

D. Forgings for Gears ...................................................................................................................... 3- 10

E. Forgings for Boilers, Pressure Vessels, Process Equipment and Pipelines ................................ 3- 13

F. Steel Forgings Tough at Sub-Zero Temperatures ....................................................................... 3- 15

G. Non-destructive Testing of Forged Components ........................................................................ 3- 17

H. List of Forged Components for which Non-destructive Tests are Required ............................... 3- 23

I. Classifying of Inspection Zones for Magnetic Particle Testing (MT) ........................................ 3- 24

J. Classifying of Inspection Zones for Ultrasonic Testing (UT) .................................................... 3- 29

Section 4 Cast Steel

A. General Rules ............................................................................................................................. 4- 1

B. Steel Castings for Machine Construction and Shipbuilding ....................................................... 4- 5

C. Steel Castings for Crankshafts and Connecting Rods ................................................................. 4- 8

D. Steel Castings for Steam Boilers, Pressure Vessels and Pipelines ............................................. 4- 8

E. Steel Castings for Use at Low Temperatures ............................................................................. 4- 10

F. Stainless Steel Castings .............................................................................................................. 4- 13

G. Non-destructive Testing of Cast Steel Components ................................................................... 4- 16

H. List of Cast Steel Components for which Non-destructive Tests are Required .......................... 4- 28

I. Testing Instructions for Hull Structural Parts ............................................................................. 4- 29

J. Testing Instruction for Diesel Engine Parts ................................................................................ 4- 37

II - Part 1 GL 2009

Table of Contents Chapter 2Page 3

Section 5 Cast Iron

A. General Rules .............................................................................................................................. 5- 1

B. Nodular Cast Iron ....................................................................................................................... 5- 3

C. Grey Cast Iron ............................................................................................................................. 5- 8

Section 6 Fittings and Pressed Parts, Bolts and Nuts

A. Pressed Parts ............................................................................................................................... 6- 1

B. Pipe Fittings ................................................................................................................................ 6- 4

C. Bolts and Nuts ............................................................................................................................. 6- 6

Chapter 2 Page 4

II - Part 1GL 2009

Section 1

Steel Plates, Strips, Sections and Bars

A. General Rules

1. Scope

1.1 General rules to be applied in the manufac-ture and testing of hot-rolled plates, strips, sections (including hollow sections), rods and bars are con-tained in A.

1.2 Hot-rolled round bars intended for the manu-facture of shafts, tie rods and bolts are subject to Section 3, B.

1.3 Where stated in B. to J. of this Section, steels conforming to national or international standards may be used, provided that they satisfy the minimum re-quirements of these Rules.

2. Requirements to be met by manufacturers

Manufacturers wishing to supply products in accor-dance with these Rules shall fulfil the requirements set out in Chapter 1 – Principles and Test Procedures, Section 1, C., and shall demonstrate this to GL prior to commencing supplies. This applies also for manufac-turers of semi-finished products such as ingots, slabs, blooms and billets.

3. Steelmaking process

3.1 The steels are to be manufactured by the basic oxygen process, the electric furnace process or by other methods approved by GL. On request, GL shall be informed of the steelmaking process used.

3.2 The steels may be cast in ingots (static cast-ing) or continuously.

Special casting processes require initial appraisal by GL.


4.1 All products are to be supplied in the heat treated conditions described in the following individ-ual Sections, unless supply in the as-rolled condition is allowed.

This may be the case if, for instance, the product is to undergo further hot forming.

4.2 If the material is suitable, products may also be supplied in normalising rolled (controlled rolled) or thermo-mechanically rolled condition (see 4.3), pro-vided that the processes have been checked and ap-proved by GL on the manufacturer's premises.

4.3 Definitions

The processes mentioned in 4.2 are defined as follows:

4.3.1 Normalising rolling

Normalising rolling (controlled rolling) is a rolling process involving final forming in a specific tempera-ture range which results in a material condition equivalent to that achieved by normalising treatment; thus the desired values of the mechanical properties are preserved even after an additional normalising treatment.

Products supplied in this condition are designated by the code NW.

4.3.2 Thermo-mechanical rolling

Thermo-mechanical rolling is a rolling process incor-porating careful monitoring of both the rolling tem-perature and also the reduction per pass. The greater proportion of reductions per pass is generally carried out close to the upper transformation temperature Ar3 where rolling in the two-phase temperature range may be incorporated. Unlike normalising rolling, the prop-erties produced by thermo-mechanical rolling cannot be reproduced by subsequent normalising or other heat treatments.

Products supplied in this condition are designated by the code TM.

Accelerated cooling following TM rolling may take place if this process has been approved by GL. The same applies to tempering treatments following TM rolling.

Note on TM steels:

Any subsequent, continuous heating above 580 °C as well as significant long holding times at lower tem-peratures may impair the strength properties. The manufacturer shall be consulted where there is a re-quirement to use temperatures above 580 °C.

Flame straightening will generally be possible. To this effect flame straightening may be carried out by using flame lines/flame tracks on the surface up to 950 °C. A flame straightening by short time local through thick-

II - Part 1 GL 2009

Section 1 Steel Plates, Strips, Sections and Bars Chapter 2Page 1–1

A

ness heating (hot wedge shapted spots, hot spots) may be carried out by a heating up to 700 °C.

5. General characteristics of products

5.1 All products shall have a smooth rolled sur-face and shall be free from any defects liable to have more than an insignificantly adverse effect on their workability and intended use, e.g. laminations, cracks, blow holes, scabs and seams.

5.2 Unless otherwise stipulated by the purchaser or prescribed by GL, hot-rolled plates, wide flats and sections shall be subject to the delivery conditions stipulated in EN 10163.

5.3 Unless otherwise specified or agreed, surface defects may only be removed by grinding within the permitted tolerance on the minimum thickness. The depressions caused by grinding shall have a smooth transition to the surrounding surface of the product.

6. Dimensions, dimensional and geometrical tolerances

6.1 Plates, strips and wide flats may be delivered with the minus tolerances shown in Table 1.1 or with no minus tolerance. Where no stipulations are made in the following individual rules, e.g. for shipbuilding steels in accordance with B., flat products for cargo tanks in accordance with F. and clad plates in accor-dance with H. the permitted minus tolerance is to be agreed when the order is placed.

6.2 The thickness is to be measured at points located at least 25 mm from the edge of the product. Local depressions due to flaws and grinding marks arising from the remedying of defects are not taken into account, provided that they do not exceed the tolerances.

6.3 Unless otherwise agreed in the order, the provisions regarding form tolerances according to EN 10029 apply.

6.4 For sections and bars, the dimensions and the dimensional and geometrical tolerances specified in the standards apply.

7. General technical requirements

7.1 Chemical composition

The limit values specified in these Rules for the chemical composition apply to the melt analysis. Mi-nor positive or negative excesses beyond the limit values, established by analysis of the product, are acceptable provided that they do not impair the prop-erties of the product and/or the tolerances specified in the other relevant standards are not exceeded.

Table 1.1 Permitted minus tolerances for the thickness of plates and wide flats

Nominal thickness [mm]

Permitted minus tolerances 1 [mm]

for class

A B C

≥ 3 < 5 – 0,4 – 0,3 0

≥ 5 < 8 – 0,4 – 0,3 0

≥ 8 < 15 – 0,5 – 0,3 0

≥ 15 < 25 – 0,6 – 0,3 0

≥ 25 < 40 – 0,8 – 0,3 0

≥ 40 < 80 – 1,0 – 0,3 0

≥ 80 < 150 – 1,0 – 0,3 0

≥ 150 ≤ 250 – 1,2 – 0,3 0

1 See also EN 10029.

7.2 Weldability

Steels conforming to these Rules shall be weldable by established workshop methods. Where applicable, this includes the measures necessary to ensure the quality of the welds, e.g. preheating and/or post weld heat treatments.

7.3 Mechanical properties

The mechanical properties stated in these Rules shall be verified by means of tensile tests.

7.4 Notch impact energy

The notch impact energy specified for the individual steels shall be fulfilled by the average value of three specimens, one of which may produce a value below, though not less than 70 % of, the average value.

7.5 Other properties

Where special properties such as resistance to inter-crystalline corrosion, resistance to brittle fracture or high-temperature strength are prescribed for certain groups of products, these shall be proved by appropri-ate tests, as necessary.

8. General instructions for testing

8.1 Testing of chemical composition

The manufacturer shall determine the chemical com-position of each melt and shall submit a corresponding certificate to the Surveyor. The chemical composition specified for the steel grade shall be shown in the certificate.


Section 1 Steel Plates, Strips, Sections and Bars II - Part 1GL 2009

A

In the event of any doubt as to the composition of the products, a product analysis shall be carried out at the request of the Surveyor.

8.2 Testing of mechanical properties and posi-tion of specimen

8.2.1 From each test batch, at least one tensile test specimen shall be taken and tested. A test batch shall comprise either the rolled length (the unit subjected to the heat treatment) or the number of items from the same heat specified in the following Sections.

8.2.2 In the case of plates and wide flats with a width of ≥ 600 mm, the tensile test specimens shall be taken transverse, in all other products parallel to the rolling direction. The necessary test sections shall be taken from the products at the following points (see Fig. 1.1):

– plates, wide flats and strip ≥ 600 mm wide: from halfway between the centre line and a longitudi-nal edge

– wide flats and strip < 600 mm wide: from a position lying 1/3 of the product width from a longitudinal edge

– sections: wherever possible, from a flange at a position corresponding to 1/3 of the flange width from the longitudinal edge of the flange. In the case of channels and joists, test sections may also be taken from the web at a distance corresponding to 1/4 of the web height from the centre line of the web

– bulb flats: from the web at a distance from the edge of the web corresponding to 1/3 of the height of the section

– bars: from a position lying at a distance of 1/6 of the diameter or the diagonal from the surface or the corner respectively

8.2.3 Test sections may normally be taken from products only after the final heat treatment. Where products have to undergo further hot working and testing of the properties in the final heat-treated condi-tion is required, the test sections may be subjected to separate heat treatment.

8.3 Determination of 0,2 % proof stress at elevated temperatures

For products intended for elevated temperature appli-cation on the basis of their high-temperature mechani-cal characteristics, the 0,2 % or 1 % proof stress shall be proved by a hot tensile test performed on at least one specimen from each heat. The test temperature shall be that specified in E.

The test may be dispensed with in the case of steels conforming to recognized standards whose mechanical characteristics at high temperature are considered to be already proven.

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8.4 Notched bar impact tests

8.4.1 The tests shall be performed on Charpy V-notch specimens with the notch perpendicular to the

II - Part 1 GL 2009


A

surface of the product. Where the thickness of the product is ≤ 40 mm, the specimens shall be located close to the rolled surface. Where the product thick-ness is > 40 mm, the specimens shall be so located that their longitudinal axis lies 1/4 of the product thickness from the surface. Furthermore, the test specimens shall be taken at a sufficient distance from flame-cut or sheared edges.

8.4.2 With products < 10 mm thick, specimens of reduced size are to be prepared with thicknesses of 7,5 or 5 mm. Unless otherwise specified, e.g. in B.6.3 and F.9.3, the requirements in respect of the impact energy shall be converted proportionally to the specimen cross-section in question:

For products < 6 mm thick the test is waived.

8.5 Testing of surface finish and dimensions

8.5.1 The surface finish and dimensions of all products shall be checked by the manufacturer.

Any surface defects may be removed by grinding within the permitted tolerances, see 5. Any products which fail to meet the requirements in respect of sur-face finish and dimensional tolerances shall be re-jected by the manufacturer.

8.5.2 Unless otherwise specified, all plates subject to individual testing shall be submitted to the Surveyor for final testing. The Surveyor may further require that products subject to batch testing be similarly submit-ted.

8.6 Ultrasonic tests

The tests shall be performed in accordance with EN 10160 or another standard accepted by GL. The testing staff shall be adequately qualified for this task and the Surveyor shall be furnished with proof thereof if he so requests. The Surveyor shall be permitted to take part in the tests at his request.

8.7 Retesting in the event of specimen failure

Where specimens subjected to tensile or impact testing fail to meet the requirements or where, in the impact test, one value is less than 70 % of the required aver-age value, the retesting procedures described in Chapter 1 – Principles and Test Procedures, Section 2, H. may be applied before the unit test quantity is re-jected. This also applies where specimens fail to meet the requirements in the testing of special characteris-tics such as shear strength, ductility as measured by the technological bend test applied to clad plates or reduction in area of through thickness tensile test specimens.

9. Marking of products

9.1 With the exception of the products with small dimensions specified in 9.2, every item shall be

clearly identified by the manufacturer in at least one place with the following marks:

– steel grade

– manufacturer's mark

– heat number, manufacturing serial number

– specimen number (where necessary)

Plates and sections shall be marked with punches. Products with sensitive surfaces or with wall thick-nesses of ≤ 10 mm may be marked by a different method, e.g. with a coloured impression or with a low-stress or a rubber stamp. Following agreement with the Surveyor, products may also be marked with code numbers, the meaning of which is explained in the covering certificate.

9.2 In the case of shapes and bars weighing ≤ 25 kg or less per metre which are bundled together, the marking specified in 9.1 may be applied on a tag.

9.3 Where individually tested rolled lengths (plates) are cut up into sections, each section shall be marked in a manner identifying its relationship to the original rolled length (plate).

10. Certificates

10.1 The Surveyor shall be given the test certifi-cates or consignment lists for all the materials tested by him in at least three copies. The documents shall be issued separately for each grade or type of steel if necessary. The documents shall at least contain the following details:

– purchaser and order number

– where known, the newbuilding and project num-ber respectively

– item number and quantities

– size and indication of products

– steel grade, type or brand name

– steel making process

– heat number

– chemical composition of the heat

– condition in which supplied if other than the as-rolled condition

– product identifying marks

– specimen number, where applicable

The certificate shall also state the results of the special tests carried out by the manufacturer, e.g. ultrasonic tests and tests of resistance to intercrystalline corro-sion, together with details of the test method used.

10.2 Before the test certificates or consignment lists are countersigned by the Surveyor, the manufac-turer shall confirm to the Surveyor in writing that the



A

material was manufactured by an approved process and tested in accordance with GL Rules for Materials, and the requirements were satisfied. The name "Ger-manischer Lloyd" (GL) shall be mentioned in the test certificate. The following wording of the declaration is adequate for this purpose if it is stamped or printed on every test certificate and/or consignment list together with the manufacturer's name and is certified on the manufacturer's behalf by a works employee appointed by him.

"We hereby declare that the material has been pro-duced by an approved method and has satisfied Rules of GL for testing."

10.3 Where the steels are not produced and rolled by the same manufacturer, a certificate issued by the steelmaker specifying at least the heat numbers and the chemical compositions shall be handed to the Surveyor.

B. Normal and Higher Strength Hull Struc-tural Steels

1. Scope

1.1 These requirements apply to weldable normal strength and higher strength hot-rolled plates, wide flats, sections and bars made of steel designed for shipbuilding use.

1.2 The requirements are primarily intended to apply to steel products with the following thicknesses:

– for plates and steel wide flats:

all grades up to 150 mm thick

– for sections and steel bars:

all grades up to 50 mm thick

For greater thicknesses certain variations in the re-quirements may be allowed or required in particular cases after consideration of the technical circum-stances involved.

1.3 Provision is made for four grades of normal strength steel based on the impact test requirements. For higher strength shipbuilding steels provision is made for three strength levels (315, 355 and 390 N/mm2) each subdivided into four grades based on the impact test temperature.

1.4 Steels differing in chemical composition, deoxidation practice, condition of supply and me-chanical properties may be accepted, subject to the special approval of GL. Such steels are to be given a special designation.

Note

The attention of the users shall be drawn to the fact that when fatigue loading is present, the effective

fatigue strength of a welded joint of higher strength steel may not be greater than that of a welded joint in normal strength steels.

2. Approval

2.1 All materials are to be manufactured at works which have been approved by GL for the grade of steel and the shape of the product which is being sup-plied.

2.2 The suitability of each grade for forming and welding is to be demonstrated during the initial ap-proval tests at the steelworks. The type and extent of testing required is at the discretion of GL.

2.3 If the steel is not smelted in the mill where it was rolled, a certificate is to be given to the Surveyor in the rolling mill indicating the smelting process used, the name of the steel producer, the heat number and the smelt analysis (ladle analysis). The Surveyor shall be allowed access to the steel producing works.

3. Method of manufacture

3.1 The steel is to be manufactured by the basic oxygen process, in an electric furnace or by other processes specially approved by GL.

3.2 The deoxidation practice used for each grade is to comply with the appropriate requirements of Tables 1.2 and 1.3.

3.3 The definitions relating to the rolling process in question, such as normalising rolling or thermo-mechanical rolling, with or without subsequent accel-erated cooling are stipulated in A.4.3.

4. Chemical Composition

4.1 The chemical composition of samples taken from each heat is to be determined by the manufac-turer in an adequately equipped and competently staffed laboratory and is to comply with the appropri-ate requirements of Tables 1.2 and 1.3.

For plates and wide flats more than 50 mm thick, slight variations in the prescribed chemical composi-tion may be permitted by arrangement with GL.

4.2 The manufacturer's declared analysis will be accepted subject to occasional checks if required by the Surveyor.

4.3 The following special rules apply to TM rolled steels:

4.3.1 The carbon equivalent value Ceq shall be within the tolerances given in Table 1.4.

4.3.2 Rather than using the carbon equivalent value when assessing weldability, the Pcm-value (suscepti-bility to cold cracking) may also be calculated based

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B

on the following formula:

[ ]

cmSi Mn Cu Ni

P C30 20 20 60

Cr Mo V5 B %

20 15 10

= + + + + +

+ + +

In such cases, the Pcm value shall be agreed with GL.

5. Condition of supply

The condition in which all products are supplied shall correspond to the data given in Tables 1.5 and/or 1.6.

6. Mechanical properties

6.1 For tensile testing either the upper yield strength ReH or, where this is not stipulated, the 0,2 per cent proof stress Rp0,2 is to be determined and the material is considered to satisfy the requirements if one of these values meets or exceeds the prescribed minimum value for the yield strength Re.

6.2 The results obtained from tensile tests shall comply with the appropriate requirements of Tables 1.7 and 1.8.

Table 1.2 Chemical composition and deoxidation practice for normal strength steels

Grade GL–A GL–B GL–D GL–E

For t ≤ 50 mm any method except 1

rimmed steel

For t ≤ 50 mm any method except

rimmed steel

For t ≤ 25 mm killed,

Deoxidation practice

for t > 50 mm killed

for t > 50 mm killed

for t > 25 mm fully killed an fine

grain treated

Fully killed and fine grain treated

Chemical composition (%) (ladle analysis) 4, 7, 8

Carbon plus 1/6 of the manganese content is not to exceed 0,40 %

Cmax 0,21 2 0,21 0,21 0,18

Mnmin 2,5 × C 0,80 3 0,60 0,70

Simax 0,50 0,35 0,35 0,35

Pmax 0,035 0,035 0,035 0,035

Smax 0,035 0,035 0,035 0,035

Al (acid soluble) min –– –– 0,015 5, 6 0,015 6

t = Material thickness

1 Grade GL–A sections up to a thickness of 12,5 mm may be accepted in rimmed steel subject to the special approval of GL. 2 Max. 0,23 % for sections. 3 When Grade GL-B steel is impact tested the minimum manganese content may be reduced to 0,60 % 4 When any grade of steel is supplied in the thermo-mechanically rolled condition variations in the specified chemical composition may

be allowed or required. 5 For Grade GL–D steel over 25 mm thick. 6 For Grade GL-D steel over 25 mm thick and for Grade GL-E steel, the total aluminium content may be calculated in place of the acid

soluble part. In such cases, the total aluminium content may not be less than 0,020 %. GL may also specify a maximum limit for aluminium. Other grain refining elements may also be permitted subject to approval.

7 In the melt, the maximum values of the following elements may not be exceeded:

– Cu : 0,30 %

– Cr : 0,20 %

– Ni : 0,40 %

– Mo : 0,08 %

8 Where the manufacturing process demands the addition of additional elements, their contents are to be indicated in the manufacturer's certificate.



B

Table 1.3 Chemical composition and deoxidation practice for higher strength steels

Grade 1 GL–A32, GL–D32, GL–E32 GL–A36, GL–D36, GL–E36 GL–A40, GL–D40, GL–E40

GL–F32 GL–F36 GL–F40

Deoxidation practice Killed and fine grain treated

Chemical composition (%) 5, 7 (ladle analysis)

C max. 0,18 0,16

Mn 0,90 – 1,60 2 0,90 – 1,60

Si max. 0,50 0,50

P max. 0,035 0,025

S max. 0,035 0,025

Al (acid soluble) min. 0,015 3, 4 0,015 3, 4

Nb 0,02 – 0,05 4 0,02 – 0,05 4

V 0,05 – 0,10 4 0,05 – 0,10 4

Ti max. 0,02

⎫⎪⎬⎪⎭

0,02

⎫⎪⎬⎪⎭

Cu max. 0,30 0,30

Cr max. 0,20 0,20

Ni max. 0,40 0,80

Mo max. 0,08 0,08

N max. –– 0,009 (0,012 where Al is present)

Carbon equivalent value 6

1 The letter "H" may be added to the steel grade designation, e.g. GL–AH 36

2 Up to a thickness of 12,5 mm the minimum manganese content may be reduced to 0,70 %.

3 The total aluminium content may be calculated in place of the acid-soluble part. In such cases the total aluminium content may not be less than 0,020 %.

4 The steel is to contain aluminium, niobium, vanadium or other suitable grain refining elements, either singly or in any combination. When used singly the steel is to contain the specified minimum content of the grain refining element. When used in combination, the specified minimum content of the refining element is not applicable.

5 Where a higher strength steel is supplied in a thermo-mechanically rolled condition, variations in the chemical composition may be approved or required.

6 When required, the carbon equivalent value is to be calculated from the ladle analysis using the following formula:

Ceq CMn Cr Mo V Ni Cu

= + ++ +

++

6 5 15

This formula is applicable only to steels which are basically of the carbon-manganese type and gives a general indication of the weldability of the steel.

7 When the manufacturing process demands the addition of other elements, their content is to be indicated in the manufacturer's certificate.

total 0,12 max. total 0,12 max.

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Table 1.4 Carbon equivalent values for TM rolled, higher strength shipbuilding steels up to a product thickness of 150 mm

Carbon equivalent value [%], max. 1

Thickness of product t [mm] Steel grade

t ≤ 50 50 < t ≤ 150

GL–A 32, GL–D 32, GL–E 32, GL–F 32 GL–A 36, GL–D 36, GL–E 36, GL–F 36 GL–A 40, GL–D 40, GL–E 40, GL–F 40

0,36 0,38 0,40

0,38 0,40 0,42

1 It is up to the manufacturer and material user (yard) to agree lower values in special cases.

Table 1.5 Condition of supply for normal strength steels

Grade Thickness of product t [mm] Condition of supply

≤ 50 any GL–A

50 < t ≤ 150 normalised, normalising or TM-rolled 1

≤ 50 any GL–B

50 < t ≤ 150 normalised, normalising or TM rolled 1

≤ 35 any GL–D


GL–E ≤ 150 normalised, or TM rolled 2

Notes

1 Subject to the special approval of GL, plates in Grade GL–A and GL–B steel may also be supplied in the as-rolled condition, see 13.2. 2 Subject to the special approval of GL, sections in Grade GL-D steel may be supplied in the as-rolled condition provided satisfactory

results are consistently obtained from notch impact tests. Accordingly sections in Grade GL–E steel may be supplied in the as rolled or normalising rolled condition. The frequency of impact tests is to be determined in accordance with 13.2.2 and 13.3.3 respectively.

Table 1.6 Condition of supply for higher strength steels

Grades Grain refining elements used

Thickness range t [mm] Condition of supply

≤ 12,5 any Nb or V

12,5 < t ≤ 150 normalised, normalising or TM rolled 2

≤ 20 any

20 < t ≤ 35 any, but as-rolled subject to special approval of GL 1

GL–A 32 GL–A 36

Al alone or with Ti


≤ 12,5 any

12,5 < t ≤ 50 normalised, normalising or TM rolled GL–A 40 any

50 < t ≤ 150 normalised, TM rolled or quenched and tempered

≤ 12,5 any Nb or V

12,5 < t ≤ 150 normalised, normalising or TM rolled 2

≤ 20 any

20 < t ≤ 25 any, but as-rolled subject to special approval of GL 1

GL–D 32 GL–D 36

Al alone or with Ti




B

Table 1.6 Condition of supply for higher strength steels (continued)

Grades Grain refining elements used

Thickness range t [mm] Condition of supply

≤ 50 normalised, normalising or TM rolled GL–D 40 any

50 < t ≤ 150 normalised, TM rolled or quenched and tempered

≤ 50 normalised or TM rolled 2 GL–E 32 GL–E 36

any 50 < t ≤ 150 normalised or TM rolled

GL–E 40 any ≤ 150 normalised, TM rolled or quenched and tempered

GL–F 32 GL–F 36 GL–F 40

any ≤ 150 normalised, TM rolled or quenched and tempered 3

1 The frequency of impact tests is to be in accordance with 13.2.2. 2 Subject to the special approval of GL, sections in Grade GL–A 32, GL–A 36, GL–D 32 and GL–D 36 steels may be supplied in as-

rolled condition provided satisfactory results are consistently obtained from notch impact tests. Accordingly, sections in grade GL–E 32 and GL–E 36 steels may be supplied in as-rolled or normalising rolled condition. The frequency of notch impact tests is to be in accordance with 13.2.2 and 13.2.3 respectively.

3 Subject to special approval of GL, sections in Grade GL–F 32 and GL–F 36 steels with thickness ≤ 50 may be supplied in as-rolled condition or normalising rolled condition. The frequency of notch impact tests is to be in accordance with 13.3.3.

Table 1.7 Mechanical properties for normal strength steels

Notched bar impact energy

KV [J]

min.

Yield strength

ReH

Tensile strength

Rm

Elongation 1

A

( )o oat L =5,65 S⋅ Test temp.

t ≤ 50 [mm] 50 < t ≤ 70 [mm] 70 < t ≤ 150 [mm]

Grade

[N/mm2] min.

[N/mm2] [%] min.

[°C] long. transv. long. transv. long. transv.

GL–A +20 –– –– 34 4 24 4 41 4 27 4

GL–B 0 27 3 20 3 34 24 41 27

GL–D –20 27 20 34 24 41 27

GL–E

235 400–520 2 22

–40 27 20 34 24 41 27


1 Required elongation for flat tensile test specimens with gauge length Lo = 200 mm, width = 25 mm and a thickness equal to the product thickness:

Thickness of product t [mm] ≤ 5 > 5 ≤ 10

> 10 ≤ 15

> 15 ≤ 20

> 20 ≤ 25

> 25 ≤ 30

> 30 ≤ 40

> 40 ≤ 50

Elongation A200 mm [%] 14 16 17 18 19 20 21 22

2 For Grade GL–A sections the upper limit for the specified tensile strength range may be exceeded at the discretion of GL, irrespective of product thickness.

3 Notch impact tests are generally not required for Grade GL–B steels with thickness of 25 mm or less.

4 For Grade GL–A products with thickness in excess of 50 mm, notch impact tests are not required provided that the steel has been fine grain treated and normalised. TM rolled steels may also be supplied without notch impact testing provided that GL has waived the need.

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Table 1.8 Mechanical properties for higher strength steels


KV [J]

min.

Yield strength

ReH

Tensile strength

Rm

Elongation 1

A

( )o oat L =5,65 S⋅

Test temp.

t ≤ 50 [mm] 50 < t ≤ 70 [mm] 70 < t ≤ 150 [mm]

Grade

[N/mm2] min.

[N/mm2] [%] min.

[°C] long. transv. long. transv. long. transv.

GL-A32

GL-D32

GL-E32

GL-F32

315 440–570 2 22

0

–20

–40

–60

31 22 38 26 46 31

GL-A36

GL-D36

GL-E36

GL-F36

355 490–630 2 21

0

–20

–40

–60

34 24 41 27 50 34

GL-A40

GL-D40

GL-E40

GL-F40

390 510–660 2 20

0

–20

–40

–60

41 27 46 31 55 37


1 Required elongation for flat tensile test specimens with gauge length Lo = 200 mm, width = 25 mm and a thickness equal to the product thickness:

Thickness of product t [mm] > 5 > 5 ≤ 10

> 10 ≤ 15

> 15 ≤ 20

> 20 ≤ 25

> 25 ≤ 30

> 30 ≤ 40

> 40 ≤ 50

Elongation A200 mm [%] GL-A32, -D32, -E32, -F32 GL-A36, -D36, -E36, -F36 GL-A40, -D40, -E40, -F40

14 13 12

16 15 14

17 16 15

18 17 16

19 18 17

20 19 18

21 20 19

22 21 20

2 For TM-rolled steels, the tensile strength may be up to 30 N/mm2 below the lower limit for this value without giving cause for complaint.

6.3 The minimum impact energy requirements relate to Charpy V-notch impact test specimens, which are taken in either the longitudinal or transverse direc-tions. Generally only longitudinal test specimens need be prepared and tested. For special applications, if required by GL or the purchaser, transverse specimens are to be tested. The requirements in respect of the transverse test specimens shall be guaranteed by the manufacturer.

The tabulated values are for standard specimens 10 mm × 10 mm. For plate thicknesses lower than 10 mm, the requirement for performing a notch impact test may be waived with the approval of GL or sub-size specimens with reduced requirements may be taken as follows:

Specimen dimensions 10 mm × 7,5 mm:

– 5/6 of the tabulated value

Specimen dimensions 10 mm × 5,0 mm:

– 2/3 of the tabulated value

6.4 The average notch impact energy value ob-tained from one set of three tests is to comply with the requirements given in Tables 1.7 or 1.8. One individ-ual value only may be below the specified average value provided it is not less than 70 % of that value.

6.5 Notch impact tests are generally no longer required if the product is less than 6 mm thick.



B

7. Freedom from defects and repair of sur-face defects

7.1 General characteristics

7.1.1 All products shall satisfy the requirements applicable to general characteristics set out in A.5.1. Unless otherwise agreed, the surface finish of the products shall be subject to standard EN 10163, speci-fications relating to the surface finish of hot-rolled steel products (plate, steel wide flat and sections), Class A, or equivalent national or international stan-dard, however, grinding of defects may only be car-ried out within the limits given in 7.2.

7.1.2 Notwithstanding the provisions of A.5.3, surface defects may be removed not only by grinding but also by welding according to the principles stated below, provided that the defects in question are iso-lated, of locally limited extent and the sum of the defective areas covers not more than 2 % of the rele-vant face of the product.

7.2 Repairs by grinding

The manufacturer may, at his discretion, remove sur-face defects by grinding, provided that the depth of material ground away does not exceed 3 mm in rela-tion to the nominal thickness of the product and pro-vided also that at least 93 % of the nominal thickness remains. In addition, the depressions caused by the grinding shall have a smooth transition to the sur-rounding surface of the product.

7.3 Repairs by welding

Defects which cannot be removed by grinding may be repaired by chipping and/or grinding with subsequent welding, provided that the Surveyor has consented to the repair and that the following requirements are met.

7.3.1 After chipping or grinding the defect, the remaining thickness shall be equal to at least 80 % of the nominal thickness. The remaining thickness may be less than this limit value only in exceptional cases where the specific application of the product is not thereby impaired.

7.3.2 All welds shall be performed by trained welders using approved methods and electrodes with a controlled low hydrogen content. At least one layer of weld metal is to be welded in excess which shall thereafter be ground flush to the surface level.

7.3.3 Wherever possible, products which are to be supplied in the normalised condition shall be welded prior to the heat treatment. If welding is required after normalising an additional treatment may be requested.

Products which are supplied thermo-mechanically treated or hot-rolled are to receive stress-relief heat treatment after welding, if appropriate further process-ing cannot be ensured.

7.3.4 The repaired items shall be submitted to the Surveyor for final inspection and freedom from de-

fects shall be proved by a suitable non-destructive method.

7.3.5 For every repair weld, the manufacturer shall prepare a report containing details of the size and location of the defects, the welding method used and any heat treatment applied, and shall hand this report to the Surveyor.


The provisions of A.6. are applicable. With regard to flat products (plates and steel wide flat) for shipbuild-ing use, Class B given in Table 1.1 may be considered as the permitted lower deviation from the nominal thickness. This means that the permitted lower devia-tion for all product thicknesses is a uniform – 0,3 mm.

9. Material identification

9.1 The manufacturer is required to set up an identification system for ingots, slabs and finished products so that the material can be traced back as far as smelting.

9.2 The Surveyor is to be allowed every facility in order to carry out this trace-back procedure as ap-propriate.

10. Testing and inspection

10.1 Test facilities

The manufacturer is required to allow the Surveyor access to all works departments and to provide all the necessary facilities as may be required to establish the approved manufacturing process, the selection of test material, supervision of tests in accordance with the rules and also to establish the precision of the test equipment.

10.2 Test methods

The prescribed tests and surveys shall be conducted at the place of manufacture prior to despatch of products. The test specimens and test methods shall comply with the information given in Chapter 1 – Principles and Test Procedures, Section 2. Unless otherwise agreed with GL, the specimens shall be selected by the Surveyor, marked and tested in his presence.

10.3 Tensile testing of specimens taken in the direction of thickness

Where plates and steel wide flats with thicknesses ranging from 15 to 150 mm are ordered with require-ments as to the direction of thickness, tensile test specimens shall be prepared and tested with their axis perpendicular to the surface of the product as de-scribed in I.

10.4 Non-destructive testing

10.4.1 Where plates and steel wide flats are ordered with an ultrasonic test certificate, the tests are to be executed in accordance with a standard approved by

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B

GL, e.g. EN 10160. The quality class is to be stipu-lated when the order is placed.

10.4.2 The seams of welded hollow sections of hull structural steel are to be subjected to non-destructive testing over their entire length.

10.4.2.1 Electrical welded hollow sections

The weld seam of hollow sections is to be examined according to one of the following European standards:

– EN 10246-3, acceptance category E4, except that the technique of rotating pipes or with rotat-ing saddle coils is not permitted

– EN 10246-5, acceptance category F5, or EN 10246-8, acceptance category U5

10.4.2.2 Submerged-arc welded hollow sections

The weld seam of hollow sections is to be examined according to acceptance category U4 in accordance with EN 10246-10, image quality class R2.

Butt welds serving to connect strip or plate lengths by spiral submerged-arc welding have to be examined over their entire length according to the same test procedure and shall satisfy the same acceptance crite-ria as the main weld seam.


Inspections of surface finish and dimensional checks are the responsibility of the rolling mill. Acceptance testing by the Surveyor does not release the manufac-turer from this responsibility.

11. Test material

11.1 Definitions

11.1.1 "Piece" denotes the rolled product which has been rolled directly from an ingot, billet or slab into a plate, section or bar.

11.1.2 "Batch" denotes a test batch, made up of products of the same kind and originating from the same heat, which has been submitted as a whole for testing.

11.2 Test section

11.2.1 The material which has been combined in one batch (one test batch) for testing shall have the same shape e.g. plate, steel wide flat, section, originate from the same heat and be delivered in the same condition.

11.2.2 The test sections shall be representative of the material and may only be cut from the test piece fol-lowing the final heat treatment - unless there are tech-nical reasons why they should not be.

11.2.3 Test sections may not be heat treated sepa-rately.

11.2.4 The removal of test sections is subject to the rules laid down in A.8.2.

12. Specimens for mechanical tests

12.1 Tensile test samples

The dimensions of the tensile test samples are to be selected from those given in Chapter 1 – Principles and Test Procedures, Section 2, D. Full thickness flat tensile test specimens should generally be selected as the test thickness for plates, steel wide flats and sec-tions. Round tensile test specimens may be used where the thickness of the product exceeds 40 mm or in the case of bars and similar products. By way of an alter-native to these specimens, full section specimens of a suitable length may also be tested in the case of small bars and sections.

12.2 Impact test specimens

Impact test specimens shall comply with the Charpy V specimen shape and be taken horizontally with the long side of the specimen 2 mm below the rolling surface. They shall be positioned so that their axes are either "longitudinal" or "transverse" to the main direc-tion of rolling as shown in Tables 1.7 and 1.8. The notch shall be milled in the side of the specimen so that the latter’s axis is vertical to the surface of the product. The position of the notch may not be less than 25 mm from one flame-cut edge or one shear edge. Where the thickness of the product exceeds 40 mm, the impact test specimens shall be taken in such a way that the axis of the specimen is positioned at 1/4 of the product thickness.

13. Number of test specimens

13.1 Number of tensile tests

For each batch presented, except where specially agreed by GL, one tensile test specimen is to be taken from one piece (max. weight 50 t from the same heat). Where the weight of finished material is greater than 50 tonnes, one extra test specimen is to be taken from a different piece from each 50 tonnes or fraction thereof. Provision shall be made for additional speci-mens for every variation of 10 mm in the thickness or diameter of products from the same heat.

13.2 Number of impact tests (except for Grades GL–E, GL–E 32, GL–E 36,GL–E 40, GL–F 32, GL–F 36 and GL–F 40)

13.2.1 Except where otherwise specially agreed by GL, for each batch presented (max. 50 t from the same heat), at least one set of three Charpy V-notch test specimens is to be made from one piece. Where the weight of finished material is greater than 50 tonnes, one extra set of three test specimens is to be made from a different piece from each 50 tonnes or fractions thereof.



B

From plates of grades GL–A 40 and GL-D 40 in quenched and tempered condition, one set of impact-tests per heat treatment length is to be taken.

Where plates, except for those in grade GL–A steel, are supplied in thicknesses greater than 50 mm in the normalising rolled condition, the test batch from which specimens are taken is no greater than 25 ton-nes or fractions thereof.

13.2.2 When, subject to the special approval of GL, material is supplied in the as rolled condition, the frequency of impact tests is to be increased to one set from each batch of 25 tonnes or fractions thereof. The same applies when plates of grade GL-A steel are supplied in thicknesses greater than 50 mm in the as-rolled condition. In this case, one set of three impact test specimens shall be taken for each 50 tonnes or fractions thereof.

13.2.3 The piece selected for the preparation of the test specimens is to be the thickest in the batch.

13.2.4 The test batch quantity depending on supply condition and thickness of product is shown in Tables 1.9 and 1.10.

13.3 Number of impact tests for Grades GL-E, GL–E 32, GL–E 36, GL–E 40, GL–F 32, GL–F 36 and GL–F 40

13.3.1 For plates supplied in the normalised or TM-rolled condition, one set of specimens is to be taken from each rolled length. In the case of quenched and tempered plates, one set of specimens is to be taken from each heat treatment length.

13.3.2 For sections one set of specimens is to be taken from each test unit of 25 tonnes or fractions thereof.

13.3.3 When, subject to the special approval of GL, sections other than those in grade GL–E 40 and GL–F 40, are supplied in the as rolled or normalising rolled condition, one set of test specimens is to be taken from each batch of 15 tonnes or fractions thereof.

13.3.4 The specimens taken as described in 13.3.1 or 13.3.3 above are to be taken from the thickest piece in each batch.

13.3.5 The test batch quantity depending on supply condition and thickness of product is shown in Tables 1.9 and 1.10.

14. Re-tests

14.1 Where the requirements are not satisfied in a tensile test, or where the average from three impact test samples fails to meet the conditions, or where an individual value from a notch impact test does not meet the requirements, re-tests are to be carried out as stipulated in Chapter 1 – Principles and Test Proce-dures, Section 2, H. In this case, the conditions speci-fied therein are to be satisfied.

15. Branding

15.1 Every finished piece is to be clearly marked by the maker in at least one place with GL's brand and the following particulars:

– identification mark for the grade steel (e.g. GL–A, GL–A 36)

– Steels which have been specially approved by GL and which differ from these requirements (see 1.4) are to have the letter "S" after the above identification mark (e.g. GL–A36 S, GL-ES)

– Material supplied in the thermo-mechanically controlled processed condition is to have the let-ters TM added after the identification mark (e.g. GL–E 36 TM)

– name or initials to identify the steelworks

– heat or other number to identify the piece

– if required by the purchaser, his order number or other identification mark

15.2 The above particulars, but excluding the manufacturer's name or trade mark, where this is em-bossed on finished products, are to be encircled with paint or otherwise marked so as to be easily recogniz-able.

15.3 Where a number of low-weight products are securely combined in packages or bundles, it is suffi-cient, subject to approval by GL, to mark only the uppermost piece in the package or robust tag which is securely fastened to the bundle.

15.4 When a product already bears GL brand but has not satisfied the test conditions, said brand shall be unequivocally removed by the manufacturer.

16. Certificates

16.1 The manufacturer shall hand over to the Sur-veyor either works acceptance test certificates (e.g. in accordance with EN 10204-3.1) or despatch docu-ments for the products accepted by him. Said docu-mentation shall be in triplicate at least. Documentation is to be produced separately for each grade of steel and shall contain the following particulars:


– where known, the newbuilding and project number respectively

– item numbers and quantities

– size and indication of products

– identification of rolling mill

– steel grade


II - Part 1 GL 2009


B

– heat number or product number and, where appropriate, specimen number

– chemical composition of the melt for the ele-ments shown in Tables 1.2 and 1.3

– delivery condition, where not supplied in the as-rolled condition, e.g. normalised, normalising

rolled, thermo-mechanically rolled or quenched and tempered

– In the case of grade GL–A steel sections up to 12,5 mm, details of whether it is rimmed steel

– marking of the products

– test results

Table 1.9 Required condition of supply and number of impact tests for normal strength steels

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Table 1.10 Required condition of supply and number of impact tests for higher strength steels

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II - Part 1 GL 2009


B

Table 1.10 Required condition of supply and number of impact tests for higher strength steels (continued)

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16.2 Before the acceptance test certificates or despatch documents are signed by the Surveyor, the manufacturer shall hand over written confirmation that the steel has been produced by an approved method has successfully passed the tests prescribed in the presence of the Surveyor or his representative ap-pointed by GL. In this regard, the following text may be also accepted, either stamped or printed on the certificate or despatch documents, and shall be veri-fied by one of the manufacturer's authorised agents:

"We hereby declare that the material has been pro-duced by an approved method and has satisfied the Rules of GL for testing".

C. Unalloyed Steels for Welded Structures

1. Scope

1.1 These Rules apply to flat products, sections and bars made from unalloyed steels with minimum nominal yield strengths up to and including 355 N/mm2

which are to be used for welded structures, e.g. in ma-chinery manufacture or in shipbuilding.

1.2 Rolled bars for the manufacture of shafts, shanks, studs, bolts and other rotating parts are gov-erned by Section 3, B.

2. Suitable steels

The following steels may be used with the require-ments laid down in the relevant standards:

2.1 Steels conforming to EN 10025, EN 10210 and EN 10219 grades as follows:

– S235: all grades

Note The grades S235 JR and S235 JR G1 according

to EN 10025 : 1990 + A1 : 1993 are excluded from application.





C

2.2 Weldable fine-grained structural steels con-forming to EN 10025-3, in the grades:

– S275 N, S 275 NL, S355 N, S355 NL (normalised or normalising rolled)

and conforming to EN 10025-4 in the grades:

– S275 M, S275 ML, S355 M, S355 ML (thermo-mechanically rolled)

2.3 Other steels after their suitability has been determined by GL, provided that they satisfy the fol-lowing minimum requirements:

2.3.1 The chemical composition [%] of the ladle analysis shall not exceed the following limit values:

C Mn Si P S Cu Cr Ni Mo

0,22 1,70 0,55 0,040 0,040 0,30 0,20 0,40 0,08

In addition, fine grain treated structural steels shall have an adequate content of grain refining elements, e.g. Al, Nb, V or Ti.

2.3.2 The elongation A5 shall be at least 20 % in tests with longitudinal specimens and 18 % in tests with transverse specimens.

2.3.3 For fine grain treated structural steels, an impact energy of not less than 27 J (average value) shall be achieved in tests with longitudinal Charpy V-notch specimens at a testing temperature of

– 20 °C, for products supplied in normalised, nor-malising rolled or thermo-mechanically rolled condition

0 °C, for products supplied in as rolled condition.


Flat products made of fine grain treated structural steels are to be supplied in normalised, normalising rolled or thermo-mechanically rolled condition. For all other products, the data in the standards apply, unless otherwise specified in the order.


A.6. applies, with the following addition:

For the minus tolerance applicable to the nominal thickness, the values stated under Class A in Table 1.1 apply to plates, strips and wide flats, unless otherwise specified in the purchase order.

5. Testing and scope of tests

The following tests shall be performed:

5.1 Test of chemical composition

The manufacturer shall determine the chemical com-position of each heat and shall issue a relevant certifi-cate.

5.2 Tensile test

5.2.1 The mechanical properties shall be verified by tensile test.

For the purpose of taking specimens, products of the same shape shall be formed according to heat and within the thickness ranges relevant to the yield strength into test batches of not more than 40 t. A tensile test specimen shall be taken from the thickest item in the test batch. In the case of plates and wide flats with a width of ≥ 600 mm, this shall be posi-tioned transverse to the rolling direction. In other products, the test specimen may lie transverse or par-allel to the rolling direction.

5.2.2 Where plates are to be tested individually, this shall be specially stipulated in the order.

5.3 Notched bar impact test

All products made of fine grain treated steels shall be subjected to notched bar impact tests performed with longitudinal Charpy V-notch specimens at the test temperatures specified in the standards or in 2.3.3. Where, in the case of plates, individual testing has not been agreed, a set of test specimens shall be taken from the thickest piece in the test batch in accordance with 5.2.1.

Testing shall be performed for products with a thick-ness of ≥ 6 mm.


The surface finish and dimensions of all products shall be checked by the manufacturers. At the request of the Surveyor, the products shall then be submitted to him for final inspection.

D. High-Strength Steels for Welded Struc-tures

1. Scope

1.1 These Rules apply to plates and wide flats up to 70 mm thick made of weldable high-strength quenched and tempered steels. The application of these Rules to products with larger thicknesses shall be specially agreed with Germanischer Lloyd (GL). The same applies if products other than plates and wide flats, e. g. sections and pipes, are to be supplied in accordance with these Rules.

1.2 Steels falling within the scope of these Rules are classed into 6 groups indicated by the nominal

II - Part 1 GL 2009


D

yield strengths 420, 460, 500, 550, 620 and 690 N/mm2. Each group is further subdivided into the grades A, D, E and F based on the temperature for notched bar impact testing.

1.3 Steels which diverge from these Rules, e.g. with regard to their nominal yield strength, their me-chanical properties and their chemical composition, may not be used without the special approval of GL.

1.4 Steels conforming to EN 10025-3 and -4 may also be used in place of grades GL–A 420, GL–D 420, GL–A 460 and GL–D 460, viz:

– for grades GL–A 420 and GL–D 420:

S420 N and S420 NL, EN 10025-3 S420 M and S420 ML, EN 10025-4

– for grades GL–A 460 and GL–D 460:

S460 N and S460 NL, EN 10025-3 S460 M and S460 ML, EN 10025-4

2. Approval

The steels shall be approved by GL. For this purpose, the steel manufacturer shall send GL a material speci-fication containing the required information, such as chemical composition, manufacturing process, me-chanical properties, condition of supply, as well as recommendations for welding, hot or cold forming, and heat treatment. GL reserves the right to require initial approval testing.

The material manufacturer shall verify the weldability of each grade of steel by appropriate documentation possibly in connection with welding tests.

3. Requirements

3.1 Manufacturing process

The steels shall be manufactured in works approved by GL by the basic oxygen process, in electric arc furnaces, or by another process approved by GL. They shall be cast in killed condition and fine grain treated.


3.2.1 The chemical composition shall satisfy the requirements stated in the authorized specification and in Table 1.11.

Elements used for alloying and fine grain treatment are to be indicated in the manufacturer’s specification.

3.2.2 To assess weldability, sensitivity to cold cracking may be calculated from the ladle analysis according to the following formula:

P CSi Mn Cu Ni

Cr Mo VB

cm = + + + + +

+ + +

30 20 20 60

20 15 105 %

The maximum permitted value is to be agreed with GL and shall be indicated in the authorised specifica-tion.

3.3 Heat treatment

The steels shall be supplied in quenched and tempered condition. However, for grades GL–A 420, GL–D 420, GL–E 420, GL–F 420 and also for GL–A 460, GL– D 460, GL–E 460 and GL–F 460, with product thicknesses up to 50 m, normalising or normalising rolling is permitted where the required properties can be achieved thereby. This is to be demonstrated for approval testing. The same applies to thermo-mechanically rolled steels up to 70 mm thickness with nominal yield strength up to 500 N/mm2.


The requirements applicable to the mechanical proper-ties and the impact energy shall conform to the data in Table 1.12.

3.5 General condition of products

A.5. applies. In addition, it should be noted that:

– Procedures for repair welding and reporting thereon shall be approved by GL.

– If defects are removed by grinding, the thickness remaining underneath the ground area shall be within the thickness tolerance.

3.6 Dimensions, dimensional and geometrical tolerances

A.6. applies, with the following addition:

For the minus tolerance applicable to the nominal thickness, the values stated under Class A in Table 1.1 apply, unless otherwise specified in the order.

4. Testing


The manufacturer shall determine the composition of every heat and shall issue a relevant certificate.

4.2 Tensile test

4.2.1 From every piece heat-treated in a unit, at least one tensile test specimen shall be taken and tested. If plates are heat-treated by continuous proc-esses, special arrangements may be made with regard to the number of tests required and the making of the test specimens.

In the case of products which are not quenched and tempered, one tensile test specimen is to be taken for each rolled length.

4.2.2 Test specimens are to be cut with their longitudinal axes perpendicular to the final direction of rolling, except in the case of sections and wide



D

Table 1.11 Chemical composition of quenched and tempered steels

Grade, with nominal yield

strengths grade

Maximum Content of Elements 1 [%]

ReH [N/mm2] C Si Mn P S N

420 to 690

GL–A

GL–D

GL–E

GL–F

0,21

0,20

0,20

0,18

0,55

0,55

0,55

0,55

1,70

1,70

1,70

1,70

0,035

0,030

0,030

0,025

0,035

0,030

0,030

0,025

0,020

0,020

0,020

0,020

1 Elements used for alloying and fine grain treatment are to be as details in the approved specification.

flats < 600 mm in width, where longitudinal test specimens are to be taken. For other product forms, the tensile test specimens may be taken in either the longitudinal or the transverse direction as agreed with GL. Normally, flat tensile test specimens are to be used. The tensile-test specimens may be taken from the full or the half product thickness, however, one surface side shall be maintained. For thicknesses above 30 mm round tensile test specimens may be used, the axis of which shall lie at a distance of 1/4 of the product thickness from the surface.

4.3 Impact test

4.3.1 From each piece as heat treated or, in the case of products from each rolling length which have not been quenched and tempered, at least one set of three Charpy V-notch impact test specimens in accordance with Chapter 1 – Principles and Test Procedures, Sec-tion 2, E.2. is to be taken and tested. For continuous heat treated plates special consideration may be given to the number and location of test specimens required.

4.3.2 Unless otherwise accepted by GL, the V-notch impact test specimens for plates and wide flats ≥ 600 mm are to be taken with their axes transverse to the main rolling direction. For other product forms the impact tests are to be in the longitudinal direction. The specimens' axes shall be positioned at a distance of 1/4 of the product thickness from the surface or as near as possible to this position.

4.3.3 For grade GL-A steel products, the number of impact test specimens may be reduced by agreement with GL, where equivalent results are obtained during testing.

4.4 Through thickness tensile test

If required by GL, through thickness tensile tests are to be performed using test specimens taken at right angles to the surface of the product in accordance with I.

4.5 Surface inspection and dimensions

The manufacturer shall inspect the condition of the surface and the dimensions of the product and shall then submit the products to the Surveyor for inspec-tion.


4.6.1 Where plates and wide flats are ordered with a certificate of ultrasonic examination, the tests are to be carried out according to a standard accepted by GL, e.g. EN 10160. The quality class is to be defined at the time of the order.

4.6.2 The seams of welded hollow sections of hull structural steel are to be subjected to non-destructive testing over their entire length.

4.6.2.1 Electrical welded hollow sections

The weld seam of hollow sections is to be examined according to one of the following European standards:

– EN 10246-3, acceptance category E4, except that the technique of rotating pipes or with rotat-ing saddle coils is not permitted

– EN 10246-5, acceptance category F5, or EN 10246-8, acceptance category U5

4.6.2.2 Submerged-arc welded hollow sections

The weld seam of hollow sections is to be examined according to acceptance category U4 in accordance with EN 10246-10, image quality class R2.

Butt welds serving to connect strip or plate lengths by spiral submerged-arc welding have to be examined over their entire length according to the same test procedure and shall satisfy the same acceptance crite-ria as the main weld seam.

II - Part 1 GL 2009


D

Table 1.12 Mechanical and technological properties for products with 70 mm maximum thickness

Impact energy Elongation 3

( )o oat L = 5,65 S⋅

A [%] min.

KV [J]

min.

Grades

Yield strength 1, 2 ReH

[N/mm2] min.

Tensile strength Rm

[N/mm2]

long. transv.

Test temp.

[°C]

long. transv.

GL–A 420 0

GL–D 420 – 20

GL–E 420 – 40

GL–F 420

420 530 – 680 20 18

– 60

42 28

GL–A 460 0

GL–D 460 – 20

GL–E 460 – 40

GL–F 460

460 570 – 720 19 17

– 60

46 31

GL–A 500 0

GL–D 500 – 20

GL–E 500 – 40

GL–F 500

500 610 – 770 18 16

– 60

50 33

GL–A 550 0

GL–D 550 – 20

GL–E 550 – 40

GL–F 550

550 670 – 830 18 16

– 60

55 37

GL–A 620 0

GL–D 620 – 20

GL–E 620 – 40

GL–F 620

620 720 – 890 17 15

– 60

62 41

GL–A 690 0

GL–D 690 – 20

GL–E 690 – 40

GL–F 690

690 770 – 940 16 14

– 60

69 46

1 Where the yield strength ReH does not mark in the tensile test, the 0,2 % proof stress Rp0,2 is applicable. 2 The permissible ratio between yield strength and tensile strength is to be agreed between the manufacturer and GL.

4 Where flat tensile test specimens 25 mm wide and with a gauge length of 200 mm are used, the minimum requirements in respect of elongation are to be obtained from Table 1.13.



D

Table 1.13 Minimum values in respect of elongation when using specimens 25 mm wide and with a gauge length of 200 mm

Elongation A200 mm [%]

Nominal yield strength Thickness of product t [mm]

ReH [N/mm2] ≤ 10 >≤

10

15

>≤

15

20

>≤

20

25

>≤

25

40

>≤

40

50

>≤

50

70

420

460

500

550

620

690

11

11

10

10

9

9

13

12

11

11

11

10

14

13

12

12

12

11

15

14

13

13

12

11

16

15

14

14

13

12

17

16

15

15

14

13

18

17

16

16

15

14

4.7 Retest procedures

4.7.1 If one of the tensile tests fails to meet the requirements two additional test specimens are to be taken from the same position of the piece and sub-jected to the test. The piece will be accepted, if both additional tests are satisfactory.

4.7.2 When the average value of the impact test fails to meet the requirements or more than one value is below the required average value or when one value is below 70 % of the specified average value, the procedure described in Chapter 1 – Principles and Test Procedures, Section 2, H. is to be followed.

5. Marking

Every finished piece is to be clearly marked by the maker in at least one piece with GL brand and the following particulars:

– Marks of the manufacturer

– Unified identification mark for the grade of steel (e.g. GL–E 620) or manufacturer's trade name

– Heat number, plate number or equivalent identi-fication mark.

The entire markings are to be encircled with paint or otherwise marked so as to be easily recognized.

E. Steels for Steam Boilers and Pressure Vessels

1. Scope

These Rules apply to flat products made from ferritic steels, which are intended for the manufacture of steam boilers, pressure vessels, heat exchangers and other process equipment.

2. Approved steel grades

The materials listed below may be used:

2.1 Flat products made of steels used for pressure vessels conforming to EN 10028-2 "Alloyed and Unalloyed High Temperature Steels".

2.2 Flat products made of steels used for pressure vessels conforming to EN 10028-3, "Weldable fine-grained structural steels, normalised".

2.3 Flat products made of GL-steels used for pressure vessels according to Table 1.14 and 1.15. For the 0,2 % proof stress at elevated temperatures, Table 1.16 applies.

2.4 Flat products made of other steels, provided that their suitability for the intended purpose and their properties have been proved to GL. For this, the fol-lowing requirements are to be satisfied:

2.4.1 The elongation (A) shall have the minimum values which characterise the grade of steel, as speci-fied in the GL report, but shall be not less than 16 %.

2.4.2 The impact energy shall meet or exceed the requirements of EN 10028-2 and -3 respectively for flat products of the same strength, see Table 1.14. In the case of plates to be used for shell rings and heads, the manufacturer and the steel user shall ensure that the values required for the final condition can be com-plied with.

2.4.3 Proof of weldability shall be furnished by the manufacturer. Details of preheating, temperature con-trol during welding and heat treatment after welding shall be furnished by the manufacturer.

2.4.4 The yield strength at elevated temperature and, where necessary, the long-time rupture stress properties at elevated temperature shall be verified by the manufacturer if they are different from Table 1.16.

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Table 1.14 Mechanical and technological properties of flat products made of GL-steels used for pressure vessels 1


Steel grade Normal delivery

condition

Yield strength ReH and

Rp0,2 respectively

[N/mm2] min.

Tensile strength Rm

[N/mm2]

Elongation A

[%] min.

Test temp. [°C]

KV [J]

min. transv.

GL-P235W N 235 360 to 480 25 0 34

GL-P265W N 265 410 to 530 23 0 34

GL-P295W N 295 460 to 580 22 0 34

GL-P355W N 355 510 to 650 21 0 34

1 N = normalized, T = tempered.

Table 1.15 Chemical composition of GL-steels used for pressure vessels

Chemical composition [%] Steel grade

C Si Mn P S Altot. Cr Mo

all ≤ 0,23 ≤ 0,55 0,60–1,70 ≤ 0,025 ≤ 0,015 ≥ 0,020 ≤ 0,30 ≤ 0,08

Table 1.16 0,2 %-Proof stress at elevated temperatures for flat products made of GL-steels used for pres-sure vessels

Rp0,2-Yield strength [N/mm2] min.

Temperature [°C] Steel grade

50 100 150 200 250 300 350 400

GL-P235W 227 214 198 182 167 153 142 133

GL-P265W 256 241 223 205 188 173 160 150

GL-P295W 285 268 249 228 209 192 178 167

GL-P355W 343 323 299 275 252 232 214 202

2.5 For plates to be used for shell rings and heads, the following additional requirements apply:

For steels for welded boiler drums, the impact energy shall be 31 J at ± 0 °C in tests performed on the fin-ished component, if in the case of plate thicknesses ≥ 50 mm the yield strength of these steels is ≥ 310 N/mm2 at room temperature. This energy value is an average for three individual tests with (trans-verse) Charpy V-notch specimens, in which none of the individual values may be more than 15 % lower than the stated average of 31 J. The stated impact energy value at ± 0 °C is a minimum requirement. In

addition, the individual steels shall exhibit their char-acteristic impact energies.

2.6 Plates to be manufactured into fire tubes shall exhibit adequate formability - elongation (A) ≥ 20 % at 20 °C .


The products shall be delivered in the heat-treated conditions specified in the standards and/or in the expert's report, unless they are to be further processed at elevated temperature.



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A.6. applies with the following addition: The minus tolerances for the nominal thickness shall be as stated under Class B in Table 1.1. If lower minus tolerances are required for technical reasons, this shall be stated in the order.




The manufacturer shall determine the chemical com-position of each heat and issue a relevant certificate.

5.2 Tensile test

The mechanical properties shall be verified by tensile testing. Test specimens shall be taken from the prod-ucts transverse to the direction of rolling in the follow-ing quantity:

– For sheet and plate, the specimens shall be taken as follows:

– unalloyed steel sheet ≤ 50 mm thick:

- one specimen from one end of each rolled length

– unalloyed steel plate > 50 mm thick:

- one specimen from one end if the rolled length is ≤ 15 m, one specimen from each end if the rolled length is > 15 m

– alloy steels with rolled length ≤ 7 m:

- one specimen from one end, one speci-men from each end if the rolled length is > 7 m.

– For sheets made from hot-rolled wide strip, at least one specimen shall be taken from the outer end of each coil.

5.3 Tensile test at elevated temperature

The 0,2 % proof stress is to be verified at elevated temperature. A tensile test at elevated temperature shall be performed for each heat. The test temperature shall be 300 °C, unless no other temperature is speci-fied in the order.


5.4.1 All products with thicknesses ≥ 6 mm shall be impact tested using Charpy V-notch specimens at the test temperature of 0 °C. The specimens shall be taken from the products transverse to the direction of rolling. The number of sets (each of 3 specimens) required for this purpose shall be determined in the same way as the number of tensile test specimens prescribed in 5.2.

The test temperatures for flat products complying with EN 10025 are given in the standard.

For other steels as per 2.4, the test temperature will be stipulated in the GL approval.


The surface finish and dimensions of all products shall be checked by the manufacturer. The products shall also be submitted to the Surveyor for final inspection; as far as possible, the undersides of the products shall be inspected at the same time.


Where specified in the order or required in special cases, e.g. in the case of products subject to require-ments in the thickness direction in accordance with I., an ultrasonic test shall be carried out in accordance with A.8.6.

6. Marking of products

The manufacturer shall mark the products in the pre-scribed manner, see EN 10028-1. In the case of plates which are not supplied in bundles, the marking shall be applied 200 to 400 mm from the bottom end in such a way that, looked at from the bottom end of the plate, the characters are upright and therefore indicate the direction of rolling.

7. Strength parameters for calculations

The strength parameters for calculations are:

7.1 For flat products conforming to EN 10028-2 and -3, the values stated in these standards.

For flat products made of GL-steels used for pressure vessels according to 2.3, the values stated in Table 1.16.

7.2 For flat products made of other steels as per 2.4, the values approved by GL.

7.3 The strength parameters indicated in the above standards for 100 °C are valid up to 120 °C. In the other ranges, the values are to be determined by linear interpolation between the stated values, e.g. for 180 °C between 100 °C and 200 °C; rounding up is not allowed.

F. Steels for Cargo Tanks

1. Scope

1.1 These Rules apply to flat products made from

– fine-grained structural steels,

– high strength, quenched and tempered fine-grained structural steels,

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– nickel alloy steels which are tough at low tem-peratures

– austenitic steels

which are intended for the fabrication of cargo tanks and process pressure vessels for carrying liquefied gases.

1.2 Steels conforming to these rules shall be approved by GL for the above-mentioned purpose and design temperature.

To this end, the steels listed under 1.1 above shall be subjected to an approval test by GL. GL shall decide on a case to case basis on the need for an approval test on austenitic steels and other special structural steels.


The following steel grades may be used considering the minimum design temperatures stated in Table 1.17 provided that they satisfy the additional requirements stipulated in these Rules:

2.1 Weldable, fine-grained structural steels con-forming to EN 10028-3.

Note:

The use of steel grade P460 NH for tanks designed to carry pressure-liquefied ammonia at ambient tem-peratures is prohibited.

2.2 Fine-grained structural steels with nominal yield strengths above 335 N/mm2 in accordance with EN 10028-3, -5 and -6.

2.3 Nickel alloy steels which are tough at low temperatures, conforming to EN 10028-4.

2.4 Stainless, austenitic steels conforming to EN 10028-7, provided that they are suitable for the intended design temperature.

2.5 Other weldable steels conforming to other standards or to material specifications of the manufac-turer or the purchaser, after initial approval testing by GL.

Table 1.17 Minimum design temperatures for steels used in the fabrication of cargo tanks

Steel designation References to standards and

rules Minimum design temperature

[°C]

Fine-grained structural steels for ammonia which has been liquefied under pressure

For chemical composition, see Table 1.18

0

Normalized, TM rolled and fine-grained structural steels with nomi-nal yield strengths above 355 N/mm2

e.g. according to EN 10028-3, -5 or -6 and Section 8, D.

0

Other fine-grained structural steels with nominal yield strengths up to 355 N/mm2

e.g. according to EN 10028-3, -5 or -6

– 45 1

Nickel alloy steels containing

0,5 % Nickel

Steels according to EN 10028-4

11MnNi5-3, 13MnNi6-3

– 55

1,5 % Nickel 15NiMn6 – 60 2

3,5 % Nickel 12Ni14 – 90 2

5 % Nickel X12Ni5 – 105 2

9 % Nickel X7Ni9, X8Ni9 – 165

e.g. steels according to EN 10028-7

1.4306 (AISI 304 L)

1.4404 (AISI 316 L)

1.4541 (AISI 321)

Austenitic steels

1.4550 (AISI 347)

– 165

1 GL reserve the right to approve a lower design temperature (max. – 55 °C) if suitable properties are demonstrated during approval testing.

2 A lower design temperature may be approved for steels containing 1,5 %, 3,5 % and 5 % nickel if the steels are quenched and tem-pered. In these cases, the test temperatures will be specially stipulated by GL.



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3. Approval test

3.1 On the subject of approval of materials, the material manufacturer or tank manufacturer shall provide GL with a material specification containing all the particulars needed to evaluate the material. The specification shall give the minimum particulars as follows:

– material designation/standard

– material manufacturer

– recommended values for chemical composition

– mechanical properties

– intended minimum design temperature

– range of product thicknesses

– delivery condition

– associated standards or specifications, e.g. for tolerances, surface finish, freedom from defects

– heat treatments

– working method

3.2 By means of an approval test, the material manufacturer shall demonstrate that the material is suitable for the intended minimum design temperature, the cargo carried and the intended method of process-ing, especially if this involves welding.

The scope of the approval test is set down by GL on a case by case basis. It shall include notch impact and drop weight tests in the appropriate temperature range, and for quenched and tempered steels with nominal yield strength of 620 and 690 N/mm2 it shall also include fracture mechanics tests on the base metal.

4. Limits to use

For fabrication of cargo tanks and process pressure vessels, the limit values for the lowest design tempera-tures as per Table 1.17 shall apply.


All products shall be supplied in the heat treated con-ditions specified during the approval test and/or in the standards or material specifications.

6. Dimensions, dimensional tolerances

For plates for parts of the tank or vessel shell includ-ing the end plates and domes, the minimum thickness shall be the nominal thickness prescribed in the order specification. Plates, strips and wide flats which do not form part of the shell may be supplied with the minus tolerances stated in A.6., Table 1.1, Class A.

7. Freedom from defects and repair of sur-face defects

The provisions of A.5. are applicable. Surface defects may generally be removed only by grinding, which shall not at any point reduce the thickness below the prescribed minimum. Where defects are to be repaired by welding, this shall be preceded by a welding pro-cedure test, and the conditions for welding shall then be established.

8. Requirements applicable to the material


8.1.1 The chemical composition shall conform to the data in the recognised standard or the material specification authorised by GL.

In addition the limiting values for the chemical com-position of fine-grained structural steels with a nomi-nal yield strength of up to 355/Nmm2 used in the fab-rication of tanks carrying pressure-liquefied ammonia as given in Table 1.18 are to be met.

8.1.2 On the subject of the evaluation of the weld-ability of high-strength, quenched and tempered fine-grained structural steels, sensitivity to cold-cracking is to be determined from the ladle analysis in accordance with the following formula:

P CSi Mn Cu Ni

Cr Mo VB

cm = + + + + +

+ + +

30 20 20 60

20 15 105 %

The boundary value shall be specified when approval is given for the material.

Table 1.18 Chemical composition for fine-grained structural steels suitable for ammonia which has been liquefied under pressure (ladle analysis)

[%] maximum in the absence of any other indication 1

C Si Mn P S Al Cr Cu Mo Ni 2 V

0,18 0,10 –

0,50 1,65 0,030 0,025

min 0,020

0,20 0,35 0,04 0,40 0,02

1 For steels with nominal yield strengths of 355 N/mm2, the chemical composition shall be set so that an upper yield strength figure of

440 N/mm2 is not exceeded. 2 Where nickel is intentionally alloyed, the upper boundary value is 0,85 %.

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8.2.1 The requirements applicable to the mechani-cal properties which are stated in the recognised stan-dard or the authorised material specification shall be verified during testing.

8.2.2 The following also applies to fine-grained structural steels for pressure-liquefied ammonia:

The actual yield strength ReH may not exceed 440 N/mm2 or 470 N/mm2 in the case of hot-formed dished ends.

Elongation A5 shall be at least 22 %.

8.3 Impact energy

The required impact energy values specified in Table 1.19 and 1.20 respectively for the steel grade con-cerned shall be achieved in tests on Charpy V-notch specimens at the prescribed test temperatures. This requirement also applies to comparable steels con-forming to the standards or specifications, irrespective of the values stated therein.

8.4 Brittle fracture behaviour

When subjected to Pellini's drop weight test at a test temperature 5 K below the design temperature (but no higher than – 20 °C), ferritic steels shall display a "no break performance".

8.5 Resistance of austenitic grades to inter-crystalline corrosion

In the condition in which they are supplied, austenitic steels shall be resistant to intercrystalline corrosion. Where the materials undergo welding without subse-quent heat treatment (solution annealing), only those grades of steel may be used which are corrosion-resistant in this condition, e.g. Ti or Nb stabilized steels or steels with carbon contents of C ≤ 0,03 %.


The following tests are to be performed:



9.2 Tensile test

9.2.1 All products shall be subjected to the tensile test. For this purpose, specimens shall be taken trans-verse to the direction of rolling in the case of plate, hot-rolled wide strip and wide flats with a width of ≥ 600 mm. For all other products they may be taken transverse or parallel to the rolling direction.

9.2.2 The number of specimens shall be deter-mined as follows:

– normalised and TM-rolled plates: one specimen from one end of each rolled length. If this is greater than 15 m, one specimen shall be taken from each end.

– all quenched and tempered plates: one specimen from one end of each heat-treated length. If this is greater than 7 m, one specimen shall be taken from each end.

– sheets taken from hot-rolled wide strip which do not undergo individual heat treatment: one specimen each from the outer end of the coil.

– for plates of austenitic stainless steels one specimen of each heat treatment length. If this is greater than 15 m one specimen shall be taken from each end.

9.2.3 Specimens taken from the top and bottom ends of a rolled plate may not differ in tensile strength by more than the following amounts:

– rolled lengths of ≤ 10 m: 60 N/mm2

– rolled lengths of > 10 m: 70 N/mm2


9.3.1 All products with thicknesses of ≥ 6 mm shall be subjected to the notched bar impact test performed on Charpy V-notch specimens at the test temperatures specified in Table 1.19 and 1.20 respectively. In the case of plates and wide flats with a width of ≥ 600 mm the specimens shall be taken transverse to the direction of rolling. For all other products they may be taken parallel or transverse to the rolling direc-tion. The number of sets (each comprising 3 speci-mens) required shall be determined in the same way as the number of tensile specimens prescribed in 9.2.2.

9.3.2 Where the thickness of the products pre-cludes the preparation of specimens with the standard dimensions (10 mm × 10 mm), specimens measuring 7,5 mm × 10 mm or 5 mm × 10 mm should be used wherever possible. These specimens are subject to the requirements stated in Table 1.20.

9.4 Drop weight test

Products made from high-strength, quenched and tempered fine-grained structural steels and steels de-signed for a minimum design temperature of less than – 50 °C (with the exception of austenitic steels) are to be tested per heat by means of a drop weight test.

For the drop weight test, at least 2 specimens shall be taken from the thickest item from each heat and tested at a temperature of 5 K below the minimum design temperature. The test shall only be performed on products with a thickness of > 16 mm. It is to be con-ducted in accordance with a recognized standard, e.g. Stahl-Eisen-Prüfblatt (Steel-iron test specification) SEP 1325, EN 10274 or ASTM E-208, see also Chapter 1 – Principles and Test Procedures, Section 2, G.3.



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Table 1.19 Impact energy requirements for steels used for cargo tanks


KV [J] 1

min.

Steel designation Product thickness

[mm] Test temperature [°C]

long. transv.

Fine-grained structural steels for ammonia liquefied under

pressure ≤ 40 –20

Fine-grained structural steels with yield strengths ReH ≥ 355 N/mm2

≤ 40 –20

Other fine-grained structural steels, nickel alloy steel containing

0,5 % nickel

≤ 25 2 5 K below minimum design temperature, not higher than

–20 °C

Nickel alloy steels containing:

1,5 % Nickel 3,5 % Nickel 5 % Nickel 9 % Nickel

≤ 25 3 –65 –95 –110 (– 196) 4 –196

Austenitic steels ≤ 50 –196

41 (29) 27 (19)

1 Average value of 3 specimens; figures in brackets are minimum individual values.

2 The following test temperatures are applicable to product thicknesses above 25 mm:

Product thickness [mm]

Test temperature

25 < t ≤ 30

30 < t ≤ 35

35 < t ≤ 40

10 K

15 K

20 K

⎫⎬⎭

below minimum design temperature but not higher than –20 °C.

For steels intended for tanks and structural components of tanks with product thicknesses above 25 mm which are subjected to stress-

relief heat treatment after welding it is sufficient to apply a test temperature 5 K below the design temperature but not higher than – 20 °C.

For stress-relief heat-treated tank reinforcements and similar welded parts the test temperature may not be higher than that specified for the thickness of the adjoining shell plate.

3 Where, in the case of nickel alloy steels containing 1,5 % Ni, 3,5 % Ni and 5 % Ni, the product thickness exceeds 25 mm, the test temperatures shall be determined in accordance with the data given in footnote 2. They shall not, however, be higher than those shown in the Table.

For 9 % nickel steel over 25 mm thick, the requirements shall be specially agreed with GL.

4 Where 5 % nickel steel is tested and approved for a minimum design temperature of – 165 °C, the notched bar impact test shall be performed at a test temperature of – 196 °C.

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Table 1.20 Requirements applicable to specimens of reduced size according to impact energy for standard specimens

Necessary impact energy KV with specimens measuring Necessary impact acc. to Table 1.19

(standard specimens) 7,5 mm × 10 mm 5 mm × 10 mm

average value

[J] 1 min.

average value

[J] min.

minimum individual value

[J]

average value

[J] min.

minimum individual value [J]

27 (19) 22 16 18 13

41 (29) 34 24 27 22

1 Average value of 3 specimens; figures in booklets are minimum individual values..

9.5 Test of resistance to intercrystalline corro-sion

Wherever necessary or prescribed in the order, the resistance of austenitic steels to intercrystalline corro-sion shall be tested.

9.6 Test of surface finish and dimensions

The surface finish and dimensions of all products shall be checked by the manufacturer. They shall also be submitted to the Surveyor for final testing, and in the case of flat products the underside shall also be in-spected by means of random sampling.

9.7 Non-destructive tests

9.7.1 The manufacturer shall carry out an ultra-sonic test in accordance with A.8.6 on the following products and shall certify the result:

– plates for pressure-liquefied ammonia

– plates made from high-strength, quenched and tempered fine-grained structural steels

– plates which are loaded in the thickness direc-tion, e.g. those used for the central longitudinal bulkheads of bilobe tanks,

The purchaser shall indicate these requirements in his order documents.

Special arrangements are to be made for the testing of rolled sections for the equator rings of spherical tanks.

9.7.2 Ultrasonic testing is to be carried out accord-ing to EN 10160 or as stated in Stahl-Eisen-Lieferbedingungen SEL 072 (Steel-Iron Supply Speci-fications SEL 072) as follows:

Test grid ≤ 200 mm or in lines 100 mm apart.

SEL 072 EN 10160

Surface test Class 3, Table 1 S1

Marginal zone test Class 1, Table 2 E3

Zones for longitudinal, circumferential and connection welds over a width equal to the thickness of the plate, but not less than 50 mm in accordance with Class 1, Table 2 according to SEL 072 and quality class E3 according to EN 10160 respectively.

Areas for the connection of supporting brackets, lift-ing lugs and floating securing devices 100 % in accor-dance with Class 0, Table 1 according to SEL 072 and quality class S3 according to EN 10160 respectively.

9.7.3 A non-destructive test shall be performed on products other than those mentioned in 9.7.1 if this is specified at the time of the order or called for by GL in special cases.

G. Stainless Steels

1. Scope

These Rules are applicable to flat products, sections and bars made of stainless steels which are intended for the fabrication of cargo tanks of chemical tankers, pressure vessels and other vessels, for which chemical stability in relation to the cargo or operating fluid is required, and also for sleeves of rudderstocks, rudder pintles, propeller shafts etc. which are required to be seawater resistant.

2. Selection of steels

2.1 Steels shall be selected in accordance with the operator's list of cargoes, which provides informa-tion on the nature of the substances to be transported or stored.

2.2 Furthermore, steels shall be selected in such a way that also depending upon their further processing, e.g. by welding, the required chemical stability in relation to the respective cargo or operating fluid is ensured.



G

2.3 In the light of 2.1 and 2.2 above, suitable steels may be selected e.g. in accordance with EN 10088 relating to stainless steels, where the prod-ucts are not required to be supplied in accordance with a specification which has been examined by GL.

2.4 GL reserves the right to demand an approval test for the grade of steel in question.


All products shall be presented in the heat-treated condition appropriate to the material, i.e. ferritic steels shall be annealed or quenched and tempered, while austenitic and austenitic-ferritic steels shall be solu-tion-treated.

4. Dimensional tolerances

Unless otherwise stipulated in the order specification, plates are to be supplied in accordance with A.6., Class B as indicated in Table 1.1 (permitted thickness tolerance –0,3 mm). For all other products the values stated in the relevant standards shall apply.

5. General condition of products

The provisions of A.5. shall apply. Surface defects may generally only be repaired by grinding.

In doing so, the relevant minus tolerance shall not be exceeded at any point.

6. Requirements applicable to material prop-erties


6.1.1 The limit values for the chemical composi-tion stated in the standards or in the specifications approved by GL shall apply.

6.1.2 For welded structures which cannot be heat treated after welding, only steels which are resistant to intercrystalline corrosion in this condition may be used, e. g. Ti or Nb stabilized austenitic steels or steels with carbon contents of C ≤ 0,03 %.


The requirements applicable to the mechanical proper-ties which are stated in the recognised standard or the approved material specification shall be verified dur-ing testing.

6.3 Impact energy

The requirements applicable to the impact energy which are stated in the recognised standard or the approved material specification shall be satisfied.





7.2 Testing of resistance to intercrystalline corrosion

All products shall be tested for resistance to intercrys-talline corrosion. For this purpose, at least 2 speci-mens shall be taken from each heat. The test is to be performed in accordance with DIN 50914 or ISO 3651-2 on specimens in the following condition:

– stabilized steels and steels with a carbon content ≤ 0,03 %: sensitized (annealed at 700 °C for 30 minutes and quenched in water)

– all other steels: in the condition in which they are supplied

7.3 Tensile test

7.3.1 At least one tensile test specimen shall be taken from each test batch and tested. A test batch comprises:

– plates > 20 mm thick: the rolled length

– plates ≤ 20 mm thick: max. 40 rolled plates of approximately the same thickness (deviation max. 20 %) originating from the same heat and the same heat treatment batch with a total weight not exceeding 30 t.

– strip and plates taken therefrom: one specimen each from the beginning of the coil.

– all other product shapes: 5000 kg for products of the same shape originating from the same heat and the same heat treatment batch

7.3.2 In the case of plates and wide flats with a width of ≥ 600 mm, the specimens shall lie in the transverse direction. For all other product shapes they may lie in the longitudinal or transverse directions.


7.4.1 Unless otherwise required by GL or stipu-lated in the order, a notched bar impact test with Charpy V-notch specimens is required for

– flat products with a thickness > 20 mm

– rods and bars with diameters or thicknesses > 50 mm

– flat products made of austenitic-ferritic steels with thicknesses ≥ 6 mm

7.4.2 If the products are used for operating tem-peratures below –10 °C, the impact test temperature shall be agreed with GL.

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The surface finish and dimensions of all products shall be checked by the manufacturer. The products shall also be submitted to the Surveyor for final testing. In the case of flat products, the underside shall also be inspected as far as possible.

7.6 Testing for use of correct material

The manufacturer shall test his products before deliv-ery by appropriate methods as to whether the correct material has been used and shall confirm this in the acceptance test certificate.

7.7 Other tests

If there are special requirements regarding resistance to pitting or crevice corrosion, appropriate corrosion tests shall be performed, e.g. to ASTM-G48. The scope of these tests will be determined by GL from case to case.

H. Clad Plates

1. Scope

These Rules are applicable to steel plates clad with cladding materials made of stainless steels and in-tended for the manufacture of containers and tanks, e. g. for chemical tankers. It may be agreed to apply these rules to plate clad with other materials, e. g. aluminium or copper-nickel alloys.

2. Suitability of cladding process

The manufacturer shall demonstrate by means of an initial test of product suitability that the clad products satisfy the requirements stated in 8. and the required properties of the base material are preserved after cladding.

3. Suitable materials

Steels conforming to B., C. and E. shall be used as base materials. The stainless steels specified in G. and other materials approved by GL for the purpose may be used as cladding materials.

4. Method of manufacture and condition of supply

4.1 Cladding may be performed by rolling or explosive cladding or by a combination of the two methods.

4.2 Plates clad with austenitic materials shall normally be supplied in the as rolled condition. Where heat treatment is required in special cases, this is gov-erned by the base material. However, the treatment shall not impair either the chemical stability or the

bonding of the cladding material. The type of heat treatment shall be notified to GL.

5. Dimensions and tolerances

5.1 The nominal thickness of the cladding mate-rial shall be at least 2 mm. Where no closer thickness tolerances are specified in the order, the minus toler-ances for the thickness shall be as shown in Table 1.21.

Table 1.21 Minus tolerances in relation to the thickness of the cladding material

Nominal thickness [mm]

Minus tolerance [mm]

≥ 2,0 < 2,5 ≥ 2,5 < 3 ≥ 3,0 < 3,5 ≥ 3,5 < 4,0 ≥ 4,0

– 0,20 – 0,25 – 0,35 – 0,45 – 0,50

5.2 The tolerances for the base materials shall be governed by the requirements for the respective steel grades and product shapes.

6. Surface finish

6.1 The cladding materials shall have a smooth surface consistent with their purpose. The surface shall be free from scale, impurities, annealing colour and such defects as may impair the manufacturing processes applied to the material, its application or its chemical stability. The surface finish of the base mate-rial shall comply with A.5.

6.2 On the cladding material, the total surface area of all defects, with the exception of shallow de-fects as per 7.1, shall not exceed 20 % of the surface area of the cladding.

7. Repair of defects

7.1 Shallow defects in the cladding material, e.g. impressions, grooves and scratches, shall be removed by grinding within the tolerance specified in 5.

7.2 In general points where bonding has not occurred up to an area of 50 cm2 may be tolerated, except where the purchaser requires that certain areas of the plate be repaired.

7.3 Deep defects in the cladding material which cannot be removed by grinding and lack of bonding in excess of 50 cm2 may be repaired by welding pro-vided that the defects are isolated and separated from each other, do not exceed 1200 cm2 in area and do not



H

total more than 5 % of the clad surface. Welding shall be subject to the following Rules:

7.3.1 All welds shall be made by qualified welders using a technique approved by GL.

7.3.2 The welds shall be free from cracks, lack of fusion, undercuts, slag and other defects liable to im-pair the characteristics of the cladding.

7.3.3 After welding, the repaired defect shall be ground flush with the plate. Welding shall be followed by heat treatment if this was specified by the proce-dure approval test or if called for in the order.

7.3.4 After final machining, the plates shall be submitted to the Surveyor for final testing, and a suit-able non-destructive test technique, e.g. dye penetrant inspection, shall be used to prove that the repairs are free from defects.

7.3.5 For each repair weld the manufacturer shall give the Surveyor a report stating the dimensions and location of the defects, the details of the welding tech-nique used, the nature of any heat treatment applied and the results of the test.


The clad steels shall satisfy the following require-ments.

8.1 Elongation

In the case of clad steels where the elongation of the cladding material is less than that of the base material, the cladding material shall attain an elongation A5 of at least 12 % in a tensile test after the base metal has been removed by machining.

8.2 Shear strength

The bond between the base and cladding materials shall be adequate to ensure that the cladding material cannot break away from the base material when proper manufacturing processes or service loads are applied. In the case of cladding materials with a ten-sile strength of < 280 N/mm2, the shear strength shall be at least 50 % of the minimum tensile strength of the cladding material and for all other cladding materials it shall be not less than 140 N/mm2, irrespective of the direction of testing, unless otherwise agreed in the order.

8.3 Bonding

The proportion of bonded surface shall be at least 95 %, and the area of isolated points where bonding has not occurred shall not exceed 50 cm². For clad steels which are severely stressed during processing, e.g. in the manufacture of dished ends, or while in use, e.g. in tubesheets, it may be necessary for the pur-chaser to impose more stringent requirements.


When subjected to the tensile test, the clad plate shall satisfy at least the following requirements:

G G A Apl

pl

S S

S

σ ⋅ + σ ⋅σ =

σ = specified minimum value of tensile strength or yield strength or 0,2 % proof stress [N/mm2]

S = nominal thickness [mm]

Indices:

G = base material

A = cladding material

pl = clad steel

If the tensile test gives a lower value than that calcu-lated by the formula, the requirements applicable to the base material may be verified by means of speci-mens from which the cladding material has been re-moved by machining.

The elongation specified for the base material con-cerned shall be verified by tests performed on clad specimens.

8.5 Technological properties

When subjected to the side bend test, the clad plate shall be capable of being bent through 180° over a mandrel with a diameter equal to four times the thick-ness of the specimen without separation of the clad-ding material or formation of incipient cracks.

Larger bending mandrel diameters may be agreed for other cladding materials, e.g. aluminium.

8.6 Impact energy

The requirements applicable to the base material shall be capable of being satisfied after cladding has been carried out.

8.7 Resistance to intercrystalline corrosion

For austenitic or austenitic-ferritic cladding materials, the requirements applicable to the relevant grade of steel shall be satisfied.

9. Testing

The scope of the tests and the number and location of the test specimens are determined by the base mate-rial. The following tests are to be performed.


The manufacturer shall determine the chemical com-position of each heat of base and cladding material and shall issue a relevant certificate.

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In the case of austenitic and austenitic-ferritic cladding materials, the resistance to intercrystalline corrosion shall be verified for each test batch. For this purpose, those plates may be grouped together into a test batch which have been clad in the same manufacturing cycle with cladding materials originating from the same heat. Under test, the clad side shall be subjected to tensile stress.

9.3 Tensile test

The tensile test shall be performed on a transverse specimen from each test batch. Unless otherwise agreed, the cladding material shall be left on the test specimen. The gauge marks shall be applied to the base material side.

9.4 Shear test

From each test batch a specimen shall be taken with its axis transverse to the rolling direction and this shall be subjected to the shear test.

The test shall be performed in accordance with a rec-ognized standard, e.g. DIN 50162. The dimensions of the test specimen and the test arrangement are shown in Figure 1.2.

25

204,

565

10Shear test specimen

Claddingmaterial

Guideblocks

P

Fig. 1.2 Shear test

9.5 Side bend test

From each test batch a specimen shall be taken with its axis transverse to the rolling direction and this shall be subjected to the side bend test. The dimensions of the test specimen and the test arrangement are shown in Figure 1.3. Where the product thickness exceeds 80 mm, the specimens may be reduced to 80 mm by machining the base material side.


The notched bar impact test shall be performed in cases where it is specified for the base material. The number of specimens, their orientation and the test temperature are subject to the same conditions as apply to the base material.

��

��

��

��

�

Fig. 1.3 Side bend test


The surface finish and dimensions of all plates shall be checked by the manufacturer and the thickness of the cladding shall be measured at the edges and in the middle of the plate. All plates shall be submitted to the Surveyor for final testing and verification of the di-mensions.


To ascertain the quality of the bond between the base and cladding materials, the manufacturer shall carry out 100 % ultrasonic testing of the surfaces and edges of all plates.

10. Marking

All plates are to be marked as follows:


– abbreviated steel grade designation or material number of base and cladding material

– heat numbers of base and cladding material

– thickness of base and cladding material

– specimen no.

I. Steels with Through Thickness Properties

1. Scope

These Rules are supplementary to all Rules applying to plates, strips, wide flats and shapes made of fine-grained structural steels for which enhanced deforma-tion properties in the direction of product thickness are required. They apply to products with thicknesses greater than or equal 15 mm. For smaller thicknesses these Rules may be applied at discretion of GL.



I

2. Requirements

2.1 Reduction in area

The average value of the reduction in area measured on 3 tensile test specimens (Z specimens) lying in the direction of the product thickness shall be at least 25 % for the grade Z25, including one test result which may be lower than 25 % but not less than 20 %.

For the grade Z35 the reduction in area has to be at least 35 %, including one test result which may be lower than 35 % but not less than 25 %.

2.2 Freedom from defects

All products shall be free from defects liable to impair the required characteristics in the thickness direction, e.g. laminations, major non-metallic inclusions, flakes and segregations.

In addition, when subjected to ultrasonic testing flat products shall satisfy the Class 2 test requirements laid down in Stahl-Eisen-Lieferbedingung 072 (Iron and Steel Supply Conditions 072) or Class S2/E3 test requirements according to EN 10160. For sections Class 1.2/23 test requirements according to EN 10306 apply.

Note

Iron and Steel Supply Conditions 072 specify the fol-lowing Class 2 test requirements for the general ultra-sonic test:

Minimum significant flaw size: 0,5 cm2

Maximum permissible flaw size: 1,0 cm2

Permissible incidence of flaws in relation to area: locally: up to 30 m2

in relation to total plate area: up to 15/m2

Maximum permissible length of significant flaws: parallel to edge (edge testing): 4 cm

Permissible incidence of flaws (edge testing): up to 5/m


In addition to the requirements of the respective steel specification the sulphur content determined by heat analysis may not exceed 0,008 %.


The following tests shall be performed in addition to the tests prescribed for the product in question.

3.1 Tensile testing of Z specimens

3.1.1 The test shall be performed on at least 3 ten-sile test specimens taken from each unit testing quan-tity with their longitudinal axes perpendicular to the

surface of the product (Z specimens). The unit testing quantities shall be taken from Table 1.22 and consist of products of the same heat, same thickness and same heat treatment.

Table 1.22 Unit testing quantities

Sulphur content Product

S > 0,005 % S ≤ 0,005 %

Plates rolled length

Wide flats up to and including 25 mm thickness

10 t

Wide flats exceeding 25 mm thickness

20 t

50 t

3.1.2 In the case of flat products, the specimens shall be taken from one end in the longitudinal axis of the product, see Fig. 1.4. In both cases the centre of the product shall fall within the test length. In the case of sections, the specimens shall be taken from one end of the product at a distance of 1/3 of the flange width from the outside edge of the flange, see Fig. 1.4.

��

.��

.

Fig. 1.4 Sampling of Z specimens

3.1.3 Tensile test with extension pieces

Steel extension pieces, e.g. studs, shall be welded to the two surfaces of the sample which lie perpendicular to the thickness direction of the steel product; see Fig. 1.5. Examples of permissible welding processes are stud or friction welding.

��

��

�

4 ��!��

�%�!#�

Fig. 1.5 Specimen blank, consisting of test piece and welded-on extension pieces

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I

Before welding on the extension pieces, the abutting surfaces of the sample and the extension pieces shall be carefully cleaned to remove rust, scale and grease. The heat affected zone due to welding shall penetrate into the sample to the minimum possible depth.

The tensile test specimen shall be machined out of the specimen blank in accordance with Fig. 1.6.

�

� �

��

��

?�@��#�2��#��

Fig. 1.6 Tensile test specimen with extension pieces

The diameter do of the tensile test specimen shall be as follows:

do = 6 or 10 mm in the case of product thicknesses s of ≤ 25 mm,

= 10 mm in the case of product thicknesses s of > 25 mm.

The test length Lc of the tensile test specimen shall be at least 1,5 ⋅ do and shall not exceed 150 mm.

Note:

For further details see EN 10164.

3.1.4 Tensile test specimen without extension pieces

If the tensile test specimen is machined out of the test section, in the case of product thicknesses s of ≤ 150 mm its total length Lt is generally equal to the product thickness. The shape and dimensions of the tensile test specimen are shown in Fig. 1.7. The di-ameter do of the tensile test specimen is 6 mm in the case of product thicknesses s of ≤ 40 mm and 10 mm in the case of product thicknesses s of > 40 mm.

�

� �

��6��

�

Fig. 1.7 Tensile test specimen without extension pieces

The test length Lc of the tensile test specimen shall be at least 1,5 ⋅ do and shall not exceed 150 mm.

3.1.5 If the required average value is not achieved under test or if one individual value is less than al-lowed, 3 further Z specimens shall be taken immedi-

ately next to the site of the first specimen and sub-jected to the tensile test. On the basis of the results obtained, a new average value for all 6 specimens shall be calculated. The test shall be regarded as suc-cessful if the new average value meets the require-ments and no individual value yielded by the addi-tional 3 specimens is below the required average value.

3.1.6 Ultrasonic testing

The manufacturer shall perform an ultrasonic test on the surfaces and edges of each product using a 50 mm grid for the testing of the surfaces. If indications are observed which exceed the permissible limits for flaws stated in 2.2, the decision of GL shall be obtained as to the serviceability of the product.

4. Marking

Products which meet these requirements shall be iden-tified by adding the symbol Z25 and Z35 respectively to the designation of the material, e.g. Grade GL-E hull structural steel is given the designation GL-E Z25.

J. Steel-Aluminium Welding Joints

1. Scope

These requirements apply to explosion-bonded steel-aluminium joints for the connection of steel structures with aluminium structures.

2. Manufacturing technique

The manufacturer shall demonstrate by means of an initial test of product suitability that the clad products satisfy the requirements stated in 8. and the required properties of the base material are preserved after cladding.

3. Suitable materials

As base materials steels according to B., C. and E. are to be used. As cladding materials the aluminium alloys according to Chapter 3 – Non-Ferrous Metals, Section 1, A. come into question.

4. Method of manufacture and condition of supply

4.1 Cladding is performed by explosive cladding without additional heat transfer or change of thick-ness.

4.2 In general clad materials are to be delivered in untreated, smoothed condition.

5. Dimensions and tolerances

5.1 Where no other tolerances are specified in the order, the specifications in Table 1.23 apply.



J

Table 1.23 Permissible tolerances

Tolerance [mm] Product

lower upper

Thickness all – 2 + 1

Length all 0 + 10

plates 0 + 10

< 25 mm width – 1,5 + 1,5

Width rods 1

> 25 mm width – 2 + 2

< 500 mm diameter 0 + 2 Diameter

circular blanks > 500 mm diameter 0 + 5

plates (difference between the diagonals)

max. 10 Rectangularity

rods 1 (perpendicular projection of a longitudinal edge or a

transverse edge) max. 1,5

≥ 1 m length max. 5 Evenness (aluminium side)

< 1 m length max. 0,5 % of length

Straightness of longitudinal edges

rods 1 max. 5

1 Rods are contrary to plates flat products of a width ≤ 300 mm.

5.2 The tolerances for the base materials shall be governed by the requirements for the respective steel grades and product shapes.

6. Surface finish

The surface finish shall meet the respective require-ments for the base materials.


7.1 Shear strength

The bond between the base and cladding materials shall be adequate to ensure that the cladding material cannot break away from the base material when proper manufacturing processes and service condition are applied. The shear strength shall be at least 60 N/mm² irrespective of the direction of testing, unless higher values have been agreed in the order.

7.2 Bonding

The proportion of bonded surface shall be at least 99% and the area of isolated points where bonding has not occurred shall not exceed 650 mm2. Rods and circular blanks of 300 mm or less width and diameter respec-tively shall not show indications to be registered. If rods or circular blanks are cut from the original plate, the distance to indications to be registered shall be at least 20 mm.

7.3 Tensile test

The tensile strength of a clad plate subjected to a ten-sile test shall be at least 60 N/mm2, unless higher values have been agreed in the order.


When subjected to the side bend test, the clad plate shall be capable of being bent through 90° over a mandrel with a diameter of 6 times the thickness of the specimen, without separation of the cladding mate-rial or formation of incipient cracks.

8. Testing

8.1 Tensile test

From each end of the original plate 2 specimens with their longitudinal axis perpendicular to the product surface shall be taken and tested. Specimen shape is to be chosen according to I. One specimen of each end is to be heated to 300 °C before testing.

8.2 Shear test

From each test batch a specimen shall be taken with its axis transverse to the rolling direction and this shall be subjected to the shear test.

The test shall be performed in accordance with a rec-ognized standard, e.g. DIN 50162. The dimensions of

II - Part 1 GL 2009


J

the test specimen and the test arrangement are shown in Fig. 1.2.

One specimen of each end is to be heated to 300 °C before testing.

8.3 Side bend test

If specially agreed in the order, one specimen of each original plate is to be taken and tested. Dimensions of the test specimen and test arrangement are shown in Fig. 1.3. Where the product thickness exceeds 80 mm, the specimens may be reduced to 80 mm by machin-ing the base material side.


The surface finish and dimensions of all plates shall be checked by the manufacturer and the thickness of the cladding shall be measured at the edges and in the middle of the plate. All plates shall be submitted to the Surveyor for final testing and verification of the di-mensions.


To ascertain the quality of the bond between the base and cladding materials, the manufacturer shall carry out 100 % ultrasonic testing of the surfaces and edges of all plates.

9. Marking

All plates are to be marked on the base material side as follows:

– manufacturer’s mark

– short name of steel grade designation or material number of base and cladding material

– heat numbers of base and cladding material

– thickness of base and cladding material,

– specimen no.



J

Section 2

Steel Pipes

A. General Rules

1. Scope

1.1 The general Rules contained in A. to be ob-served in the manufacture of seamless and welded steel pipes apply in conjunction with the following individual requirements B. to E.

The scope of these Rules embraces all pipes used in the construction of steam boilers, pressure vessels and equipment as well as for pipelines, accumulators and pressure cylinders.

As regards steel pipes for structural applications, Section 1, B., C., D. and G. shall apply respectively.

Pipes which are individually manufactured and welded, such as masts, crane posts, pressure vessel shells etc. shall also comply with Part 3 –Welding.

1.2 Pipes conforming to national or international standards or to manufacturers' specifications may be approved provided that their properties are equivalent to the properties stipulated in these Rules or where special approval has been granted for their use. Refer-ences to standardized materials whose use is permitted are contained in the following individual Rules.

1.3 Pipes conforming to these Rules may be designated either in accordance with the relevant stan-dards or with the symbols shown in the Tables. In the latter case, pipes made of carbon and carbon-manganese steels shall be identified by their minimum tensile strength and, where applicable, by the added letter W denoting high-temperature steel or T denoting steel tough at sub-zero temperatures, while alloy pipes, with the exception of the austenitic grades, shall be identified by the symbols denoting their alloy con-tent.

2. Requirements to be met by pipe manufac-turers

2.1 Pipe manufacturers wishing to supply pipes in accordance with these Rules shall be approved by GL. Such approval is conditional upon their fulfilling the requirements stated in Chapter 1 – Principles and Test Procedures, Section 1, C. and demonstrating this to GL prior to the commencement of supplies.

2.2 In addition, where welded pipes are manufac-tured, the characteristics and the required quality of

the welded seam shall be subject to preliminary proof in the form of a procedure approval test the extent of which shall be determined by GL on a case to case basis.

GL reserve the right to demand that a test of suitability be carried out in the case of seamless pipes also where these have to meet special requirements, e.g. in respect of their impact energy at low temperatures or their high-temperature strength characteristics.

3. Manufacturing process, condition of supply

3.1 Pipe steels shall be made by basic oxygen steelmaking processes, in an electric furnace or by other methods approved by GL. Unless otherwise specified, the steels shall be killed.

3.2 Seamless pipes may be manufactured by hot or cold rolling (cold pilger rolling), by hot pressing or by hot or cold drawing.

3.3 Welded ferritic steel pipes may be manufac-tured by electrical induction or resistance pressure welding or by fusion welding of strip or plates, and may be subjected to hot or cold reduction. For austen-itic steels tough at sub-zero temperatures and austen-itic stainless steels, only fusion welding processes may be used. The manufacturing process and the testing shall ensure a weld quality factor of v = 1,0.

3.4 All pipes shall be supplied in a properly heat-treated condition over their whole length according to the requirements of B. to E.

4. General characteristics of pipes

4.1 Pipes may not display any cracks. Defects liable to have more than an insignificant effect on the use or further treatment of the pipes may be removed by grinding within the minimum permissible wall thickness. Repair welds are not allowed. This Rule may be waived in the case of the seams of fusion-welded pipes.

4.2 Pipes shall have a smooth inside and outside surface consistent with the method of manufacture. Minor depressions or shallow longitudinal grooves due to the manufacturing process may be tolerated provided that they do not impair the serviceability of the pipes and the wall thickness remains within the permitted tolerances.

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Section 2 Steel Pipes Chapter 2Page 2–1

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4.3 The upset metal on the outside of pressure-welded pipes shall be removed. In pipes having a bore of 20 mm or more, the height of the upset metal on the inside shall not exceed 0,3 mm.

4.4 On fusion-welded pipes, the inside and out-side weld reinforcement shall not exceed a value of 1 + 0,1 × seam width (mm).


The dimensions and the dimensional and geometrical tolerances of the pipes shall comply with the require-ments specified in the standards. The relevant stan-dards shall be stated in the order and made known to the Surveyor. The ends of pipes shall be cut off per-pendicular to the pipe axis and shall be free from burrs. Apart from pipes which are delivered in coils, all pipes shall appear straight to the eye.

6. Integrity of pipes All pipes shall be leak proof at the specified test pres-sures.

7. General requirements applicable to the material

7.1 Chemical composition The chemical composition of the pipe material (heat analysis) shall conform to the Tables contained in this Section or, where applicable, in the relevant standards.

7.2 Weldability

Pipes in accordance with these Rules shall be weld-able by established workshop methods. Wherever necessary, appropriate measures to safeguard quality shall be taken, e.g. preheating and/or subsequent heat treatments, see Part 3 – Welding.


The tensile strength, yield strength or proof stress, elongation and, where required, the 0,2 % or 1 % proof stress at elevated temperatures and the impact energy shall conform to the Tables contained in this Section or, where applicable, in the relevant standards. Irrespective of the provisions contained in the stan-dards, pipes made of steels tough at sub-zero tempera-tures shall at least meet the values specified in D. for the impact energy at the prescribed test temperature.


Pipes shall meet the requirements for the ring tests specified in 8.5.

8. General instructions for testing


The pipe manufacturer - and, where appropriate, the manufacturer of the starting material in the case of

welded pipes - shall verify the composition of each heat and submit the relevant certificates to the Sur-veyor. All the elements affecting compliance with the required characteristics shall be specified in the cer-tificates.

A product analysis shall be performed if there is any doubt about the composition of pipes submitted for testing.

8.2 Test of mechanical properties

8.2.1 For testing, pipes shall be grouped by steel grades and dimensions - alloy steel pipes also by heats - into test batches of 100 pipes for outside diameters ≤ 500 mm and into 50 pipes for outside diameters > 500 mm. Residual quantities of up to 50 pipes may be evenly allocated to the various test batches. Where welded pipes are concerned, a pipe is considered to be a cut length of not more than 30 m.

8.2.2 For the performance of the tensile tests, two pipes each shall be taken from the first two test batches and one pipe each from every subsequent batch. Where a consignment comprises only 10 pipes or less, it shall be sufficient to take one pipe. Nor-mally, longitudinal test specimens shall be taken from the sample pipes. Where the diameter is 200 mm or more, test specimens may also be taken transverse to the pipe axis. From welded pipes additionally test specimens are to be taken transversely to the welded seam. The weld reinforcement shall be machined off over the gauge length.

8.3 Determination of the 0,2% proof stress at elevated temperatures

Where pipes are designed for use at elevated tempera-tures on the basis of their high-temperature strength characteristics, the 0,2 % or 1 % proof stress shall be proved by a hot tensile test performed on one test specimen per heat and per pipe size. The test shall be performed at the temperature which approximates most closely to the level of the operating temperature, rounded off to the nearest 50 °C.

The test may be dispensed with in the case of pipes to recognized standards, the high-temperature mechani-cal properties of which are regarded as proven.

8.4 Notch bar impact test

Where this test is specified for the individual types of pipe, the number of sets of specimens and the position of the specimens shall be determined in the same way as the tensile test specimens called for in 8.2. The test shall be performed on Charpy V-notch specimens. In case of pipes with wall thickness above 30 mm, the longitudinal axis of the specimens is to be located in a distance of 1/4 of the pipe wall from the outer surface or as close as possible to this location.


Section 2 Steel Pipes II - Part 1GL 2009

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Table 2.1 Types of ring test

Nominal wall thickness t [mm]

Outside diameter of pipe [mm]

t < 2 2 ≤ t ≤ 16 16 < t ≤ 40

≤ 21,3 ring flattening test 1, 3 ring flattening test 1, 3 —

> 21,3 ≤ 146 ring flattening test 1, 3 ring expanding test 1, 3 ring flattening

> 146 — ring tensile test 2 ring tensile test 2

1 The drift expanding test may also be applied to welded pipes.

2 Instead of the ring tensile test, the flattening test is applied to pipes with bores of 100 mm.

3 The drift expanding test is applied to seamless and welded pipes in compliance with EN 10305-1 and -2 respectively.

8.5 Technological tests

8.5.1 The pipes selected for testing shall be sub-jected to one of the ring tests specified in Table 2.1 provided that the wall thickness of the pipe does not exceed 40 mm. For the performance of the test, see Chapter 1 – Principles and Test Procedures, Section 2, F.

The number of test specimens depends on the applica-tion of the pipes and is stipulated in the requirements of B. to E.

8.5.2 In the ring flattening test, the prescribed dis-tance between the plates H is calculated by applying the following formula:

(1 C) a

HC a / D

+=+

H = distance between the platens [mm]

a = nominal wall thickness [mm]

D = outside diameter of pipe [mm]

C = constant determined by the steel grade (see the provisions relating to technological tests according to B. to E.).

Where ring specimens of welded pipes are tested, the weld shall be set at 90° to the direction of the com-pressive load.

8.5.3 In the ring expanding test, the change in the diameter of the specimen expanded to the point of fracture shall at least equal the percentages shown in Table 2.2, depending on the material.

8.5.4 When the ring tensile test is applied to specimens of welded pipes, the weld shall be set at 90° to the direction of the tensile load.

Table 2.2 Diameter change in the ring expand-ing test

Minimum expansion [%] for ID/OD ratios of

Pipe material

≥ 0,9 ≥ 0,8 < 0,9

≥ 0,7 < 0,8

≥ 0,6 < 0,7

≥ 0,5 < 0,6

≥ 0,5

C- and CMn-steels

8 10 12 20 25 30

Mo-, CrMo- and

Ni-steels 6 8 10 15 30 30

Austenitic steels

30

8.5.5 In the drift expanding test applied to austen-itic steel pipes a 20 % expansion shall be achieved. Where pipes are made of other steels, the requirements of the other relevant standards shall be achieved.


The finish of the inside and outside surface of each pipe shall be inspected by the manufacturer. The di-ameters and wall thicknesses shall also be measured. The pipes shall then be submitted to the Surveyor for final testing.


8.7.1 The pipes shall be subjected to non-destructive tests of the extent specified in B. to E. Where tests of greater scope are prescribed in the order or in the relevant standards or specifications, these requirements shall be complied with.

8.7.2 Other test specifications require special ap-proval by GL.

8.7.3 The test equipment used for the continuous inspection of pipes shall be regularly calibrated using

II - Part 1 GL 2009


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pipes with artificial defects. The efficiency of the equipment shall be demonstrated to the Surveyor.

8.8 Tightness test

8.8.1 All pipes shall be tested for leaks by the manufacturer by applying the internal pressure test or, where GL has given its consent, by a suitable non-destructive testing method, e.g. eddy current or stray flux techniques.

8.8.2 The internal pressure test shall normally be performed at a standard hydraulic test pressure of 80 bar. Where pipes are intended for an operating pres-sure of ≤ 25 bar, the test pressure may be reduced to a standard value of 50 bar. In the case of thin-walled pipes with large outside diameters, the test pressure shall be limited so as to ensure that the yield strength or 0,2 % proof stress of the pipe material at room temperature is not exceeded. Where, in exceptional cases, testing with water is not possible, another test-ing medium may be used after agreement with the Surveyor.

8.8.3 Where a non-destructive method of testing is to be used instead of the internal hydraulic pressure test it shall be able to cover the whole circumference of the pipe. In addition, the method of testing shall conform to a recognized standard (e.g. EN 10246) or to an approved test specification. The efficiency of the method shall be initially demonstrated to GL.

8.9 Retests in the event of failure of specimens

If the requirements are not met by specimens sub-jected to tensile, ring or notched bar impact tests or if, in the notched bar impact test, one individual value falls below 70 % of the stipulated average value, then, before the unit testing quantity is rejected, the proce-dure for retests described in Chapter 1 – Principles and Test Procedures, Section 2, H. may be applied.

9. Marking of pipes

9.1 The manufacturer shall mark each pipe as follows in at least one position about 300 mm from the end:

– short designation or material number of the steel grade


– additionally, the heat number or a heat code

9.2 Markings shall be applied with punches. Pipes with sensitive surfaces or small wall thicknesses which may be damaged by punches shall be marked by another method, e.g. by coloured imprint, electrical engraving or rubber stamps.

10. Certificates

10.1 For each consignment the manufacturer shall furnish the Surveyor with a certificate containing the following details:


– newbuilding and project number respectively, where known

– quantity, dimensions and weight of delivered pipes

– strength category or pipe grade

– steel grade or material specification

– method of pipe manufacture

– heat numbers


– condition in which supplied or heat treatment applied

– marking

– results of material testing

10.2 The manufacturer shall also certify that all the pipes have been successfully tightness tested and, where applicable, have successfully undergone a non-destructive test and a test of resistance to intercrystal-line corrosion.

10.3 If the steels of which the pipes are made are not produced in the pipe works, a steelmaker's certifi-cate shall be handed to the Surveyor indicating the numbers and analyses of the heats. The steelmaker shall have been approved for the grades concerned. In case of doubt, the Surveyor shall be given facilities for carrying out a check.

10.4 Where, in exceptional cases, pipes are tested on the premises of a stockist, the latter shall keep a clear record of the origin of the pipes, which shall bear the marking specified in 9. and, in the case of boiler tubes, the stamp of the works inspector as well. In addition, the Surveyor shall be furnished with a cer-tificate issued by the pipe manufacturer and containing the following details:

– number, dimensions and weight of the pipes supplied

– steel grade or material specification

– method of pipe manufacture and condition in which supplied or method of heat treatment

– heat numbers and analyses

– confirmation that the tightness test and, where specified, the non-destructive test and test of re-sistance to intercrystalline corrosion have been carried out

– marking



A

B. Pipes for General Purpose

1. Scope

1.1 These Rules are applicable to seamless and welded pipes for use in pressure vessels, equipment, pipelines and pressure cylinders. Pipes conforming to these rules are intended for use at normal ambient temperatures.

In general for these applications pipe grades according to Table 2.3. are to be used.

If the pipes are intended for the manufacture of hy-draulic cylinders exposed to low service temperatures, a minimum impact energy of 41 J is to be proven on longitudinal ISO-V specimens, which may lead to the application of steels tough at sub-zero temperatures.

1.2 Pipes conforming to these Rules may be used for the cargo and processing equipment of gas tankers provided that the relevant design temperatures are not below 0 °C.

2. Heat treatment

The pipes shall be in a proper heat-treated condition. This is generally to be achieved by normalizing.

Subsequent heat treatment need not be applied to hot-formed pipes if the hot forming operation ensures a corresponding structure of sufficient uniformity.



The chemical composition of the pipe steels shall conform to the data given in Table 2.4 or, where ap-propriate, in the relevant standards or specifications.


The required values of tensile strength, yield strength and elongation specified in Table 2.5 or, where appro-priate, in the relevant standards or specifications shall be met under test at room temperature.


When subjected to the ring tests, the pipes shall dis-play a capacity for deformation which meets the re-quirements specified in A.8.5.

3.4 Impact energy

The pipes shall at least satisfy the impact energy re-quirements specified in Table 2.5.




The manufacturer shall determine the chemical com-position of each heat in accordance with A.8.1.

Table 2.3 Standardized pipe grades

Corresponding pipe grade to Strength category or

pipe grade to Table 2.5

EN 10216-1 1 or

EN 10217-1 2

EN 10216-3 1 or

EN 10217-3 2 EN 10305-1 EN 10305-2

GL–R 360 P235TR2 E235+N E235+N

GL–R 410 P265TR2 P275NL1 E275+N

GL–R 490 P355N E355+N E355+N

1 seamless 2 welded

Table 2.4 Chemical composition of unalloyed steel pipes

Chemical composition [%] Strength category or pipe grade Cmax. Simax. Mn max. Pmax. Smax. Altot.

GL–R 360 0,17 0,35 1,20

GL–R 410 0,21 0,35 1,40

GL–R 490 0,22 0,55 1,60

0,025 0,020 ≥ 0,020 1

1 This requirement does not apply if the steel contains a sufficient fraction of other nitrogen absorbing elements, which is to be specified.

II - Part 1 GL 2009


B

Table 2.5 Mechanical and technological properties of unalloyed steel pipes

Elongation A

[%] min.

Impact energy

KV 1

at 0 °C [J]

min.

Strength category or pipe grade

Tensile strength

Rm

[N/mm2]

Yield strength

ReH

[N/mm2] min.

long. transv. long. transv.

GL–R 360 360 – 500 235 25 23

GL–R 410 410 – 570 255 21 19

GL–R 490 490 – 650 310 19 17

41 27

1 For pipes with wall thickness > 10 mm.

4.2 Tensile test

Specimens of the sample pipes selected in accordance with A.8.2 shall be subjected to the tensile test.

4.3 Technological test

4.3.1 Pipes with longitudinal weld seams and seam-less pipes of grade GL–R490 are to be examined ac-cording to one of the ring tests specified in A.8.5, namely two pipes of one test batch.

Apart from that for fusion-welded pipes a weld seam bend test in accordance with Part 3 – Welding, Chap-ter 2 – Design, Fabrication and Inspection of Welded Joints, Section 5, D. may be carried out, applying a bending mandrel diameter of 3 t.

4.3.2 To calculate the distance between the thrust plates in the ring flattening test, the following values shall be assigned to the constant C in the formula given in A.8.5.2:

Pipes of strength category 360: C = 0,09

Other pipe grades: C = 0,07


On the pipes selected in accordance with A.8.2, the notched bar impact test shall be performed on trans-verse Charpy V-notch specimens if the outside diame-ter is ≥ 200 mm. If the outside diameter is < 200, lon-gitudinal specimens may be used.


The tests specified in A.8.6 are to be performed.


All pipes shall be subjected by the manufacturer to a non-destructive test over their whole length in accor-dance with EN 10246.

4.6.1 Non-destructive testing of seamless pipes

The pipes shall be subjected to a non-destructive test for detection of longitudinal defects according to EN 10246-7, acceptance category U2, subcategory C or EN 10246-5, acceptance category F2. Areas in way of pipe ends which have not been tested automatically, shall be subjected either to a manual or semi-automatic ultrasonic test in accordance with EN 10246-7, accep-tance category U2, subcategory C or shall be cut off.

4.6.2 Non-destructive testing of pressure-welded pipes

GL-R360 and GL-R410:

The weld seam of pipe grades GL-R360 and GL-R410 shall be tested over its entire length according to either EN 10246-3, acceptance category E3 or EN 10246-5, acceptance category F3 or EN 10246-7, acceptance category U3, subcategory C or EN 10246-8, accep-tance category U3, if applicable.

Areas in way of pipe ends which have not been tested automatically, shall be subjected either to a manual or semi-automatic ultrasonic test in accordance with EN 10246-8, acceptance category U3 or shall be cut off.

GL-R490:

Pipes of grade GL-R490 shall be subjected to an ultra-sonic test for detection of longitudinal defects according to EN 10246-7, acceptance category U2, subcategory C.

Areas in way of pipe ends which have not been tested automatically, shall be subjected either to a manual or semi-automatic ultrasonic test in accordance with EN 10246-7, acceptance category U2, subcategory C or shall be cut off.



B

4.6.3 Non-destructive testing of fusion-welded pipes

GL-R360 and GL-R410:

The weld seam of SAW pipes of grades GL-R360 and GL-R410 shall be tested either according to EN 10246-9, acceptance category U3 or EN 10246-10 image quality class R2.

Areas in way of pipe ends which have not been tested automatically, shall be subjected either to a manual or semi-automatic ultrasonic test in accordance with EN 10246-9, acceptance category U3 or shall be examined by means of radiographic testing according to EN 10246-10, image quality class R2 or shall be cut off.

GL-R490:

The weld seam of pipes of grade GL-R490 shall be tested over its entire length according to EN 10246-9, acceptance category U2 or EN 10246-10 image qual-ity class R2.

Areas of the weld seam in way of pipe ends which have not been tested automatically, shall be subjected either to a manual or semi-automatic ultrasonic test or to radiographic testing as specified above or shall be cut off.

The base material is to be tested according to EN 10246-15, acceptance category U2.

The pipe ends have to be tested in accordance with EN 10246-17. Laminations in circumferential direction of more than 6 mm length are not permitted within the last 25 mm pipe length at each end.

Plate or strip edges adjacent to the weld seam are to be tested within a 15 mm wide zone along the weld seam

in accordance with EN 10246-15 or EN 10246-16, acceptance category U2 in each case.

4.7 Tightness test

All pipes shall be tightness tested by the manufacturer in accordance with A.8.8

C. High-Temperature Steel Pipes

1. Scope

These Rules are applicable to seamless and welded pipes made of carbon steel, carbon-manganese steel, Mo steel and Cr Mo steel and intended for steam boil-ers, pressure vessels, equipment and pipelines. Pipes conforming to these Rules are intended for application at both ambient and elevated temperatures.

For these applications, standardized pipe grades are generally to be used. The appropriate pipe grades are shown in Table 2.6.

2. Heat treatment

Pipes shall be properly heat treated as follows:

a) Carbon steel, carbon-manganese steel and 0,3 Mo steel pipes:

– normalized

b) Pipes made of 1 Cr 0,5 Mo and 2,25 Cr 1 Mo steels:

– quenched and tempered.

Subsequent heat treatment need not be applied to hot formed pipes covered by a) if the hot forming opera-tion ensures a corresponding structure of sufficient uniformity. Under these conditions, tempering may be sufficient for the alloy pipes covered by b).

Table 2.6 Standardized pipes made of high-temperature steel grades

Corresponding pipe grade to Strength category or

pipe grade EN 10216-2 EN 10217-2 ISO 9329-2 ISO 9330-2

GL–R 360 W P235GH P235GH PH 23 PH 23

GL–R 410 W P265GH P265GH PH 26 PH 26

GL–R 460 W –– –– PH 29 ––

GL–R 510 W 20MnNb6 –– PH 35 PH 35

0,3Mo 16Mo3 16Mo3 16Mo3 16Mo3

1Cr05Mo 13CrMo4-5 –– 13CrMo4-5 13CrMo4-5

2,25Cr1Mo 10CrMo9-10 –– 11CrMo9-10 11CrMo9-10

II - Part 1 GL 2009


C



The chemical composition shall conform to the data given in Table 2.7 or, where appropriate, the relevant standards or specifications.


The required values of tensile strength, yield strength and elongation specified in Table 2.8 or, where appro-priate, in the relevant standards or specifications shall be met under test at room temperature.


When subjected to the ring tests, the pipes shall dis-play a capacity for deformation which meets the re-quirements specified in A.8.5.

3.4 Impact energy

The pipes shall at least satisfy the impact energy re-quirements specified in Table 2.8.

3.5 High-temperature characteristics

The 0,2 % proof stress at elevated temperatures shall satisfy the requirements specified in Table 2.9 or in the other relevant standards or specifications.

Table 2.7 Chemical compositions of high-temperature steel pipes

Chemical composition [%] Strength category or pipe grade C Simax. Mn Pmax. Smax. Cr Mo Altot.

GL-R 360 W ≤ 0,16 0,35 ≤ 1,20

GL-R 410 W ≤ 0,20 0,40 ≤ 1,40

GL-R 460 W ≤ 0,22 0,40 ≤ 1,40

GL-R 510 W ≤ 0,23 0,55 0,80 – 1,50

≤ 0,30 ≤ 0,08 ≥ 0,020 1

0,3Mo 0,12 – 0,20 0,35 0,40 – 0,90 – 0,25 – 0,35

1Cr0,5Mo 0,10 – 0,17 0,35 0,40 – 0,70 0,70 – 1,15 0,40 – 0,60

2,25Cr1Mo 0,08 – 0,14 0,50 0,30 – 0,70

0,025 0,020

2,00 – 2,50 0,90 – 1,10

≤ 0,040

1 This requirement does not apply if the steel contains a sufficient fraction of other nitrogen absorbing elements, which is to be specified.

If titanium is used, the manufacturer shall demonstrate that

Ti

Al 0, 20 %2

+ ≥⎛ ⎞⎜ ⎟⎝ ⎠

.

Table 2.8 Mechanical and technological properties of pipes made of high-temperature steel at room temperature

Elongation

( ) o oat L = 5,65 S⋅

A [%] min.

Impact energy

KV

[J] min.


Tensile strength

Rm

[N/mm2]

Yield strength

ReH

[N/mm2] min.

long. transv. long. transv.

GL–R 360 W 360 – 500 235 25 23

GL–R 410 W 410 – 570 255 21 19

GL–R 460 W 460 – 580 270 23 21

GL–R 510 W 510 – 650 355 19 17

0,3Mo 450 – 600 270 22 20

1Cr0,5Mo 440 – 590 290 22 20

2,25Cr1Mo 480 – 630 280 20 18

41 27



C

Table 2.9 Minimum values of yield strength Rp0,2 at elevated temperatures

Steel grade Minimum yield strength Rp0,2 [N/mm2]

at a temperature [°C] of

Material code

Material number 100 150 200 250 300 350 400 450 500

GL-R360W 1.0345 198 187 170 150 132 120 112 108 –

GL-R410W 1.0425 226 213 192 171 154 141 134 128 –

GL-R460W – – – 235 215 175 155 145 135 –

GL-R510W 1.0471 312 292 264 241 219 200 186 174 –

0,3Mo 1.5415 243 237 224 205 173 159 156 150 146

1Cr0,5Mo 1.7335 264 253 245 236 192 182 174 168 166

2,25Cr1Mo 1.7380 249 241 234 224 219 212 207 193 180

3.6 Dimensional tolerances for collectors

Seamless collector pipes and collectors with inside diameters ≤ 600 mm are subject to the following di-mensional tolerances:

– on the inner or outer clear width: ± 1,0 % where the outer clear width is ≤ 225 mm, or ± 1,5 % where the outer clear width is > 225 mm

– 0 % to + 25 % on the wall thickness

– the lateral curvature of square pipes shall be as shown in Fig. 2.1

��

��

��

��

��

��

�

�

� �

Fig. 2.1 Tolerance on the lateral curvature of square pipes

In square pipes, the inner corner radius r in relation to the wall thickness s shall be at least:

s

r 8 mm3

≥ ≥




The manufacturer shall determine the chemical com-position of each heat in accordance with A.8.1.

4.2 Tensile test

Specimens of the sample pipes selected in accordance with A.8.2 shall be subjected to the tensile test.

4.3 Technological test

4.3.1 The pipes, namely two pipes of one test batch, shall undergo one of the ring tests specified in A., Table 2.1 as follows:

For fusion-welded pipes a weld seam bend test in accordance with Part 3 – Welding, Chapter 2 – De-sign, Fabrication and Inspection of Welded Joints, Section 5, D. is to be carried out, applying a bending mandrel diameter of 3 t.

4.3.2 To calculate the distance between the thrust plates in the ring flattening test, the following values shall be assigned to the constant C in the formula given in A.8.5.2:

Pipes of strength categories 360: C = 0,09

Other pipe grades: C = 0,07


The test is to be carried out at room temperature on the

sample pipes selected in accordance with A.8.2, using

transverse Charpy V-notch specimens if the outside

diameter is ≥ 200 mm. If the outside diameter is < 200

mm, longitudinal specimens may be used.

4.5 High-temperature tensile test

Where stipulated in A.8.3 or in the purchase order, the 0,2 % proof stress shall be determined by a high-temperature tensile test.


The tests specified in A.8.6 are to be performed.

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C


All pipes shall be subjected by the manufacturer to a non-destructive test according to EN 10246 over their whole length and cross section, cf. A.8.7.

4.7.1 Non-destructive testing of seamless and pressure-welded pipes

The pipes shall be subjected to a non-destructive test in order to detect longitudinal defects according to EN 10246-7, acceptance category U2, subcategory C.

Areas in way of pipe ends which have not been tested automatically, shall be subjected either to a manual or semi-automatic ultrasonic test or shall be examined by means of radiographic testing according to the proce-dures specified above or shall be cut off.


The weld seam of the pipes shall be tested over its entire length according to either EN 10246-9, accep-tance category U2 or EN 10246-10, image quality class R2



The pipe ends have to be tested in accordance with EN 10246-17. Laminations in circumferential direction of more than 6 mm length are not permitted within the last 25 mm pipe length at each end. Plate or strip edges adjacent to the weld seam are to be tested within a 15 mm wide zone along the weld seam in accor-dance with EN 10246-15 or EN 10246-16, acceptance category U2 in each case.

4.8 Tightness test

All pipes shall be tightness tested by the manufacturer in accordance with A.8.8.

D. Pipes Tough at Sub-Zero Temperatures

1. Scope

1.1 These Rules are applicable to seamless or welded pipes made of carbon steel, carbon-manganese steel, nickel alloy steel or austenitic steel tough at sub-zero temperatures and with wall thicknesses up to 25 mm which are intended for the cargo and process-ing equipment of gas tankers with design temperatures below 0 °C.

For these applications, suitable standardized steel grades may also be used provided that they meet the requirements stated in these Rules, including especially those relating to impact energy at sub-zero tempera-tures. For the appropriate pipe grades see Table 2.10.

Table 2.10 Comparably suitable pipe grades of steels tough at sub-zero temperatures according to standard


EN 10216-4 1

or EN 10217-4 2

EN 10216-3 1 or

EN 10217-3 2

DIN 17458 1 or

DIN 17457 2

ISO 9329-3 1

or ISO 9330-3 2

ISO 9329-4 1 or

ISO 9330-6 2

ASTM 3 A312M

GL–R 360 T P215NL P255QL

PL25

GL–R 390 T P265NL P275NL1 P275NL2

GL–R 490 T P355NL1 P355NL2

GL–R 0,5 Ni 13MnNi6-3 13MnNi6-3

GL–R 3,5 Ni 12Ni14 12Ni14

GL–R 9 Ni X10Ni9 X10NiMn9

1.4306 X2CrNi19-11 X2CrNi1810 TP 304 L

1.4404 X2CrNiMo17-13-2 X2CrNiMo17-12 TP 316 L

1.4541 X6CrNiTi18-10 X6CrNiTi18-10 TP 321

1.4550 X6CrNiNb18-10 X6CrNiNb18-10 TP 347

1.4571 X6CrNiMoTi17-12-2 X6CrNiMoTi17-12

1 Seamless pipes 2 Welded pipes 3 The notched bar impact energies according to Table 2.14 are to be demonstrated..



D

Note:

In the case of pipes and connections which are in-tended for liquefied ammonia at design temperatures above 0 °C, the boundary values applicable to chemi-cal composition and strength properties as stated in Section 1, F.8.1.1 or 8.2.2 are to be maintained.

1.2 Where the wall thickness of the pipes exceeds 25 mm, the requirements are subject to special agree-ment with GL.

1.3 If the pipes are used for cargo and process equipment on gas tankers, the minimum design tem-peratures specified in Table 2.11 are applicable.

Table 2.11 Minimum design temperatures

Strength category or

pipe grade

Minimum design temperature

[° C]

GL-R 360 T GL-R 390 T GL-R 490 T

– 55 1

GL-R 0,5 Ni GL-R 3,5 Ni

– 55 – 90

GL-R 9 Ni – 165

Austenitic pipes – 165

1 Only applicable if the required impact energy has been demonstrated at the time of the approval tests.

2. Heat treatment

Depending on the material, the pipes shall be supplied in one of the heat treated conditions specified in Table 2.12.

Table 2.12 Heat treatment of steel pipes tough at sub-zero temperatures


Type of heat treatment

GL–R 360 T GL–R 390 T GL–R 490 T

Normalized or quenched and teampered

GL–R 0,5 Ni Normalized

GL–R 3,5 Ni Normalized and tempered or quenched and tempered

GL–R 9 Ni Double normalized and

tempered or quenched and tempered

Seamless austenitic pipes Solution annealed and

quenched

Welded austenitic pipes Solution annealed and

quenched or in the welded condition

For austenitic pipes, the heat treatment may be fol-lowed by cold drawing entailing small degrees of deformation, provided that the required characteristics can be maintained.

Welded austenitic pipes may be delivered in the welded state without post-weld heat treatment pro-vided that a test of the procedure has demonstrated that the characteristics of the material are satisfactory and that the strips or plates used for their manufacture are solution annealed. In addition, any scale, residual slag and temper colours on the inner and outer sur-faces shall be carefully removed, e.g. by pickling, grinding or sand blasting.



The chemical composition of the pipe steels shall conform to the data in Table 2.13 or, where appropri-ate, to the other relevant standards or specifications.

3.2 Resistance of austenitic pipe grades to intercrystalline corrosion

Austenitic steel pipes shall be resistant to intercrystal-line corrosion. Where welding is not followed by further heat treatment (quenching), only those pipe grades may be used which are corrosion-resistant in the welded condition, e.g. steels stabilized with Ti or Nb or steels with carbon contents of C ≤ 0,03 %, see. Table 2.13.


The values for tensile strength, yield strength or 0,2 % or 1 % proof stress, and elongation specified in Table 2.14 or, where appropriate, in the other relevant stan-dards or specifications shall be satisfied under test at room temperature.


In the ring tests, the pipes shall exhibit a capacity for deformation which satisfies the requirements stated in A.8.5.

3.5 Low-temperature impact energy

The required impact energy values specified in Table 2.14 for the pipe grade concerned shall be met at the prescribed test temperatures. This requirement is also applicable to comparable pipe grades conforming to the standards or specifications, irrespective of the values specified therein.



II - Part 1 GL 2009


D

Table 2.13 Chemical composition of steel pipes tough at sub-zero temperatures

Chemical composition [%] Strength category or pipe grade Cmax. Si Mn Pmax. Smax. Cr Ni Mo Other elements

GL–R 360 T 0,16 ≤ 0,40 0,40 – 1,20

GL–R 390 T 0,16 ≤ 0,40 0,50 – 1,50

GL–R 490 T 0,18 0,10 – 0,50 ≥ 0,90

0,025 0,020 ≤ 0,30 ≤ 0,3 ≤ 0,08 Almet ≥ 0,015 1, 2

GL–R 0,5 Ni 0,16 ≤ 0,50 0,85 – 1,70 0,025 0,015 ≤ 0,15 0,30 – 0,85 ≤ 0,10 Almet ≥ 0,015 1, 3

GL–R 3,5 Ni 0,15 0,025 3,25 – 3,75 ––

GL–R 9 Ni 0,13 0,15 – 0,35 0,30 – 0,85

0,020 0,010 ––

8,50 – 9,50 ≤ 0,10 V ≤ 0,05

1.4306 0,030 17,0 – 19,0 9,0 – 12,0 ––

1.4404 0,030 16,5 – 18,5 11,0 – 14,0 2,0 – 2,5 ––

1.4541 0,08 17,0 – 19,0 9,0 – 12,0 –– Ti ≥ 5 × % C

≤ 0,70

1.4550 0,08 17,0 – 19,0 9,0 – 12,0 –– Nb ≥ 10 × % C ≤ 1,00

1.4571 0,08

≤ 1,00 ≤ 2,00 0,040 0,030

16,5 – 18,5 11,0 – 14,0 2,0 – 2,5 Ti ≥ 5 × % C ≤ 0,80

1 Al may be wholly or partly replaced by other fine grain elements. 2 Residual elements: Cu ≤ 0,20; total Cr + Cu + Mo ≤ 0,45 % 3 Residual elements: Nb ≤ 0,05; Cu ≤ 0,15; V ≤ 0,05; total ≤ 0,30

Table 2.14 Mechanical and technological properties of steel pipes tough at sub-zero temperatures

Elongation A

[%] min.

Impact energy KV 2

[J] min.


Tensile strength

Rm

[N/mm2]

Yield strength or proof stress

ReH or Rp0,2, Rp1,0 1

[N/mm2] min. long. transv.

Test temperature [°C]

long.

[J] transv.

[J]

GL–R 360 T 360 – 490 255 25 23

GL–R 390 T 390 – 510 275 24 22

GL–R 490 T 490 – 630 355 22 20

5 K below design temperature, min. –20 °C

GL–R 0,5 Ni 490 – 610 355 22 20 – 60

GL–R 3,5 Ni 440 – 620 345 22 20 – 95

GL–R 9 Ni 690 – 840 510 20 18 –196

1.4306 480 – 680 215 40 35

1.4404 490 – 690 225 40 35

1.4541 510 – 710 235 35 30

1.4550 510 – 740 240 35 30

1.4571 510 – 710 245 35 30

–196

41(29) 27(19)

1 Rp0,2 or ReH applies to ferritic steels, Rp1,0.to austenitic steels. 2 Average value of 3 specimens; the values in brackets are the individual minima.



D


The chemical composition of each heat shall be veri-fied by the pipe manufacturer, or, where appropriate in the case of welded pipes, by the manufacturer of the starting material in accordance with A.8.1.


4.2.1 The resistance to intercrystalline corrosion shall be tested on austenitic steel pipes where this is called for in the order or where the pipes are made of materials which do not meet the requirements in re-spect of the limited carbon content or sufficient stabi-lization with titanium or niobium, see 3.2.

4.2.2 The testing of resistance to intercrystalline corrosion shall be performed in accordance with ISO 3651-2 on at least two samples per heat. The test specimens shall be treated as follows:

– Steels with C ≤ 0,03 % and stabilized steels are to undergo sensitizing heat treatment (700 °C, 30 min., water quench).

– All other grades of steel shall be in the condition in which they are supplied.

4.3 Tensile test

The tensile test shall be performed on the sample pipes selected in accordance with A.8.2.


4.4.1 The pipes shall undergo one of the ring tests specified in Table 2.1. For the performance of the tests, specimens shall be taken from one end of two pipes of a test batch.

4.4.2 To calculate the distance between the platens to be used in the ring flattening test, the values accord-ing to Table 2.15 shall be assigned to the constant C in the formula given in A.8.5.2:

Table 2.15


Constant C

GL–R 360 T 0,09

GL–R 390 T and GL–R 490 T

GL–R 0,5 Ni

0,07

GL–R 3,5 Ni 0,08

GL–R 9 Ni 0,06

Austenitic pipes 0,10


4.5.1 On pipes with wall thicknesses ≥ 6 mm, the notched bar impact test shall be performed on Charpy V-notch specimens taken from each sample pipe se-lected in accordance with A.8.2.

If the dimensions of the pipe are such that test speci-mens can be taken without straightening, these shall be taken transverse to the pipe axis. In such cases an additional (transverse) set of specimens shall be taken from fusion-welded pipes so that the notch is located in the middle of the weld metal.

In all other cases the specimens shall be taken parallel to the pipe axis.

4.5.2 If the wall thickness of the pipe does not allow the preparation of specimens with the stand-ard dimensions (10 × 10 mm), specimens measuring 7,5 × 10 mm or 5 × 10 mm shall be used. The re-quirements applicable to these specimens as compared with the standard specimens are shown in Table 2.16.


Tests shall be performed in accordance with A.8.6.

Table 2.16 Impact energy for specimens of reduced size

Required impact energy KV with specimens measuring Required impact energy 1 in Table 2.14 (standard specimens) 7,5 mm × 10 mm 5 mm × 10 mm

[J] min.

average value

[J] min.


[J]

average value

[J] min.


[J]

27 (19) 41 (29)

22 34

16 24

18 27

13 22

1 Average value of 3 specimens; values in brackets apply to the min. individual value.

II - Part 1 GL 2009


D


All pipes shall be subjected by the manufacturer to a non-destructive test over their whole length according to EN 10246.

4.7.1 Non-destructive testing of seamless and pressure-welded pipes

The pipes shall be subjected to a non-destructive test in order to detect longitudinal defects according to EN 10246-7, acceptance category U2, subcategory C or EN 10246-5 (only for ferromagnetic pipe grades), acceptance category F2.

Areas in way of pipe ends which have not been tested automatically, shall be subjected either to a manual or semi-automatic ultrasonic test according to EN 10246-7, acceptance category U2, subcategory C or shall be cut off.


The weld seam of the pipes shall be tested over its entire length according to either EN 10246-9, accep-tance category U2 or EN 10246-10, image quality class R2.



The pipe ends have to be tested in accordance with EN 10246-17. Laminations in circumferential direction of more than 6 mm length are not permitted within the last 25 mm pipe length at each end. Plate or strip edges adjacent to the weld seam are to be tested within a 15 mm wide zone along the weld seam in accor-dance with EN 10246-15 or EN 10246-16, acceptance category U2 in each case.

4.8 Tightness test


E. Stainless Steel Pipes

1. Scope

1.1 These Rules are applicable to seamless and welded austenitic and austenitic-ferritic stainless steel pipes to be used for the cargo and processing equip-ment on chemical tankers and for other lines, vessels and equipment where chemical stability is required. Suitable pipe grades conforming to international or national standards and to established and recognized specifications together with the austenitic pipe grades

specified in D., Table 2.13 are appropriate to these applications subject to the following conditions relat-ing to manufacture and testing.

1.2 Pipe grades shall be so selected with regard to subsequent manufacturing operations, e.g. welding, that they possess the chemical stability demanded by the intended application.

2. Heat treatment

The pipes shall be supplied in solution-annealed and quenched condition , although welded pipes may also be supplied without post-weld heat treatment provided that they continue to possess the required chemical stability in this condition and that the conditions stated in D.2. are complied with.



The chemical composition of the pipe steels shall conform to recognized standards or specifications.


In the condition in which they are supplied, the pipes shall be resistant to intercrystalline corrosion.

Where the welding is not to be followed by heat treat-ment (solution annealing), only those pipe grades may be used which are corrosion-resistant in the welded condition, e.g. steels stabilized with Ti or Nb or steels with carbon contents of C ≤ 0,03 %.


The required values of tensile strength, 1 % proof stress and elongation shall be satisfied in tests at room temperature in accordance with the standard or the recognized specification.


In the ring tests, the pipes shall exhibit a capacity for deformation which satisfies the requirements stated in A.8.5.

3.5 High-temperature characteristics

Where pipes are used at elevated temperatures, the required values for the 0,2 % or 1 % proof stress pre-scribed in the relevant standards or recognized specifi-cations shall be met at the corresponding temperature level.

3.6 Impact energy

The required impact energy values shall be satisfied in tests at room temperature in accordance with the rele-vant standard or the recognized specification.



E




The chemical composition of each heat shall be dem-onstrated by the pipe manufacturer, or, where appro-priate in the case of welded pipes, by the manufacturer of the starting material in accordance with A.8.1.


Depending on the application and grade of the pipes, a test of resistance to intercrystalline corrosion shall be performed on the following pipes:

– pipes for use on chemical tankers irrespective of the type of material

– pipes which do not meet the requirements in respect of stabilization or limited carbon content specified in 3.2

– pipes made of stabilized steels or steels with limited carbon contents intended for applica-tions not covered, where such testing is specially prescribed in view of the anticipated corrosive attack

The test conditions shall be as prescribed in D.4.2.2.

4.3 Tensile test

The tensile test shall be performed on specimens of the sample pipes selected in accordance with A.8.2.


Unless more extensive testing is prescribed in the standards, one of the ring tests specified in A., Table 2.1 shall be performed on one end of 2 % of the pipes. To calculate the distance between the platens to be used in the ring flattening test, a value of 0,10 shall be assigned to the constant C in the formula given in A.8.5.2.

4.5 High-temperature tensile test

Where called for in A.8.3 or stipulated in the purchase order, the 0,2 % or 1 % proof stress shall be deter-mined by a high-temperature tensile test.


Tests shall be performed in accordance with A.8.6.


All pipes shall be subjected by the manufacturer to non-destructive testing over their entire length accord-ing to EN 10246.

The pipes shall be subjected to a non-destructive test in order to detect longitudinal defects according to EN 10246-7, acceptance category U2, subcategory C.

Areas in way of pipe ends which have not been tested automatically, shall be subjected either to a manual or semi-automatic ultrasonic test according to EN 10246-6, acceptance category U2, subcategory C or shall be cut off.

4.8 Tightness test


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Section 3

Forgings

A. General Rules

1. Scope

This part contains general Rules to be applied in the manufacture and testing of forgings.

In conjunction with the individual Rules which follow, this part is also applicable to rolled steel bar, where it is to be used in place of forgings for the manufacture by machining of shafts, arbors, pins and similar parts.

2. Selection of steels

2.1 All steels shall be suitable for their application and shall satisfy the minimum requirements specified in the following individual Rules. Subject to these con-ditions, steels conforming to the relevant standards or to material specifications approved by GL may be used.

2.2 The steels shall be identified by the standard-ized designations or the designations given in the specifications.


3.1 Manufacturers wishing to produce forgings to these Rules shall fulfil the conditions stated in Chapter 1 – Principles and Test Procedures, Section 1 and shall prove this before the commencement of supplies. In addition, an approval test shall normally be performed on forgings selected for the purpose. The extent of the tests will be determined by GL on a case to case basis.

3.2 Forges without their own steelmaking facility may only use starting material supplied by producers who have been approved by GL.


4.1 Forging steel shall be produced by a basic oxy-gen process, in an electric furnace or by other methods approved by GL and shall be killed. On request, GL shall be informed of the steelmaking process used.

4.2 A sufficient amount of material shall be cropped from the top and bottom ends of ingots to ensure that the forgings are free from harmful segrega-tions. This term includes all inhomogeneities liable to impair the required characteristics.

4.3 Given a reasonable machining allowance, workpieces shall as far as possible be forged to the final dimensions. Excessive machining to give the forging its final shape which may impair its character-

istics, e.g. by laying open the core zone, is not al-lowed. Necks of shafts, pinions and journals exceed-ing 1/10 of the outer diameter shall be produced as far as possible by stepped forging. The degree of defor-mation shall be such that the core zone of the forging undergoes sufficient plastic deformation.

Unless otherwise approved the total reduction ratio is to be at least:

– for forgings made from ingots or from forged blooms or billets, 3 : 1 where L > D and 1,5 : 1 where L < D

– for forgings made from rolled products, 4 : 1 where L > D and 2 : 1 where L < D

– for forgings made by upsetting, the length after upsetting is to be not more than one-third of the length before upsetting or, in the case of an ini-tial forging reduction of at least 1,5 : 1, not more than one-half of the length before upsetting

– for rolled bars, 6 : 1.

L and D are the length and diameter respectively of the part of the forging under consideration.

4.4 Annular and hollow shapes shall be produced from sections cut from the ingot or bloom which have been suitably punched, drilled or trepanned before the parts are rolled or expanded over a suitable mandrel.

4.5 The shaping of forgings or rolled products by flame cutting and flame scarfing and gouging shall be performed using established methods prior to the final heat treatment unless otherwise agreed with GL. De-pending on its composition and/or thickness the work-piece shall be preheated. Where necessary, surfaces produced by flame cutting shall be machined.

4.6 Where two or more forgings are to be welded together, details of the welding method shall be sub-mitted for approval. GL reserves the right to call for a welding procedure approval test in these cases.


5.1 All forgings shall be suitably heat treated ac-cording to the material for obtaining a fine grain homo-geneous microstructure condition as well as the required mechanical properties. Heat treatments shall be applied in suitable furnaces, which shall be properly and regu-larly maintained. They shall be fitted with devices for controlling and indicating the temperature; these de-vices are to be checked at regular intervals. The furnace dimensions shall enable the whole forging to be raised uniformly to the required heat treatment temperature.

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5.2 All hot forming operations shall be concluded prior to the final heat treatment. Should it be necessary for some reason to reheat a forging for a further hot forming operation, then the final heat treatment shall be repeated.

5.3 Where a forging is subjected to hot or cold straightening after the final heat treatment, subsequent stress relief heat treatment to remove the residual stresses may be required.

5.4 Forgings whose section is substantially al-tered by machining after the forging operation may only be quenched and tempered after they have under-gone adequate rough machining.

The weight of the quenched and tempered forging shall not exceed 1,25 times that of the finished part.

5.5 If the prescribed heat treatment is to be re-placed by an equivalent temperature cycle during and after the hot forming process, appropriate tests shall be performed to prove to GL that the method is indeed equivalent.

6. General characteristics of forgings

6.1 All forgings shall be free from defects such as flakes, cracks, shrinkage cavities, segregation, periph-eral blow holes and major non-metallic inclusions which are capable of having a more than insignificant adverse effect on their application and treatment. Forgings deliv-ered in the unmachined condition shall have a smooth surface consistent with the method of manufacture.

6.2 Minor surface defects may be removed by grind-ing. The complete removal of the defects shall be proved by a magnetic particle or dye penetrant test. With the consent of the Surveyor, shallow depressions or indenta-tions may be allowed to remain provided that they are ground out to accommodate them to the surrounding area and that their depth, in the case of surfaces which are to be machined, lies within the machining allowance.

6.3 The removal of defects by welding is permit-ted only in exceptional cases with the agreement of GL if the defects are of limited extent and occur at points which are subject to low operating loads.

In these cases, full details of the proposed repair and of the subsequent test method shall be submitted to GL for approval before the start of the repair. In addi-tion, the test report shall be submitted with a descrip-tion or sketch showing the position and extent of all repairs together with details of the subsequent heat treatment and non-destructive tests applied.

7. Dimensions; dimensional and geometrical tolerances

The dimensions and the dimensional and geometrical tolerances are governed by the values given in the drawings accompanying the order or, where applica-ble, in the relevant standards. Instructions on this point

shall be given in the order documents and shall be made known to the Surveyor.

8. Tightness

Hollow forgings subjected to internal pressure by the operating medium shall be leakproof at the specified test pressure.

9. General requirements applicable to the material


9.1.1 The chemical composition of forged steels shall conform to the limit values indicated in the Ta-bles given in this section and/or in the relevant stan-dards or specifications. If use is made of standardized steels whose nominal carbon contents agree with the limit values indicated in the Tables, the limits speci-fied in the standards may be recognized. The steels shall also contain the quantities of deoxidizers needed to kill the steel.

Where steels are deoxidized by the vacuum-carbon method the lower limits for the Si and Al contents are inapplicable in all the rules specifying chemical com-position.

9.1.2 The steelmaker shall take appropriate steps to ensure that elements liable to impair the characteristics of the products cannot enter the heat by way of scrap or other materials used in the steelmaking process.

9.2 Mechanical and technological properties

9.2.1 Tensile test

The requirements indicated in the Tables contained in these Rules or, where applicable, in the relevant stan-dards or specifications shall be met under tensile test.

9.2.2 Notched bar impact test

The impact energy values specified for the various steel grades shall be met by the average result pro-duced by 3 specimens, one of which may give a result below the specified average value although not lower than 70 % of the specified average value.

9.2.3 Other characteristics

Where special characteristics are specified for particular grades of steel, e.g. resistance to intercrystalline corro-sion or 0,2 % proof stress at high temperatures, these characteristics shall be verified by appropriate tests.

10. Testing

10.1 Proof of chemical composition

The manufacturer shall determine the chemical com-position of each heat and present a corresponding certificate to the Surveyor. The certificate shall indi-cate the chemical composition of the heat characteris-tic of the steel grade concerned.


Section 3 Forgings II - Part 1GL 2009

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Should there be any doubt as to the composition or where the connection between the certificate and the forgings cannot be proved, a product analysis shall be performed.

10.2 Test of mechanical properties and selection of specimens

10.2.1 The mechanical properties shall be ascer-tained by tensile test to determine tensile strength, yield strength or 0,2 % proof stress, elongation and reduction in area.

10.2.2 Unless otherwise specified, the impact energy shall be determined by notched bar impact tests on each forging or each test batch, as appropriate.

10.2.3 Unless otherwise specified, the following shall apply to the verification of the mechanical prop-erties with regard to the test batches and the test specimens:

10.2.3.1 Forgings with similar dimensions which originate from the same heat and have been heat treated together shall be grouped into a test batch.

10.2.3.2 Testing of normalized forgings with unit weights of ≤ 1000 kg or quenched and tempered for-gings with unit weights of ≤ 500 kg shall be per-formed in test batches. Unless otherwise agreed with GL, the size of the test batch shall be as detailed in Table 3.1.

Surplus quantities up to 10 % of the number of for-gings per test batch can be allotted to a test batch

Forgings with unit weights > 1 000 kg (normalized) and > 500 kg (quenched and tempered) shall be tested individually.

Table 3.1 Heat treatment weight of individual forging and number of forgings per test batch

Heat treatment weight of individual forging

[kg]

Number of forgings per test

batch

up to 15 ≤ 300

> 15 to 150 ≤ 100

> 150 to 300 ≤ 50

> 300 to 1000 ≤ 25

10.2.3.3 The number of test sections required for the tensile test and the notched bar impact test is as fol-lows:

– normalized forgings: one test section from one forging per test batch.

– quenched and tempered forgings: per test batch one test section from two forgings. With batches of 10 forgings or less, a test section is required from only one forging.

At least 5 % of all quenched and tempered forgings which undergo batchwise testing shall be subjected to a hardness test.

In the case of products ≥ 3 m in length and weighing over 4 000 kg in heat-treated condition which do not undergo heat treatment in a continuous furnace, one test section shall be taken from each end of the forging to be tested.

10.2.3.4 Depending on the conditions agreed on plac-ing the order, the test sections shall be taken as fol-lows:

– from a forging (which is then destroyed in its entirety)

– from additional material provided on the forging

– from a sample of similar dimensions from the same heat, which has been forged in the same way as the other forgings and heat treated to-gether with them

10.2.3.5 The location of the test specimens in the cross section of the heat-treated region shall be as follows:

The specimens shall be taken starting from the surface at a distance of 1/4 of the diameter or the (wall) thick-ness, but max. 80 mm, and at a corresponding distance from a further, adjacent surface.

10.2.3.6 It may be necessary to distinguish between the geometrical position of the specimens in the forg-ing and their location in relation to the direction of the fibre.

For forgings, the references in the tables to longitudi-nal, tangential and transverse orientations refer to the position of the specimen in relation to the direction of the fibre and should be understood as follows:

Longitudinal: The longitudinal axis of the specimen is parallel to the main direction of elongation of the non-curved fibre pat-tern;

Tangential: The longitudinal axis of the specimen traverses the curved fibre pattern in the form of a chord (and thus "slopes", so to speak, in relation to it);

Transverse: The longitudinal axis of the specimen traverses the fibre pattern at right an-gles. Specimens with a longitudinal axis lying in the direction of an addi-tional compression (perpendicular to an expansion) of the fibre pattern (so-called location "in the thickness direc-tion") are not covered by the specimen positions termed "transverse".

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10.2.3.7 Normally, test specimens shall be taken from the test sections forged together with the workpieces. This test section may normally be separated from the forging only after the latter has undergone final heat treatment. In this context, subsequent heat treatment for stress relief may be disregarded. Prior separation is permitted only where the manufacturing process makes this unavoidable. In these circumstances, the forging and the test section shall be heat treated to-gether.

10.2.3.8 All test sections shall be forged with the same degree of deformation to a cross section corre-sponding to the relevant cross section of the forging. The test sections shall be large enough to provide material not only for the specimens required for the initial test but also for specimens needed for possible retests.

All test sections and samples shall be so marked that they can be clearly related to the forgings or test batches which they represent.

10.2.4 For forgings whose method of manufacture is subject to special approval by GL, see 5.5, the number and position of the test sections shall be specially determined with regard to the method of manufacture.


10.3.1 The manufacturer shall inspect each forging for surface finish and compliance with the dimen-sional and geometrical tolerances and shall then sub-mit the forgings to the Surveyor for final inspection. The inner surfaces of hollow forgings and bores are to be included in these inspections.

10.3.2 The surface of the forgings shall be clean and properly prepared for inspection. Surface defects are to be removed. Where necessary this condition shall be achieved by pickling, local grinding, shot or sand blasting, cleaning with wire brushes or by chemical means, unless the parts are submitted in the rough machined condition.

10.3.3 If the surface condition suggests that welds have been carried out on the forging, the Surveyor may demand local etching to reveal possible welds.


10.4.1 Where non-destructive tests are called for, these are to be performed by the manufacturer and/or finishing plant. Tests may also be arranged by the Society.

10.4.2 Non-destructive tests are to be performed in accordance with the specifications stated in G. in consideration of the specifications in Chapter 1 – Principles and Test Procedures, Section 3.

10.5 Retests in the event of failure of specimens

If the required values of tensile strength or notched bar impact tests are not achieved or if a notched bar im-pact test produces an individual value which is lower than 70 % of the required average value, then, before the forging or the unit test quantity is rejected, the procedure for repeat tests prescribed in Chapter 1 – Principles and Test Procedures, Section 2, H. may be applied. The additional test specimens shall be taken either from the same test section as the original speci-men or from other test sections or samples which are representative of the test batch concerned.

11. Identification and marking

11.1 The manufacturer shall institute a monitoring system enabling all forgings to be traced back to the original heat, and this shall be demonstrated to the Surveyor on request.

11.2 Prior to final inspection, all forgings shall be stamped by the manufacturer in at least one place with the following marks:

– steel grade


– item or heat number, or another mark enabling the manufacturing process to be traced back

– specimen number

– date of test

The area receiving the stamp marks shall be ground.

11.3 In the case of small, series-manufactured forgings, agreement may be reached with the Surveyor to apply stamp marks other than those stated in 11.2.

12. Certificates

For each consignment the manufacturer shall supply to the Surveyor a certificate containing at least the fol-lowing details:


– newbuilding number and project number, if known

– nature of forging and grade of steel

– purpose and drawing number, if necessary

– weight of the forging

– method of forging

– item number and number of units

– heat number



– details of heat treatment



A

– results of the mechanical tests

– results of any special tests applied, e.g. test of resistance to intercrystalline corrosion, determi-nation of proof stress at elevated temperatures or non-destructive tests

B. Forgings for Machine Construction and Shipbuilding

1. Scope

These Rules are applicable to forgings made of unal-loyed and low alloy steels intended for the manufac-ture of components and structural parts in machine construction and shipbuilding, e.g. shafts, piston rods, connecting rods, rudderstocks and heel pintles.

They are also applicable to rolled round bars for the manufacture of shafts, pins, tie-rods and similar com-ponents which are given their final shape by machin-ing.

2. Suitable grades of steel

On condition that they meet the requirements specified in 4., the following steels may be used:

2.1 Suitable grades of forging steel conforming to recognized standards, e.g. EN 10083, EN 10250-2, EN 10250-3 and SEW 550.

2.2 Other unalloyed and low alloy steels con-forming to other standards or material specifications, provided that their suitability has been confirmed by GL. An initial test of product suitability may be re-quired for this purpose.


3.1 All forgings shall be properly heat treated. Acceptable methods of heat treatment are:

– for carbon and carbon-manganese steels:

– normalizing

– normalizing and tempering (air quenching and tempering)

– quenching and tempering

– for alloy steels:


3.2 Large forgings of complex shape made of carbon or carbon-manganese steel which are to be supplied in normalized condition shall undergo addi-tional stress-relieving heat treatment if they have been extensively machined subsequent to normalizing.



4.1.1 The chemical composition of the forging steels is subject to the limit values in Table 3.2.

Table 3.2 Limit values for the chemical compo-sition of forging steels

C- and CMn steels Alloyed steels

Chemical composition 1

[%]

Permitted residual elements

[%]

max.

Chemical composition 2

[%]

Cmax. 0,50 3, 4 Cu 0,30 Cmax. 0,45 3

Simax. 0,45 Cr 0,30 Simax. 0,45

Mn 0,30 – 1,70 Ni 0,40 Pmax. 0,035

Pmax. 0,035 Mo 0,15 Smax. 0,035

Smax. 0,035

1 Where necessary, grain-refining elements, e.g. aluminium, may be added.

2 For the alloying elements the data given in the standards or approved specifications are applicable.

3 The use of steels with carbon contents of C > 0,50 % and C > 0,45 %, respectively, shall be specially authorized by GL.

4 For welded constructions, rudderstocks and pintles: max. 0,23 % C.

4.1.2 Where forgings are to be used in welded assemblies, the composition shall be specially deter-mined by reference to the welding method used and shall be submitted to GL for approval.


4.2.1 The required values of yield strength, reduc-tion in area and elongation shown in Tables 3.5 and 3.6 respectively in relation to the prescribed minimum tensile strength shall be met.

4.2.2 The strength levels of 40 and 50 N/mm² stated in Tables 3.5 and 3.6 respectively should not be regarded as minimum tensile strengths for certain grades of forging steel, but are intended to enable the required property values (yield strength, elongation, reduction in area and impact energy) to be determined by interpolation in relation to the prescribed minimum tensile strengths.

4.2.3 If two test specimens are taken from forgings, the difference between the measured tensile strength values may not exceed the magnitudes stated in Table 3.3.

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Table 3.3 Differences permitted between tensile strength values

Minimum tensile strength

Rm [N/mm2]

Difference permitted between tensile strength

values [N/mm2]

< 600 70

≥ 600 < 900 100

≥ 900 120

4.3 Impact energy

The required impact energy values shown in Tables 3.5 and 3.6 in relation to the specified minimum ten-sile strength shall be met.

Irrespective of this, for heel pintles and rudderstocks an impact energy of at least 27 J shall be attained with longitudinal Charpy V-notch specimens measured at 0 °C for ships with ice class symbols E3 and E4 and at – 20 °C for ships with the arctic ice class symbols ARC1 to ARC4. One individual value may be below the average value but shall not be less than 19 J.

For propeller shafts intended for ships with ice class an impact energy of at least 27 J with longitudinal Charpy V-notch specimens measured at – 10 °C shall be attained.

4.4 Hardness

4.4.1 The hardness values prescribed in the ap-proval drawings or specifications of the forgings are mandatory. The figures shown in Tables 3.5 and 3.6 are guide values only.

4.4.2 Where a hardness test is stipulated, the hard-ness values measured at different points on the forging or on different units within a unit test quantity respec-tively may not differ by more than the amounts stated in Table 3.4.

If the hardness is measured in other units, the values shall be converted into the corresponding Brinell units.

Table 3.4 Differences permitted between hard-ness values

Minimum tensile strength

Rm [N/mm2]

Difference in hardness Brinell units

< 600 up to 25

≥ 600 < 900 up to 35

≥ 900 up to 42

5. Testing

5.1 Mechanical testing

5.1.1 Testing shall be accomplished by tensile tests and notched bar impact tests in accordance with A. 10.2. Quenched and tempered forgings grouped into test batches shall be subjected to additional hardness testing.

5.1.2 Notched bar impact testing of propeller shafts, rudderstocks and heel pintles for ships with ice class symbols shall be carried out with Charpy V-notch specimens. For all other products, the selection of the specimen shape according to Chapter 1 – Prin-ciples and Test Procedures, Section 2, E.1. and E.2. shall be at the manufacturer's discretion.

5.1.3 The test specimens may be taken from the samples in longitudinal, tangential or transverse direc-tion in relation to the fibre pattern; cf. Figures 3.1 to 3.3.


The specifications in G. do apply. The components indicated in H. are to be tested according to the scope prescribed there.


All forgings shall be presented to the Surveyor in the condition in which they are delivered for testing of the surface finish and the dimensions.

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Fig. 3.1 Location of specimens in unflanged shafts and rods

C. Forgings for Crankshafts

1. Scope

These Rules are applicable to solid forged crankshafts and to the forged throws, webs and pins of semi-built crankshafts of unalloyed and low alloy steels.

2. Approved materials

Only materials which have been approved by GL as suitable for the intended application may be used. To this end, the engine manufacturer shall submit to GL for approval specifications and/or drawings containing



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Fig. 3.2 Location of specimens in flanged shafts with thrust flange

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Fig. 3.3 Location of specimens in flanged shafts

all the data required for evaluating the material, e.g. method of manufacture, chemical composition, heat treat-ment and mechanical properties. The minimum re-quirements as per Tables 3.5 and 3.6 are to be satisfied.


3.1 With regard to the chemical composition, mechanical properties and required impact energy and hardness values of the steel, the data contained in the approved specification or drawing are applicable.

3.2 The steel shall undergo vacuum degassing following its production to ensure that the hydrogen content of the heat does not exceed 2 ppm.

4. Manufacture and condition of supply

4.1 Wherever possible, the throws of built crank-shafts shall be preforged as a flat semi-finished prod-uct and then folded in a press to produce a rough forg-ing having a fibre pattern with favourable loading characteristics. However, other processes may be used

if they achieve the required characteristics. GL shall be advised of the method of manufacture.

4.2 Where crankshaft webs are produced by thermal cutting from forged or rolled flat products, the heat-affected area at the cut faces shall be completely removed by machining. This Rule does not apply to webs which are cut out of the starting material before the specified heat treatment is applied.

4.3 Crankshafts shall normally be supplied in quenched and tempered condition. However, crank-shafts and their components which are made of carbon and carbon-manganese steels may also be normalized or normalized and tempered. Where crankshafts are to be surface-hardened, the nature of the heat treatment shall be stated in the manufacturer's specification.

5. Testing

5.1 Tensile test

The mechanical properties shall be verified by tensile test. Test specimens shall be taken for this purpose in accordance with 5.1.1 to 5.1.4.

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Table 3.5 Mechanical and technological properties of carbon and carbon manganese steel forgings in nor-malized or quenched and tempered condition for room temperature

Impact energy Elongation

( )o ofor L 5,65 S= ⋅

A [%] min.

Reduction in area

Z [%] min.

KV 3

[J] min.

KU [J]

min.

Minimum tensile

strength 1, 2

Rm

[N/mm2]

Relevant heat

treatment diameter

[mm]

Yield strength

ReH

[N/mm2] min.

long. tang. trans. long. tang. trans. long. tang. trans. long. tang. trans.

Brinell hardness

HB (Guide values)

≤ 250 40 32 25 38 30 25

> 250 ≤ 500 32 25 18 30 25 20 360

> 500 ≤ 1000

180 28 24 20 50 42 35

32 25 18 29 23 18

95 – 125

≤ 250 40 32 25 38 30 25

> 250 ≤ 500 32 25 18 30 25 20 400

> 500 ≤ 1000

200 26 23 19 50 42 35

32 25 18 27 22 17

110 – 150

≤ 250 38 30 22 35 27 22

> 250 ≤ 500 32 25 18 30 25 20 440

> 500 ≤ 1000

220 24 21 18 50 42 35

30 24 18 25 20 15

125 – 160

≤ 250 35 27 22 32 25 22

> 250 ≤ 500 32 25 18 30 25 20 480

> 500 ≤ 1000

240 22 19 16 45 38 30

26 24 14 22 17 12

135 – 175

≤ 250 32 25 20 30 25 20

> 250 ≤ 500 25 20 15 25 20 17 520

> 500 ≤ 1000

260 21 18 15 45 38 30

24 18 13 20 15 11

150 – 185

≤ 250 25 20 15 25 20 17

> 250 ≤ 500 25 20 15 25 20 17 560

> 500 ≤ 1000

280 20 17 14 40 34 27

23 14 12 19 12 10

160 – 200

≤ 250 18 15 12 20 17 15

> 250 ≤ 500 18 15 12 20 17 15 600

> 500 ≤ 1000

300 18 16 13 40 34 27

18 14 12 17 12 10

175 – 215

≤ 250 18 15 12 20 17 15 640

> 250 ≤ 500 320 17 15 12 40 32 27

18 15 12 20 17 15 185 – 230

≤ 250 18 15 12 20 17 15 680

> 250 ≤ 500 340 16 14 12 40 32 27

18 15 12 20 17 15 200 – 240

≤ 250 18 15 12 20 17 15 720

> 250 ≤ 500 360 15 13 11 40 32 27

18 15 12 20 17 15 210 – 250

≤ 250 18 15 12 20 17 15 760

> 250 ≤ 500 380 14 12 10 35 30 24

18 15 12 20 17 15 225 – 265

1 Where the minimum tensile strength of a steel grade falls between two of the graduated values, the requirements are to be determined by interpolation, see 4.2.2.

2 The tensile strength determined by testing may not exceed the specified minimum tensile strength, if less than 600 N/mm2, by more than 120 N/mm2. Where the minimum tensile strength is ≥ 600 N/mm2 not more than 150 N/mm2 may be exceeded.

3 The propeller shafts, rudderstocks and heel pintles of ships with ice class symbols are subject to the impact energy values stipulated in 4.3.



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Table 3.6 Mechanical and technological properties of alloy steel forgings in quenched and tempered condi-tion for room temperature


( )o ofor L 5,65 S= ⋅

A [%] min.

Reduction in area

Z [%] min.

KV 4

[J] min.

KU 4 [J]

min.

Minimum tensile

strength 1, 2

Rm

[N/mm2]

Relevant heat treatment diameter

[mm]

Yield strength 3

ReH

[N/mm2] min. long. tang. trans. long. tang. trans. long. tang. trans. long. tang. trans.

Brinell hardness

HB (Guide values)

≤ 250 20 18 16 41 32 24 35 30 24 550

> 250 ≤ 500 18 16 14 50 45 35

32 25 18 30 25 20 160 – 200

≤ 250 20 18 16 41 32 24 35 30 24 600

> 250 ≤ 500 18 16 14 50 45 35

32 25 18 30 25 20 175 – 215

≤ 250 18 16 14 32 28 22 30 27 23 650

> 250 ≤ 500 17 15 13 50 45 35

25 18 13 25 20 15 190 – 235

≤ 250 17 15 13 32 28 22 30 27 23 700

> 250 ≤ 500 16 14 12 50 45 35

25 18 13 25 20 15 205 – 245

≤ 250 17 15 13 32 26 20 30 26 22 750

> 250 ≤ 500

0,6 × minimum

tensile strength

15 13 11 45 40 30

25 18 13 25 20 15 215 – 260

≤ 250 15 14 12 32 26 20 30 26 22 800

> 250 ≤ 500 14 12 10 45 40 30

25 18 13 25 20 15 235 – 275

≤ 250 14 13 11 27 23 18 29 25 20 850

> 250 ≤ 500 13 11 10 45 40 30

25 18 13 25 20 15 245 – 290

≤ 250 14 13 11 27 23 18 29 25 20 900

> 250 ≤ 500 13 11 10 40 35 27

25 18 13 25 20 15 260 – 320

≤ 250 13 11 10 25 21 16 29 25 20 950

> 250 ≤ 500 12 10 10 40 35 27

25 18 13 25 20 15 275 – 340

≤ 250 12 11 10 25 21 16 25 22 18 1000

> 250 ≤ 500 12 10 10 40 35 27

25 18 13 25 20 15 290 – 365

≤ 250 11 10 8 25 18 13 25 20 15 1050

> 250 ≤ 500 11 10 8 40 35 27

25 18 13 25 20 15 310 – 375

≤ 250 11 10 8 25 18 13 25 20 15 1100

> 250 ≤ 500

0,7 × minimum

tensile strength

11 10 8 40 35 27

25 18 13 25 20 15 320 – 385

1 Where the minimum tensile strength of a steel grade falls between two of the graduated values, the requirements are to be determined by interpolation, see 4.2.2.

2 The tensile strength determined by testing may not exceed the specified minimum tensile strength, if less than 900 N/mm2, by more than 150 N/mm2. Where the minimum tensile strength is 900 N/mm2 not more than 200 N/mm2 may be exceeded.

3 For case-hardening steels a value of 60 % of the specified minimum tensile strength is sufficient irrespective of the value of the tensile strength.

4 Where the heat treatment diameter is > 500 mm, the requirements shall be agreed with GL.

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5.1.1 Independently of the selection of test speci-mens according to test batches as prescribed in 5.1.3, at least one longitudinal or transverse tensile test speci-men shall be taken from the driven side of each crank-shaft. Where a solid forged crankshaft weighs more than 3000 kg, test specimens shall be taken from both ends, on the driven side as a transverse specimen. The weight applicable is the weight of the crankshaft in the heat-treated condition minus the weight of the test sections.

5.1.2 Where the throws are machined or flame cut from a preforged crankshaft, a second set of test specimens shall be taken in the transverse direction from the material removed from the throw furthest from the driven side, cf. Fig. 3.4.

The test sections may not be removed prior to quench-ing and tempering.

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��

Fig. 3.4 Location of test specimens in crankshafts

5.1.3 Crankshafts of the same dimensions up to a weight in heat-treated condition of 500 kg which originate from the same heat and form part of the same heat treatment batch may be grouped into test batches in accordance with Table 3.1, A.10.2.3. For quenched and tempered crankshafts, two tensile test specimens shall be taken from each test batch; for normalized shafts, one specimen is sufficient.

5.1.4 Transverse test specimens shall be taken from forged throws. Unless otherwise agreed with GL, at least one specimen shall be taken from each forging.

5.1.5 Where two test specimens are taken from large crankshafts, the difference between the measured tensile strength values may not exceed the magnitudes stated in B.4.2.3.


Each forging or unit test quantity, as applicable, shall be subjected to the notched bar impact test. The num-ber of sets of specimens (each comprising 3 speci-mens) and their position are subject to the conditions stated in 5.1.1 to 5.1.4 for tensile test specimens.

5.3 Hardness testing

5.3.1 Where testing is performed in test batches, at least 10 % of the crankshafts shall be subjected to hardness tests.

The method of hardness testing and the position of the hardness testing impressions on the forgings shall be agreed with GL.

5.3.2 The differences in the hardness values meas-ured at different points on the forging or on different units within a test batch may not exceed the magni-tudes stated in B.4.4.2.


The crankshaft manufacturer shall test the surface finish and dimensions of the crankshafts and give the measurement records to the Surveyor. He shall also present the crankshafts to the Surveyor for final in-spection and hold in readiness the measuring instru-ments required for checking the dimensions.


Crankshafts shall be subjected to non-destructive testing according to the scope stipulated in G.

D. Forgings for Gears

1. Scope

These Rules are applicable to forgings made of car-bon, carbon-manganese and low alloy steels which are intended for the manufacture of wheels and wheel rims for the gears of the main engine and auxiliary equipment.


On condition that they satisfy the requirements of 6., the following grades of steel may be used:

2.1 Quenched and tempered steels conforming to EN 10083-1, case hardening steels conforming to EN 10084 and nitriding steels conforming to EN 10085, provided that proof has been furnished of the suitability of the individual grade of steel for the intended purpose. Table 3.7 contains a selection of suitable steel grades.

2.2 Steels conforming to other standards, pro-vided that they are comparable with the steel grades specified in 2.1 and proof has been furnished of their suitability for the intended purpose.

Table 3.7 Suitable steel grades for gears

Steel grade Standard

42CrMo4 EN 10083-1

16MnCr5

20MnCr5

18CrNiMo7-6

EN 10084



D

2.3 Steels conforming to particular material specifications, provided that GL has authorised their use. To this end, the gear manufacturer shall submit the corresponding specifications for approval. These specifications shall contain all the data required for their evaluation, e.g. method of manufacture, chemical composition, heat treatment, surface hardening and mechanical properties.

3. Welded wheels

Where gear wheels are made up of components welded together, full details of the welding process, the scope of non-destructive testing and the acceptability criteria for welding defects shall be submitted to GL for approval. The characteristics of the welds shall first be demon-strated by a welding procedure specification test.

4. Heat treatment

4.1 Forgings for which surface hardening after the cutting of the teeth is not specified shall be quenched and tempered. Carbon and carbon-manganese steels may also be normalized and tempered.

4.2 In the case of forgings which undergo surface hardening after the cutting of the teeth, the heat treat-ment depends on the nature of the surface hardening process, as follows:

4.2.1 After carburization, case-hardening steels are to be hardened and then tempered at low temperature. The depth of case hardening, the time-temperature cycle and the hardness range (min/max) shall be stated in the specification.

4.2.2 Steels for induction hardening shall normally be quenched and tempered prior to hardening. Carbon and carbon-manganese steels may also be normalized instead of quenching and tempering. The nature of the heat treatment, the depth of hardening, the hardening temperatures, the quenching media and the hardness range (min/max) shall be stated in the specification.

4.2.3 Nitriding steels shall be quenched and tem-pered prior to nitriding. Where possible, nitriding shall be effected by the action of gases. The nature of the heat treatment, the nitriding depth and the hardness range (min/max) shall be stated in a specification.

4.3 The heat treatments and surface hardening processes referred to in 4.2 shall be carried out in such a way as to produce uniform hardening of the depth and hardness stipulated in the specification. GL re-serves the right to require the manufacture of samples on which the uniformity, depth and hardness of the surface layer shall be demonstrated.


The data shown in the drawings relating to the order are applicable.



6.1.1 The chemical composition is subject to the limit values specified in the relevant standard or the approved specification.

6.1.2 Where forgings are to be used for welded wheel assemblies, their composition shall be specially determined to suit the method of welding and shall be submitted to GL for approval.


For quenched and tempered steels, the minimum re-quired values for the yield strength, elongation and reduction in area specified in Tables 3.5 and 3.6 in C. shall be met in relation to the prescribed minimum tensile strength.

For case-hardening steels, the requirements specified in Table 3.8 apply to specimens which have undergone heat treatment together with the forging (coupons).

Table 3.8 Required values for mechanical and technological properties of specimens made of coupons


A 1 [%] min.

Reduction in area

Z 1 [%] min.

KV 1 [J]

min.

KU 1

[J] min.

Steel grade Sample

dia. ∅

[mm]

Yield strtength

ReH

[N/mm2] min.

Tensile strength

Rm

[N/mm2] l t, q l t, q l t, q l t, q

16MnCr5 590 780 –1080 10 8 40 27 22 16 24 18

20MnCr5 690 980 –1280 8 6 35 27 18 13 20 15

18CrNiMo7-6

30

785 1080–1320 8 6 35 27 18 13 20 15

16MnCr5 440 640 –940 11 9 40 27 22 16 24 18

20MnCr5 540 780 –1080 10 8 35 27 22 16 24 18

18CrNiMo7-6

63

685 980 –1280 8 6 35 27 18 13 20 15

1 Orientation of specimen axis: l = longitudinal, t = tangential, q = transverse

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D

6.3 Hardness

For all gear components, the hardness values pre-scribed for the tooth area in the specification or ap-proval drawing are mandatory.

7. Testing



The material manufacturer shall determine the compo-sition of each heat and issue a relevant certificate.

7.2 Tensile test on finally heat-treated, induc-tion-hardened and nitrided forgings

The mechanical properties shall be verified by tensile test. Test specimens shall be taken as follows:

7.2.1 Pinions over 200 mm in diameter:

If the diameter in the area of the teeth is greater than 200 mm, a tangential test specimen shall be taken from a position adjoining the tooth area, see Fig. 3.5. If the dimensions of the blank do not allow a specimen to be taken from this position, then a transverse specimen may be taken from an extension of the bearing journal. If the diameter of the bearing journal is 200 mm or less, then a longitudinal specimen may be taken. If the length of the finished tooth system is more than 1250 mm, test specimens shall be taken from both ends of the blank.

7.2.2 Pinions up to 200 mm in diameter:

In the case of small pinions with diameters of up to 200 mm in the area of the teeth, a longitudinal test specimen shall be taken from the bearing journal, see Fig. 3.5.

��

�

�

��

��

��

��

� � �� !�� !�� "�� #��

Fig. 3.5 Pinion

7.2.3 Gear wheels:

A tangential test specimen shall be taken from gear wheel blanks, see Fig. 3.6.

7.2.4 Wheel rims:

In the case of wheel rims which are normally made by piercing a bar and enlarging the hole by forging or rolling, a tangential test specimen shall be taken, see Fig. 3.7.

��

Fig. 3.6 Gear wheel

��

Fig. 3.7 Wheel rim

If the diameter of the tooth system exceeds 2500 mm or the heat-treated workpiece, excluding the material for testing, weighs more than 3000 kg, specimens shall be taken from two diametrically opposite points on the rim.

7.2.5 Pinion blanks:

From hollow pinion blanks, the length of whose fin-ished tooth system is 1 250 mm or less, a test speci-men shall be taken from one end at right angles to the longitudinal axis of the workpiece; where the length of the tooth system is more than 1 250 mm, specimens shall be taken from both ends, see Fig. 3.8.

��

Fig. 3.8 Hollow pinion

A distinction is to be made here according to whether the workpiece has been forged as a solid blank and then drilled or has been produced by piercing a rough forging and opening up the hole over a mandrel.

Where the workpiece is drilled, the specimens are considered to be transverse, but where the blank is expanded over a mandrel the specimens are consid-ered to be tangential.



D

7.3 Tensile test on case-hardening steels

7.3.1 The respective test sections are to be heat-treated together with the associated gear component or the test batch. For this purpose, the test sections are to be machined to a diameter corresponding to the smaller of the following two values:

0,25 × diameter of tooth system or

63 mm diameter

If the diameter of the test specimen is less than 63 mm, in agreement with the surveyor a test speci-men with standardized dimensions may be used (e.g. 30 mm diameter according to DIN 17210).

Tensile test specimens shall then be taken from the test sections and tested.

7.3.2 The gear manufacturer has the option of pro-ducing test sections with a cross section greater than that specified in 7.3.1. However, for the final harden-ing and tempering the pieces shall be given the speci-fied dimensions.

7.4 Strength differences in the forging

Where two test specimens are taken from large for-gings, the difference between the measured tensile strength values may not exceed the magnitudes speci-fied in B.4.2.3.


Each forging or unit test quantity, as applicable, shall be subjected to the notched bar impact test. The num-ber of sets of specimens (each comprising 3 speci-mens), the positions in the forgings or test sections from which the specimens are taken and their heat treatment are subject to the provisions of 7.2 and 7.3, as appropriate.

The test may be carried out on Charpy V- or Charpy U-notch samples as chosen by the manufacturer.

7.6 Hardness test

7.6.1 After heat treatment but before the cutting of the teeth, hardness tests are to be carried out on all forgings at the points specified in the approval draw-ings. Where the length L of the teeth of a gear compo-nent exceeds 500 mm, testing shall be performed at both ends of the tooth system.

7.6.2 On all surface-hardened gear parts, additional hardness tests are to be carried out on the teeth after hardening and grinding. The number of measuring points shall be such that compliance with the specified hardness values can be verified over the periphery and the width of the tooth system.

7.6.3 The differences in the values measured at the prescribed points on a forging or on different units within a test batch may not exceed the magnitudes specified in B.4.4.2.


The gear manufacturer shall check the surface finish and dimensions of the tooth system. The products shall then be presented to the Surveyor for final inspection and he shall be given the measurement records. For retests by the Surveyor, the gear manufacturer shall hold the necessary measuring instruments in readiness.

7.8 Batchwise testing

Forgings with similar dimensions up to a weight in heat-treated condition of 300 kg which originate from the same heat and form part of the same heat treatment batch may be grouped into test batches in accordance with A.10.2, Table 3.1. Two test sections shall be taken from each test batch for the tensile test and the notched bar impact test. Every forging shall be sub-jected to a hardness test.


7.9.1 The manufacturer shall carry out an ultra-sonic test on the tooth area of all forgings where the diameter of the tooth system exceeds 200 mm.

7.9.2 The entire tooth system of gear parts with surface-hardened teeth shall be tested for cracks using the magnetic particle or dye penetrant method.

The welds of gear wheels built up of separate parts shall be subjected to non-destructive testing of the scope specified at the time of the process approval.

The tests shall be performed in comliance with G.

E. Forgings for Boilers, Pressure Vessels, Process Equipment and Pipelines

1. Scope

1.1 These Rules are applicable to unalloyed and alloy steel forgings for the manufacture of flanges, nozzles, valve housings, socket welding and welding neck components. Steel forgings tough at sub-zero temperatures are subject to F.

1.2 In the case of forgings for steam boilers on vessels sailing under the German flag, the "Technical Rules for Steam Boilers" of series TRD 100 shall be complied with.


The following materials may be used:

2.1 Weldable unalloyed structural steels con-forming to EN 10250-2 up to an operating temperature of 300 °C.

2.2 Forgings made of ferritic and martensitic steels with specified properties at elevated tempera-tures conforming to EN 10222-2.

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E

2.3 Forgings made of weldable fine-grained structural steels conforming to EN 10222-4.

2.4 Austenitic or austenitic-ferritic stainless steel forgings conforming to DIN 17440, EN 10222-5 or "Stahl-Eisen-Werkstoffblatt" (Iron and Steel Material Specification) SEW 400.

2.5 Steel flanges conforming to DIN 2528.

2.6 Steels conforming to other standards or mate-rial specifications, provided that they are comparable to the steel grades listed in 2.1 to 2.5 and proof has been furnished of their suitability for the intended application. An initial test of product suitability may be requested for this purpose. Ferritic steels shall addi-tionally satisfy the following minimum requirements.

2.6.1 The elongation (A) shall have the character-istic minimum values for the respective steel grades as specified by GL; however, it shall be not less than 14 % in transverse and tangential direction and not less than 16 % in longitudinal direction.

2.6.2 The impact energy shall have the characteris-tic minimum values for the respective steel grades as specified by GL; however, it shall be not less than 27 J in transverse and tangential direction and 39 J in lon-gitudinal direction at room temperature in tests con-ducted with Charpy V-notch specimens. This value is an average value from three tests, in which one indi-vidual value may be below the prescribed average value but not less than 70 % of the average value.

3. Heat treatment and condition of supply

All forgings shall be supplied in a heat treated condi-tion appropriate to the grade of steel. In the case of unalloyed steel grades, normalizing may be replaced by an equivalent method of temperature control during or after forging or rolling, provided that GL has ap-proved the method.

If parts are manufactured from bars or plates by ma-chining, heat treatment of the starting material is suffi-cient.


4.1 General requirements

The chemical composition, mechanical properties, and impact energy and hardness values of the steel shall conform to the standards stated in 2.1 to 2.5 or, where applicable, the data contained in the approved specifi-cations.

4.2 Weldability

Steels conforming to these Rules shall be weldable by established workshop methods. Depending on the chemical composition, preheating and/or post-weld heat treatments may be required for this purpose.


Austenitic steel grades shall be resistant to intercrys-talline corrosion in the condition in which they are supplied. If forgings for welded assemblies (e.g. weld-on valves, flanges) are to be used without post-weld heat treatment, steel grades which are corrosion-resistant in this condition as well shall be selected, e.g. steels stabilized with Ti or Nb or steels with carbon contents of C ≤ 0,03 %.

5. Testing

The forgings shall be presented for testing in finished condition (condition of supply) and shall undergo the following tests. With regard to forgings for steam boilers, 1.2 shall be complied with.

5.1 Tensile testing

5.1.1 The mechanical properties shall be verified by a tensile test. For preparing the test specimens, forgings with similar dimensions and nominal weights up to 1 000 kg which originate from the same heat and form part of the same heat treatment batch may be grouped into test batches in accordance with A.10.2, Table 3.1. For normalized forgings, one specimen shall be taken from each test batch, while for forgings in other heat-treated conditions, 2 specimens shall be taken from each test batch. For quantities of ≤ 10, and ≤ 30 in the case of nominal weights not exceeding 15 kg, one specimen is sufficient.

5.1.2 For batchwise testing, the hardest and softest forgings in each batch shall be selected for testing, see 5.3.

5.1.3 In the case of forgings with unit weights of more than 1 000 kg, a test specimen shall be taken from every forging.


The forgings shall be subjected to the notched bar impact test. The number of sets of test specimens (3 Charpy V-notch specimens per set) shall be determined in the same way as the number of tensile test specimens.

5.3 Hardness tests

5.3.1 In the case of quenched and tempered forgings, with the exception of flanges with standardized dimen-sions, a hardness test shall be performed on each forging.

5.3.2 Flanges with standardized dimensions shall be subjected to the following scope of testing:

– normalized steels: at least 3 %,

– quenched and tempered, and austenitic-ferritic steels: at least 10 % of the same test batch

5.3.3 In the case of parts not mentioned in para-graphs 5.3.1 and 5.3.2, at least 20 % of each test batch shall be tested.



E


The manufacturer shall test the surface finish and dimensions of the products and shall then present the parts to the Surveyor for final acceptance testing.

5.5 Test for use of correct material

Alloy steel forgings shall be subjected by the manu-facturer to appropriate tests to ensure that the correct material has been used.


Forgings with a nominal weight of over 300 kg shall be subjected by the manufacturer to an ultrasonic test and, where necessary, a supplementary test for surface cracks. The tests shall be performed in compliance with G.

5.7 Testing of resistance to intercrystalline corrosion

The manufacturer shall check the resistance to inter-crystalline corrosion of austenitic and austenitic-ferritic steel forgings intended for welded assemblies and - where stipulated in the order - of other austenitic steels as well. Testing shall be carried out in the fol-lowing conditions:

– steels containing C ≤ 0,0 3% and stabilized steels: after sensitizing heat treatment (700 °C, 30 min, quenching in water)

– all other steels: in the condition of supply. At least two specimens from each heat shall be tested in accordance with a recognized standard (e.g. ISO 3651-2).

F. Steel Forgings Tough at Sub-Zero Tem-peratures

1. Scope

1.1 These Rules are applicable to steel forgings tough at sub-zero temperatures and high-strength, quenched and tempered steel forgings which are in-tended for cargo and processing equipment on gas tankers, e.g. flanges, valve parts, weld-on and socket welding parts.

1.2 In the case of forgings which are intended for pressure-liquefied ammonia at design temperatures not lower than 0 °C, e.g. forged flanges, rings and connec-tions, the boundary values given in Section 1, F.8.1.1, Table 1.18 for chemical composition and in Section 1, F.8.2.2 for mechanical properties are to be observed. The required values for impact energy given in Section 1, F.8.3 shall also apply.

1.3 In the case of high-strength, quenched and tempered fine-grained structural steel forgings having

nominal yield strengths of between 420 and 690 N/mm2

which are designed for gas tanks with design tempera-tures no lower than 0 °C, the requirements according to 1.2 apply.


The following grades of steel may be used within the minimum design temperature limits specified in Table 3.9, provided that they satisfy the requirements of 5.

2.1 Standardized steels conforming to Table 3.9.

2.2 Other steels conforming to other standards or material specifications, provided that they are compa-rable with the steel grades specified in 2.1 and proof has been furnished of their suitability for the intended application. An initial approval test may be required for this purpose.


All forgings shall be supplied in a heat-treated condi-tion appropriate to the grade of steel, i. e normalized, quenched and tempered, or solution-annealed and quenched.

If parts are manufactured from bars or plates by ma-chining, heat treatment of the starting material is suffi-cient.


The data in the standards or specifications are applicable.



The chemical composition, the mechanical properties and the hardness shall conform to the data contained in the relevant standards or approved specifications.

5.2 Weldability

Steels conforming to these Rules shall be weldable by established workshop methods.

5.3 Impact energy at low temperatures

The required impact energy values specified in Table 3.10 for the grade of steel concerned shall be met at the test temperatures specified in the table, using Charpy V-notch specimens.


Austenitic steel grades shall be resistant to intercrys-talline corrosion in the condition in which they are supplied. If forgings are to be used for welded assem-blies (e.g. weld-on valves, flanges) without post-weld heat treatment, steel grades which are corrosion-resistant in this condition as well shall be selected, e.g. steels stabilized with Ti or Nb or steels with carbon contents of C ≤ 0,03%.

II - Part 1 GL 2009


F

Table 3.9 Approved grades of forging steels tough at sub-zero temperatures

Type of steel Approved minimum design temperature

Steel grade or Material no. Standard

P285NH

P285QH

P355N

Weldable fine-grained structural steels –20 °C

1

P355QH

EN 10222-4

0,5 % nickel steel –55 °C 13MnNi6-3 EN 10222-3

2,25 % nickel steel –65 °C ––

3,5 % nickel steel –90 °C 12Ni14

–105 °C 12Ni19 5 % nickel steel

⎧⎨⎩

–165 °C 2 X12Ni5

9 % nickel steel –165 °C X8Ni9

EN 10222-3

1.4301 (304) 3

1.4307 (304 L)

1.4401 (316)

1.4404 (316 L)

1.4541 (321)

Austenitic steel –165 °C

1.4550 (347)

EN 10222-5

1 Lower design temperatures may be established by means of an approval test. 2 The minimum design temperature of – 165 °C is only valid if this has been demonstrated by an approval test. 3 The numbers in brackets denote comparable steels conforming to AISI standards.

Table 3.10 Required impact energy values for steel forgings tough at sub-zero temperatures

Impact Energy

KV [J] 1 min.

Type of steel Test

temperature

longitudinal transverse

Weldable fine-grained structural steels and 0,5 % nickel steel

5 K below minimum design temperature but at least

– 20 °C

27 (19)

22 (15)

2,25 % nickel steel – 70 °C

3,5 % nickel steel – 95 °C

5 % nickel steel –110 °C

5 % nickel steel –196 °C 2

9 % nickel steel –196 °C

34 (24)

24 (17)

Austenitic steels –196 °C 41 (27) 27 (19)

1 Average value measured on 3 Charpy V-notch specimens; the figures in brackets indicate the minimum individual value. 2 The test temperature of –196 °C applies if the 5 % nickel steel has been approved for a minimum design temperature of –165 °C.



F

6. Testing

The forgings shall be presented for testing in the fin-ished condition (condition of supply) and subjected to the tests specified below.

6.1 Tensile test

6.1.1 The mechanical properties shall be tested by tensile test. For preparing the test specimens, forgings with similar dimensions and nominal weights up to 1 000 kg which originate from the same heat and form part of the same heat treatment batch may be grouped into test batches in accordance with A.10.2, Table 3.1.

For normalized forgings, one specimen shall be taken from each test batch, while for forgings in other heat-treated conditions, 2 specimens shall be taken from each test batch. For quantities of ≤ 10 - and ≤ 30 in the case of nominal weights not exceeding 15 kg - one specimen is sufficient.

6.1.2 For the batchwise testing, the hardest and softest forgings in each batch shall be selected for testing, see 6.3.

6.1.3 In the case of forgings with unit weights of more than 1 000 kg, a test specimen shall be taken from every forging.


The forgings shall be subjected to the notched bar impact test using Charpy V-notch specimens. The number of sets of test specimens (3 specimens per set) shall be determined in the same way as the number of tensile test specimens. The tests shall be performed at the test temperatures specified in Table 3.10.

6.3 Hardness testing

6.3.1 In the case of forgings in quenched and tem-pered condition, with the exception of flanges with standardized dimensions, a hardness test shall be per-formed on every forging.

6.3.2 Flanges with standardized dimensions shall be subjected to the following scope of testing:

– Normalized steels: at least 3 %,

– quenched and tempered, austenitic and austenitic-ferritic steels: at least 10 % of the same test batch

6.3.3 In the case of parts not mentioned in 6.3.1 and 6.3.2, at least 20 % of each test batch shall be tested.


The manufacturer shall test the surface finish and dimensions of the products and then present the parts to the Surveyor for final acceptance testing.

6.5 Test for use of correct material

Alloy steel forgings shall be subjected by the manu-facturer to appropriate tests to ensure that the correct material has been used.


Forgings with a nominal weight of over 300 kg shall be subjected by the manufacturer to an ultrasonic test and, where necessary, a supplementary test for surface cracks. The test shall be performed in compliance with G.


The manufacturer shall check the resistance to inter-crystalline corrosion of austenitic steel forgings in-tended for welded assemblies and - where stipulated in the order - other austenitic steels as well. Testing shall be carried out in the following conditions:

– steels containing C ≤ 0,03 % and stabilized steels: after sensitizing heat treatment (700 °C, 30 min, quenching in water)

– all other steels: in the condition of supply. At least two specimens from each heat shall be tested in accordance with a recognized standard (e.g. ISO 3651-2).

G. Non-destructive Testing of Forged Com-ponents


1.1 These Rules apply to the non-destructive testing of forged components for which in B. to F. appropriate requirements are prescribed, and for which no other regulations or manufacturer specifications are agreed upon.

A list containing the forged components for which non-destructive testing is required and the specific tests to be performed is contained in H.

1.2 The general requirements for inspection bod-ies, inspection personnel, testing methods and certifi-cation of the results are prescribed in Chapter 1 – Prin-ciples and Test Procedures, Section 3 and are manda-tory for all tests.

1.3 The methods indicated in these Rules con-cerning the magnetic particle test and ultrasonic tests are limited to the application of forged components made of ferritic steel grades.

For forged components made of austenitic or austen-itic-ferritic steel grades the methods and acceptance criteria for the ultrasonic and penetrant tests shall be agreed upon with GL individually. This may be per-formed based on standards or specifications from the manufacturer or the orderer.

1.4 Taking into account the prescriptions in 1.3, in these Rules the following testing methods are de-scribed, see Table 3.11.

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G


Testing of Method Short name 2

Visual testing VT

Magnetic particle testing 1 MT External condition


Internal condition Ultrasonic testing UT

1 only for forged components made of ferritic steel grades 2 definition according to DIN EN 473

1.5 The methods and testing criteria indicated in G. are to be employed by the manufacturers and com-panies performing the further processing.

In case the orderer wants further regulations to be applied on specific forged components e.g. for engines and turbines, he shall state this in a test specification and make this known to the GL Surveyor.

Alternatively non-destructive testing may be per-formed in accordance with test specifications from the manufacturer or the orderer on condition that the methods and acceptance criteria fulfil the following requirements.

1.6 For testing, the forged components shall be classified in inspection zones of type I, II and III, ac-cording to the possible effects of defects on the struc-tural integrity. For magnetic particle testing there will be the addition of type IV. In inspection zone I the allow-able number and size of indications are the smallest.

For classifying in inspection zones the following prin-ciples are decisive:

– the operation loads to be expected

– the effects of the defects on the reliability of the component

– possible risk of damage if the component fails

– Freedom of defects and surface condition after the final machining

For the most important forged components of the propulsion plant the classifying in inspection zones is prescribed in I. and J.

1.7 For forgings where in I. for magnetic particle testing and in J. for ultrasonic testing no classifying in inspection zones is indicated, the manufacturer or orderer shall prescribe the inspection zones in a test specification taking into consideration the principles in 1.6 and shall be make them known to the GL Sur-veyor.

Further, the test specification shall contain details concerning the required acceptance criteria (e.g. qual-ity class according to EN 10228-1, -2, -3).

2. Performing the tests

2.1 After the inspector of the internal or external inspection body in charge of testing has performed the prescribed tests, the final machined forged compo-nents shall be presented to the GL-Surveyor for visual testing.

2.2 Concerning the tests it shall be differentiated between pre-testing and acceptance testing. With pretests, where decisions concerning the testability and the employability of the forged component are made, they are in general the business of the manufac-turer.

Acceptance tests shall be performed preferably on the final machined component after the heat treatment appropriate for the required properties has been per-formed.

If necessary acceptance tests may be performed at a production stage with little machining allowance, and for ultrasonic testing after pre-machining in a condi-tion with less contours.

Details for this are to be prescribed in a test specifica-tion and to be made known to GL.

2.3 The Surveyor shall be informed by the manu-facturer or the company performing the further proc-essing about the intended tests. It is up to the discre-tion of the Surveyor to attend the tests.

2.4 The tests shall be performed for the zones described for the forged components in H. and J., or for those indicated in the test specification. In case the results indicate that further defects are present in the forged component, the test scope shall be extended according to agreement with the Surveyor.

2.5 Indications exceeding the allowable size, number and position indicated in the tables shall be removed if technically possible. Excavated areas at the surface are to be subjected to retesting.

2.6 In case internal defects or defects close to the surface cannot be removed by grinding with satisfac-tory results, the manufacturer, the orderer and the GL-Surveyor shall decide on the employability of the forged component.

3. Visual testing (VT)

3.1 The manufacturer shall verify for each pro-duction stage of the forged components the external condition and the compliance of the dimensions. Forg-ing defects are to be removed, unless they are re-moved by the following machining.

3.2 For the acceptance test the forged component are to be presented to the Surveyor in final machined condition.



G

If necessary an inspection of forged components in raw condition or in premachined condition by the GL-Surveyor can be agreed on.

3.3 Discontinuities of the material such as cracks, forging laminations or inclusions open towards the surface are not allowed and shall be repaired. The repaired areas shall be subjected to additional surface crack detection.

3.4 The Surveyor certifies the visual inspection on the GL acceptance test certificate. E.g. the follow-ing text can be typed in the test certificate:

"The aforementioned forged components were visually tested.

The prescribed requirements are fulfilled."

3.5 On demand of the orderer the manufacturer shall issue an inspection certificate according to EN 10204-3.1 containing the details of the tests and the test results.

4. Magnetic particle testing (MT)

4.1 The surfaces to be tested shall be free of scale, grease, dirt and protecting paint as well as other contami-nations which may affect the detection of indications.

4.2 The roughness of the machined test areas shall not exceed an average roughness of Ra = 12,5 μm for

premachined surface, and Ra = 6,3 μm for final ma-chined surface.

4.3 Contact points visible on the surface are to be ground and to be retested by yoke magnetization if they will not be removed by the following machining.

It is not allowed to employ prods on final machined surfaces.

The testing of final machined forged components shall preferably be performed with stationary test appliances.

4.4 In case deviant of 2.1, tests have to be per-formed before final machining, e.g. before bore holes or lubricating oil channels are realized. This shall be indicated in the test instructions. The acceptance test will be performed by the Surveyor after the final ma-chining of the component.

4.5 The indications of magnetic particle testing shall be evaluated depending on the specific inspec-tion zone I to IV (cf. 1.6) concerning their size and number in accordance with Table 3.12. The reference area for this shall be a rectangle with 148 mm × 105 mm (size DIN A6) and shall be placed on the specific most unfavourable area for each case (area with the highest number of indications).

4.6 Concerning the evaluation it shall be differ-entiated between isolated and aligned indications. These terms are explained in Fig. 3.9.

4.7 All indications exceeding the registration levels indicated in Table 3.12 are to be reported.

Where indications concerning their size and number exceed the indicated values for the appropriate inspec-tion zone (or the appropriate class of quality according to EN 10228-1, respectively), as well as cracks, open forging laps and discontinuities are to be regarded as defects and shall be removed.

4.8 For the circumferential surfaces of grooves and oil bore holes of crankshafts indications of every type in zone I are not allowed.

4.9 In case doubts exist whether an indication is generated by a crack, additional penetrant testing shall be performed.

Table 3.12 Acceptance criteria for magnetic particle testing according to EN 10228-1

Acceptance limits for inspection zone

IV III II I

appropriate class of quality according to EN 10228-1

Parameter for evaluation

1 2 3 1 4 2, 3

Recording level: length of indications [mm] ≥ 5 ≥ 2 ≥ 2 ≥ 1

max. allowed length Lg of aligned or isolated indications Ln [mm] 20 8 4 2

max. allowed cumulative length of indications Lk [mm] 75 36 24 5

max. allowed number of indications on the reference area 15 10 7 5

1 Class of quality not applicable for testing of surfaces with machining allowance exceeding 3 mm. 2 Class of quality not applicable for testing of surfaces with machining allowance exceeding 1 mm. 3 Class of quality not applicable for surfaces of fillets and oil hole bores of crankshafts (cf. G.4.8).

II - Part 1 GL 2009


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4.10 Repair of defects

Defects are to be removed by suitable measures. In doing so it shall be ensured that the dimensions of the forged component will not exceed the prescribed tol-erances. Removal of a defect by grinding shall be performed perpendicular to the defect in such a way that the end of the groove is prepared in a longitudinal direction and smoothly blends to the adjacent surface. The transition radius shall be at least three times the groove depth.

4.11 After the removal of defects by grinding the ground areas are to be subjected again to magnetic particle testing.

4.12 The evaluation of excavated areas concerning their size and position in the specific inspection zones shall be performed by means of manufacturer and/or

orderer specifications. If the dimensions fall below the minus tolerances the consent of the Surveyor shall be requested.

5. Penetrant testing (PT)

5.1 The surfaces to be tested shall be free of scale, grease, dirt and protecting paint as well as other contaminations which may affect the detection of indications.

5.2 Penetrant testing is to be performed on forged components made of austenitic or austenitic-ferritic steel grades. It may be performed on forged compo-nents made of ferritic steel grades in addition to mag-netic particle testing (MT), nevertheless the results of the magnetic particle tests are decisive concerning the acceptance criteria.



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5.3 Testing is to be performed in accordance with Chapter 1 – Principles and Test Procedures, Section 3, K. or with other recognized standards such as e.g. EN 571-1 and ISO 3452-2 or EN 10228-2 "Non-destructive testing of steel forgings, Part 2, Penetrant testing".

5.4 The manufacturer shall prepare a test instruc-tion which shall contain at least the following infor-mation:

– details of the forged component including the material grade

– standards and specifications to be applied

– description of the test method

– employed testing agent system

– qualification of the inspection personnel

– surface areas to be tested

– required surface condition

– test criteria

– type of testing report

5.5 Unless otherwise agreed the testing according to Chapter 1 – Principles and Test Procedures, Section 3, J. shall be performed on the final machined forged component and shall be performed in the presence of the Surveyor.

6. Ultrasonic testing (UT)

6.1 In the areas to be tested an appropriate sur-face condition shall be achieved which enables a fault-less coupling of the probe. Forging fin, scale, paint, dirt, unevenness and mechanical damages shall be removed/corrected.

6.2 For premachined surfaces the average value of the roughness shall be Ra ≤ 25 μm. It is recom-mended to agree on the appropriate class of quality for the surface roughness according to Table 3.13.

6.3 The tests are to be performed in accordance with Chapter 1 – Principles and Test Procedures, Sec-tion 3, L. Unless otherwise agreed it may also be per-formed according to EN 583-1, SEP 1921, SEP 1923, EN 10228-3 and/or other equivalent and recognized standards, manufacturer or orderer specifications.

6.4 Unless no other recording levels were agreed on, all indications exceeding a KSR 1 with diameter = 2 mm shall be registered and evaluated and reported concern-ing their position, size, number and acceptability.

6.5 For indications which shall be registered, the amplitude of the back wall echo in the area of the indication is to be compared with the adjacent areas free of indications.

Attenuations of the back wall echo with ≥ 4 dB are to be recorded in the testing report in dB.

6.6 Cracks of any type, size and distribution are not allowed.

6.7 Indications exceeding the limiting values contained in Table 3.14 or 3.15, are to be regarded as defects and in the first instance result in rejection of the forged component by the Surveyor. If the tests are performed in accordance with a manufacturer or or-derer specification approved by GL then the limiting values indicated there are decisive and the procedure is accordingly.

6.8 The acceptance of the forged component which in the first instance had been rejected is possi-ble on condition that after further evaluation of the indications performed by the orderer and the Surveyor proof has been furnished that due to their size, posi-tion and distribution the defects have no considerable effect on utilization of the forged component. In this case the acceptance of the forged component shall be approved by an acceptance test certificate by both the orderer and the Surveyor.

_____________________________

1 KSR = disc shaped reflector (= Kreisscheibenreflektor)

Table 3.13 Recommendations for the surface quality

Class of quality and roughness Ra [μm]

1 2 3 4 Surface quality

≤ 25 ≤ 12,5 ≤ 12,5 ≤ 6,3

machined × × × ×

machined and heat treated × × ×

forged ×

Note "×" indicates the class of quality which can be achieved with the prescribed roughness.

II - Part 1 GL 2009


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Table 3.14 Acceptance criteria for ultrasonic testing of forged components

Forged component Zone

Size of the max. allowable

KSR 1 [mm]

Max. allowable length of indications 3

[mm]

Min. distance between two indications 3

[mm]

Total of all indication lengths

[mm] per "m"

component length

Propeller shafts I 2 ––

Intermediate shafts outside: 2 10 10 0,05 ⋅ d

Thrust shafts II 2

inside: 4 15 10 0,10 ⋅ d

Rudder stocks and pintles

outside: 3 10 10 0,15 ⋅ d

Piston rods 4

III 2

inside: 6 15 10 0,20 ⋅ d

Connecting rods 5 I ––

Piston rods II 2 10 10 0,05 ⋅ d

Cross heads III 4 10 10 0,15 ⋅ d (s) 5

1 KSR = disc shaped reflector

2 The classifying in inspection zones is depicted in Fig. 3.15 to 3.20. 3 For accumulations of 2 or more isolated indications to be recorded the minimum distance between 2 adjacent indications shall be at least

of length of the major indication.

This applies to distances in axial as well as in thickness direction.

Isolated indications with smaller distance are to be regarded as aligned indication. 4 Piston rods with shaft diameter larger than 150 mm.

5 For rectangular cross-section "d" corresponds to the smallest side length "s".

Table 3.15 Acceptance criteria for ultrasonic testing of crank shafts

Size of the max. allowable

KSR 1

Max.

allowable length

of indications

Min.

distance between two indications 3

Max. number of isolated

indications 3, 4 Zone 2

[mm] [mm] [mm] [ − ]

Total of all indication length

[mm] 4 per pin or journal,

or per web or flange,

respectively

I –– –– –– –– ––

II 2 10 10 0,01 ⋅ d (D) 1

mm⋅ 0,20 ⋅ d (D)

III 4 15 10 0,02 ⋅ d (D) 1

mm⋅ 0,40 ⋅ d (D)

1 KSR = disc shaped reflector

2 The classifying in inspection zones is depicted in Fig. 3.21.

3 For accumulations of 2 or more isolated indications to be recorded the minimum distance between 2 adjacent indications shall be al least of length of major indication.

This applies to distance in axial as well as in thickness direction.

Isolated indications with smaller distance are to be regarded as aligned indication.

4 Related to be diameter of crank pin "d" or to the diameter of main journal "D", respectively.



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H. List of Forged Components for which Non-destructive Tests are Required

Test method to be employed Name of the forged component

VT MT UT

Structural parts concerning the hull:

rudder stocks and pintles X X X 1

Parts for diesel engines: – crank shafts X X X 3 – connecting rods X X X 2 – piston rods X X X 2 – crossheads X X X – piston crowns X X 2 X – cylinder covers X X 2 X – piston pins X X 2 – tie rods X X 2 – bolts ≥ M50 for: – main bearing X X 2 – connecting rod bearing X X 2 – cross heads X X 2 – cylinder covers X X 2 – camshaft drive gear wheels and chain wheels X X 2

Main shafting and gears: – propeller shafts X X X 1 – intermediate shafts X X 1 – thrust shafts X X X 1 – gear wheels X X X 4 – gear shafts X X X 4 – pinions X X X 4 – wheel rims X X X 4

Turbo machinery (main drive): – rotors X X X – rotor discs X X – shafts X X X – blades guide vanes and blades X X 7, 8 – turbine casing bolt ≥ M50 X X 7

Other components: – shafts for e-engines (main) X X – forged components made of steels for use at elevated

temperatures X X 5, 6 X 5

made of steels tough at sub-zero temperatures

X X 5, 6 X 5

– bolts for fixing of propeller blades ≥ M50 X X 6 – bolts for superheated steam pipelines X X 6

1 for diameters ≥ 250 mm 2 for diesel engines with cylinder diameter > 400 mm 3 for batchwise testing of small crankshafts ultrasonic testing of the prematerial is sufficient. Small crankshafts are those with gross weights not exceeding 500 kg. 4 for diameter of the gearing or of the shafts > 200 mm 5 for finished weights > 300 kg 6 for austenitic or austenitic-ferritic steels penetrant testing (PT) instead of magnetic particle testing (MT) 7 for main steam temperatures > 350 °C 8 Instead of surface crack testing (MT, PT) eddy current testing may be considered, too.

II - Part 1 GL 2009


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I. Classifying of Inspection Zones for Magnetic Particle Testing (MT)

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II - Part 1 GL 2009


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II - Part 1 GL 2009


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Section 4

Cast Steel

A. General Rules

1. Scope

This Part contains general rules to be applied in the manufacture and testing of steel castings. Also appli-cable are Chapter 1 – Principles and Test Procedures, Sections 1 – 3.

2. Selection of grades of cast steel

2.1 All cast steel shall be suitable for the in-tended application and shall satisfy the minimum requirements specified in the following individual Rules. Subject to these conditions, grades of cast steel conforming to the relevant standards or to the material specifications approved by GL may be used.

2.2 The grades of cast steel shall be identified by the standardized designations or the designations given in the specifications.

3. Requirements to be met by foundries

3.1 Foundries wishing to supply castings in ac-cordance with these Rules shall be approved by GL. This is conditional upon their fulfilling the manufac-turing and quality control requirements stated in Chap-ter 1 – Principles and Test Procedures, Section 1, C. and furnishing proof of this to GL prior to the com-mencement of supplies.

3.2 Irrespective of the requirements stated in 3.1, the manufacturer shall demonstrate by approval tests carried out on the products that these can be manufac-tured in accordance with the conditions imposed. The scope of these tests will be determined by GL.


4.1 Cast steel shall be produced in an electric furnace, by a basic oxygen process, in an induction furnace or by other methods approved by GL. On request, the steel-making process shall be made known to GL for approval.

4.2 Where castings are produced by welding together two or more separate components, details of the method shall be submitted for approval. This nor-mally calls for a test of the welding procedure.

5. Condition of supply, heat treatment

5.1 All castings shall undergo heat treatment appropriate to the material. The heat treatments shall be performed in suitable furnaces. The dimensions of the furnace shall enable the entire casting to be raised uniformly to the required heat treatment temperature. Where, in the case of large castings, the size of the furnace does not allow the entire casting to be normal-ized at once, other arrangements shall be agreed with GL.

5.2 Where, following final heat treatment, a cast-ing is heated locally or undergoes hot or cold straight-ening, subsequent stress relief heat treatment may be required to remove residual stresses.

5.3 Flame cutting, flame scarfing or flame goug-ing to remove excess material or feeders shall be car-ried out by a recognized method prior to final heat treatment. Preheating shall be applied where the chemical composition and/or the thickness of the casting make this necessary. Where required, the heat-affected zones of the casting shall be machined or ground off.

6. General characteristics of castings

6.1 All castings shall have a clean surface com-patible with the conditions of manufacture. Minor casting defects such as small sand and slag marks, small cold shuts and small scabs may be trimmed off within the negative tolerance on the wall thickness.

6.2 Defects liable to impair the use and workabil-ity of the material to a more than minor degree are not allowed. They may be removed by one of the methods named in 13.


The dimensions and the dimensional and geometrical tolerances are governed by the values specified in the drawings relating to the order or in the relevant stan-dards, as applicable. Appropriate details shall be made known to the Surveyor.

8. Tightness

All castings which are subjected to internal pressure by the operating medium or for which special proof of impermeability is required shall be leakproof at the specified test pressures after being machined.

II - Part 1 GL 2009

Section 4 Cast Steel Chapter 2Page 4–1

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9. General requirements applicable to cast materials


The chemical composition of grades of cast materials shall conform to limit values specified in the Tables contained in this Section and/or in the relevant stan-dards or specifications, as applicable. The manufac-turer shall take suitable measures to ensure that the residual elements remain within the permitted limits.


9.2.1 Tensile test

The tensile characteristics indicated in the Tables contained in this Section or, where applicable, in the relevant standards or specifications shall be verified by tensile test.

9.2.2 Notch bar impact test

The impact energy specified for the various grades of cast steel shall be satisfied by the average value meas-ured on 3 Charpy V-notch or Charpy U-notch test specimens, one of which may give a result below the required average value although it may not be less than 70 % of the required average value.

9.3 Other characteristics

Where special characteristics are specified for particu-lar grades of cast steel, e. g. resistance to intercrystal-line corrosion and mechanical characteristics at ele-vated temperatures, these shall, where necessary, be proved by appropriate tests.

10. Testing


The manufacturer shall determine the chemical com-position of each heat or, where necessary, of each ladle and shall present corresponding certificates to the Surveyor.

Should there be any doubt as to the chemical composi-tion of the products, a product analysis shall be per-formed.

10.2 Testing of the mechanical properties and the selection of specimens

10.2.1 The mechanical properties shall be ascer-tained by tensile test to determine tensile strength, yield strength or 0,2 % proof stress, reduction in area and elongation.

The notched bar impact test shall also be performed where specified for particular grades of cast steel.

10.2.2 The tests shall be performed on a heat-by-heat basis. Castings from each heat that undergo the same heat treatment shall be grouped into test batches of up to 4 500 kg. Residual quantities of up to

1 250 kg shall be allocated to the preceding test batch. Parts with unit weights > 1 000 kg shall be tested individually.

If the finished weight exceeds 10 000 kg, at least two test specimens shall be taken. For this purpose, test samples spaced as widely as possible shall be cast integrally with the casting.

10.2.3 For each casting or for each test batch, as applicable, a sufficient number of samples shall be provided which shall normally be cast integrally with the cast component. The number of samples shall be sufficient to provide material for the test specimens needed for possible retests. The sample may only be removed from the casting after the final heat treat-ment. The thickness of the sample shall be matched to the relevant wall thickness of the casting, but shall be at least 30 mm. In the case of thick-walled steel cast-ings, the sample thickness need not exceed 100 mm.

10.2.4 Where a number of small castings of ap-proximately the same dimensions are produced from the same heat and are heat treated in the same furnace charge, then, notwithstanding the provisions stated in 10.2.3, specimens may be taken from separately cast samples. For this purpose, at least one sample per furnace charge shall be provided, which shall be heat treated together with the castings to which it relates.

10.2.5 If separately cast samples are used, these shall be cast in moulds made of the same moulding material as that used for the castings themselves.

10.2.6 All samples shall be marked in such a way that they can be clearly related to the castings which they represent. The type of marking shall be agreed with the Surveyor.

10.2.7 Where castings are manufactured by a method subject to the special approval of GL, see 4.1, the number and position of the samples shall be spe-cially agreed so as to take account of the method of manufacture.


10.3.1 All castings shall be inspected by the manu-facturer for surface finish and compliance with the dimensional and geometrical tolerances and shall then be presented to the Surveyor for final inspection. In-side surfaces are to be included in the inspection.

10.3.2 The surface of the castings shall be free from material from the mould and shall be properly pre-pared for inspection. Where necessary, this conditions shall be achieved by pickling, local grinding, shot or sand blasting, cleaning with wire brushes or by chemi-cal means. Chipping and hammering are allowed only if this does not conceal surface defects.


Section 4 Cast Steel II - Part 1GL 2009

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10.3.3 Where there is reasonable suspicion that welds have been carried out on a casting, the Surveyor may require certain areas of the surface to be etched in order to reveal possible welds.


10.4.1 Where non-destructive tests are required, these shall be performed by the manufacturer of the castings and/or the finishing plant. Tests may also be arranged by GL.

10.4.2 Non-destructive tests shall be performed in accordance with the specifications stated in G. to J. in consideration of the specifications in Chapter 1 – Principles and Test Procedures, Section 3.

10.5 Retests in the event of failure

If tensile test specimens fail to meet the required val-ues under test, if the specified average value is not achieved in a notched bar impact test or if an individ-ual value is less than 70 % of the required average value, then, before the unit test quantity or the casting is rejected, the procedures for retests prescribed in Chapter 1 – Principles and Test Procedures, Section 2, H. may be applied. The additional test specimens shall be taken either from the same test sample as the origi-nal specimen or from other samples which are repre-sentative of the casting or of the unit test quantity.

11. Identification and marking of castings

11.1 The manufacturer shall institute a monitoring system enabling all castings to be traced back to the original heat, and this shall be demonstrated to the Surveyor on request.

11.2 Prior to final inspection, all castings shall be provided by the manufacturer in at least one place with the following marks:

– cast steel grade


– heat number, casting number, casting date or an abbreviated symbol enabling the manufacturing process to be traced

– specimen number

– date of test

– test pressure, where applicable

11.3 In the case of series-manufactured castings, agreement may be reached with the Surveyor to apply marks other than those specified in 11.2.

12. Certificates

For each consignment the manufacturer shall supply to the Surveyor a certificate or delivery specification containing at least the following details:


– newbuilding and project number, as applicable, if known

– nature of castings and grade of cast steel

– purpose and drawing number, if necessary

– item numbers and numbers of units

– weight of delivery

– method of manufacture

– heat numbers

– chemical composition


– details of heat treatment

– test pressures, where applicable

– results of the mechanical tests

– results of any special tests applied, e.g. non-destructive tests and test of resistance to inter-crystalline corrosion

– condition of surface

13. Repair of defects

13.1 Methods

Defects may be repaired by machining, grinding, flame scarfing or gouging, or by welding. The method is to be agreed with the Surveyor except where the approval of the Head Office of GL is required for the welding of highly stressed castings, e.g. diesel engine parts and turbine casings.

13.2 Machining and grinding

The repair shall be performed in such a way as to remove the defect completely and provide a gradual transition between the resulting depression and the contour of the casting. The transition shall be 2 to 3 times the depression. The depth of the repair may not have more than an insignificant effect on the strength of the component and the wall thickness shall not be reduced below the minimum tolerance.

13.3 Flame scarfing and gouging

Defects may be removed by flame scarfing and goug-ing. Cast materials liable to hardening shall be appro-priately preheated. The depressions caused by the re-moval of metal shall afterwards be bright ground. The grinding shall be sufficiently thorough to ensure the removal of any metal with a heat-affected structure.

13.4 Fabrication welding

13.4.1 If major defects have to be welded on steel castings the details of the proposed welding method

II - Part 1 GL 2009


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are to be submitted to GL by means of WPS 1 for approval. The latter shall be amended with sketches or photographs showing the location of major defects which impair the mechanical strength.

For the purpose of these Rules, the term "major de-fect" includes any defects, the depth of which exceeds 25 % of the wall thickness or 2,5 cm, the area of which exceeds 1 250 cm2, and those which due to their amout and distribuition exceed an area of 2 % of the casting surface.

The characteristics of the weld shall be verified by welding procedure tests. These are to be performed on test pieces according to Chapter 5 – Materials for Propeller Fabrication, Annex B, using filler metals ap-proved by GL. Welding procedure tests and welder’s qualification tests respectively which have been per-formed by means of above mentioned test pieces re-main valid for 3 years and cover thicknesses up to 1,5 "t", with "t" being the thickness of the test piece.

In the case of minor repairs, the decision as to the execution of the repair shall rest with the Surveyor, and the method shall be agreed with him.

It is a basic principle that the welding of major defects may only be started after authorization has been granted and the castings have been presented to the Surveyor in the condition prepared for welding.

13.4.2 Companies wishing to carry out fabrication welds on castings shall have available the necessary workshops, lifting gear, welding appliances, preheat-ing and heat treatment facilities, testing instruments and equipment as well as qualified welders and com-petent welding supervisors so that the work can be properly executed. As a preliminary measure, compli-ance with these conditions shall be proved to GL and a description of the welding facilities and procedures shall be submitted.

13.4.3 The following conditions shall be complied with in carrying out welding work:

– Highly stressed parts and alloy steel castings shall be in the prescribed heat-treated condition for welding. This also applies to other castings on which major defects have to be repaired.

– Defects are to be gouged out in such a way as to provide good accessibility for welding. Having been prepared for welding, the sites concerned shall be subjected to non-destructive tests to es-tablish that the defective material has been com-pletely removed. The castings prepared for welding are to be submitted to the Surveyor.

– Steel castings shall be suitably preheated for welding. The level of preheating shall be deter-mined in each case by reference to the chemical composition, the carbon equivalent and the wall thickness, see B.4.1.4. Exceptions to this Rule

–––––––––––––– 1 WPS = Welding Procedure Specification

are austenitic grades of cast steel and, with the consent of the Surveyor, unalloyed grades of cast steel of small wall thickness which because of their composition (C ≤ 0,18 %) are consid-ered to be unsusceptible to cracking.

– All welding work is to be performed by quali-fied welders, whose work is supervised while in progress, in bays which are protected from draughts and the effects of the weather. Wher-ever feasible, welding shall be performed in the downhand position.

– The filler materials to be used shall produce a weld deposit with mechanical characteristics matching those of the casting. In the case of stainless grades of cast steel, the deposit shall ensure the sufficient chemical stability of the weld. Wherever possible the work shall be per-formed by manual arc welding using basic-coated electrodes with a controlled, low hydro-gen content.

– After welding, the castings shall be properly heat treated as follows:

– unalloyed steel castings: stress relief heat treatment in temperature range 580 – 620 °C, or renewed normalizing treatment

– quenched and tempered steel castings: re-newed tempering or quenching and temper-ing

– ferritic stainless steel and all grades of aus-tenitic steel castings: the heat treatment pre-scribed in the relevant standard or recog-nized material specification, as applicable.

– Attention shall be paid to the effect of the heat treatment on the mechanical properties of the weld metal.

– Following welding and heat treatment, the welds and their surrounding areas are to be ground smooth and inspected by the magnetic particle or dye penetrant method. Depending on the na-ture and size of the original defect, further non-destructive testing by ultrasonic or radiographic inspection may be required. For the evaluation of the indications 10.4.2 is applicable.

13.4.4 After repair and subsequent heat treatment, all castings shall be presented to the Surveyor for reinspection, and the tests for cracks and the ultrasonic tests shall be performed wholly or partly in the Sur-veyor's presence at his discretion. In the case of radio-graphic tests, the radiographs shall be submitted to the Surveyor for expert appraisal.

13.4.5 For large welds on highly stressed or alloy steel castings, the manufacturer shall hand the Sur-veyor a report containing full details of the repair, in-cluding the results of the non-destructive tests. In this report he shall also confirm that the weld has been made in accordance with an approved welding procedure.



A

B. Steel Castings for Machine Construction and Shipbuilding

1. Scope

These Rules are applicable to castings made of unal-loyed and alloyed grades of cast steel which are in-tended for the manufacture of components and struc-tural parts in machine construction and shipbuilding, e.g. diesel engine components (excluding crankshafts), gears, couplings, and also stem and stern posts, stern tubes, shaft struts, rudder bearings and anchors.

2. Suitable grades of cast steel

On condition that they meet the requirements specified in 4., the following grades of cast steel may be used:

2.1 General-purpose cast steels conforming to DIN 1681.

2.2 General-purpose cast steels with enhanced weldability and toughness conforming to DIN 17182.

2.3 Quenched and tempered cast steels conform-ing to DIN 17205.

2.4 High-tensile cast steel with good weldability conforming to "Stahl-Eisen-Werkstoffblatt" SEW 520.

2.5 Other grades of cast steel with minimum impact energy values conforming to other standards or material specifications, provided that they are equiva-lent to the grades described in 2.1 to 2.4 and their suitability has been confirmed by GL. An initial test of product suitability may be required for this purpose.


3.1 All castings shall be properly heat treated. Acceptable methods of heat treatment are:

– normalizing

– normalizing and tempering


3.2 Where castings are subject to special re-quirements with regard to their geometrical and di-mensional stability or to the absence of internal stresses, e.g. diesel engine bedplates, stem and stern post parts, additional stress-relieving heat treatment is required. For carbon and carbon-manganese steels, the heat treatment shall be performed at a temperature of at least 550 °C followed by cooling in the furnace to below 300 °C. For quenched and tempered steel cast-ings, the heat treatment temperatures shall be specially determined. The stress-relieving heat treatment may be dispensed with in the case of quenched and tem-pered steel castings where tempering is followed by a cooling rate of up to 15 °C/h.



4.1.1 Carbon and carbon-manganese steel castings including the grades of cast steel described in 2.1 and 2.5 are subject to the limits for the chemical composi-tion of the heat specified in Table 4.1.

Where necessary, the manufacturer may add grain refining elements, e. g. aluminium.

4.1.2 For grades of cast steel conforming to 2.2, 2.3 and 2.4, the limits for the chemical composition speci-fied in the standards are applicable.

4.1.3 For cast alloy steels conforming to 2.5, the limits for the chemical composition specified in the recognised standards or material specifications shall apply.

4.1.4 Where the weldability of the casting is sub-ject to special requirements, the carbon equivalent shall be calculated according to the following formula:

[ ]äqMn Cr Mo V Ni Cu

C C %6 5 15

+ + += + + +

Table 4.1 Limits for chemical composition [%]

Residual elements

Application C max.

Si max.

Mn

S max.

P max. Cu Cr Ni Mo

Sum of the max.

permissible residual elements

Castings for general shipbuilding and machinery application

0,40 1 0,60 0,50–1,60 0,040 0,040 0,30 0,30 0,40 0,15 0,80

Castings for welded structures for shipbuilding

0,23 0,60 1,60 max. 0,015 0,020 0,30 0,30 0,40 0,15 0,80

1 for welded structures for machinery application C ≤ 0,23 or Ceq ≤ 0,49

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4.2.1 For grades of cast steel conforming to 2.1 to 2.4, the requirements specified in the respective stan-dards shall apply, see Table 4.2 (grades of cast steel conforming to DIN 1681) and Table 4.3 (grades of cast steel conforming to DIN 17182).

4.2.2 Other grades of cast steel as per 2.5 shall have the characteristic properties of the respective grade ac-cording to the standard or the specification. In addition,

the minimum requirements specified in Table 4.4 are applicable to castings made of C and CMn cast steels.

4.2.3 The cast steels shown in Table 4.4 may be supplied with any minimum tensile strength within the limits specified in the table. The values graduated in steps of 40 N/mm2 do not represent the minimum tensile strengths of particular grades of cast steel but are intended to provide means of determining the required mechanical characteristics by interpolation in relation to specified minimum tensile strengths.

Table 4.2 Mechanical properties of cast steels conforming to DIN 1681

Impact energy 1 KV

[J] 2 min.

Grade of cast steel

Yield strength

ReH

[N/mm2] min.

Tensile strength

Rm

[N/mm2] min.

Elongation

A [%] min.

Reduction in area

Z [%] min. t ≤ 30 mm 3 t > 30 mm 3

GS–38 200 380 25 40 35 35

GS–45 230 450 22 31 27 27

GS–52 260 520 18 25 27 22

GS–60 300 600 15 21 27 20 1 testing temperature = room temperature For castings for welded structures in shipbuilding the requirements according to Table 4.3 do apply. 2 Average value of 3 tests 3 t = sample thickness

Table 4.3 Mechanical properties of cast steels in the style of DIN 17182

Grade of cast steel

Heat-treated

condition 1

Wall thickness [mm]

Yield strength 2

ReH

[N/mm2] min.

Tensile strength

Rm

[N/mm2]

Elongation

A [%] min.

Impact energy

KV [J] 3 min.

Transition temp.

TÜ [27 J] 5

≈

up to 50 260 430 – 600 25 65 –25 °C GS-16Mn5

(N) over 50 to 100 230 430 – 600 25 45 –15 °C

up to 50 300 500 – 650 22 55 –20 °C

over 50 to 100 260 500 – 650 22 40 –10 °C

over 100 to 160 (260) 4 480 – 630 20 35 0 °C

GS-20Mn5

(N)

over 160 (240) 4 450 – 600 20 27 RT

up to 50 360 500 – 650 24 70 –30 °C

over 50 to 100 300 500 – 650 24 50 –20 °C

over 100 to 160 (280) 4 500 – 650 22 40 –10 °C

GS-20Mn5

(Q+T)

over 160 (260) 4 480 – 630 22 30 RT

1 (N) = normalized; (Q+T) = quenched and tempered 2 If there is no marked yield strength, the 0,2 % proof stress applies. 3 Average value of 3 tests at room temperature (individual value at least 70 %). 4 The values in brackets are only an approximate indication of the minimum yield strength in the casting. 5 Requirements for welded structures for shipbuilding.



B

Table 4.4 Mechanical properties of cast steels conforming to B.2.5

Impact energy 3

Grades of steel

Minimum tensile strength 1, 2

Rm

[N/mm2]

Yield strength

ReH

[N/mm2] min.

Elongation

A

[%] min.

Reduction in area

Z

[%] min.

KV [J]

min.

KU [J]

min.

400 200 25 40 25 25

440 220 22 30 20 22

480 240 20 27 18 20

520 260 18 25 15 17

560 280 15 20 12 15

Ordinary quality C- and CMn cast steel

600 300 13 20 10 12

400 200 28 45 32 30

440 220 26 45 28 27

480 240 24 40 25 25

520 260 22 40 20 22

560 280 20 35 18 20

Special quality C and CMn cast steel

600 300 18 35 15 17

1 Where the minimum tensile strength of a steel grade falls between two of the graduated values, the requirements may be determined by interpolation.

2 The tensile strength determined by testing may not exceed the specified minimum tensile strength by more than 150 N/mm2 in case of the ordinary qualities and 120 N/mm2 in the case of the special qualities.

3 Average value of 3 tests (individual value not less than 70 %).

4.3 Impact energy

All grades of cast steel shall meet the energy impact values prescribed for the grade in question.

5. Testing

5.1 Tensile test

The mechanical properties shall be verified by tensile test. The test specimens shall be prepared in accor-dance with A.10.2.2.


Notched bar impact testing shall be performed on each test batch or, where applicable, each casting. The test specimens shall be prepared in accordance with A.10.2.2. The type of specimen is governed by the relevant standard or specification.


5.3.1 In case non-destructive tests are prescribed for castings they shall be performed in accordance with G. to J.

5.3.2 Where castings are welded together, the welds shall be subjected to magnetic particle and ul-trasonic or radiographic inspection. The extent of the inspection shall be as specified on the approval draw-ing or will be determined at the time of approval of the welding procedure.

5.4 Tightness test

Castings subjected to internal pressure, e.g. stern tubes, shall be subjected to a hydraulic pressure test. The test shall be performed with the casting in ma-chined condition. The test pressure is to be 1,5 times of the service pressure and for stern tubes uniformly 2 bars. The test pressure shall be kept for at least 10 Min.

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C. Steel Castings for Crankshafts and Con-necting Rods

1. Scope

These Rules are applicable to throws and webs of built crankshafts and connecting rods made of carbon, car-bon-manganese and low-alloy grades of cast steel.

2. Approved grades of cast steel

Only grades of cast steel which have been approved by GL as suitable for the intended application may be used. To this end, the engine manufacturer shall sub-mit to GL for approval specifications or drawings containing all the data required for evaluating the castings, e.g. method of manufacture, chemical com-position, heat treatment and mechanical properties.


3.1 With regard to the chemical composition, mechanical properties and required impact energy and hardness values, the data in the approved specifica-tions or drawings are applicable. However, the re-quirements specified in B.2.5 and, for special quality steel castings, Table 4.4 are to be satisfied as a mini-mum requirement.

3.2 The cast steel shall undergo vacuum degas-sing or another suitable treatment after melting, so that the properties mentioned in the specification may be achieved.

4. Method of manufacture and condition of heat treatment

4.1 The method of manufacture shall be ap-proved by GL. The details of the approval test are established by GL from case to case.

4.2 All castings shall be in a heat treated condi-tion appropriate to the grade of steel. The following processes are acceptable:

– normalizing

– normalizing and tempering


Where possible, heat treatment shall be carried out after preliminary machining. If this is not possible, additional stress-relieving heat treatment shall be performed after preliminary machining with the minimum possible cutting allowance.

4.3 Defects shall normally be removed by grind-ing, gouging and/or machining. Care shall be taken to ensure that the required minimum cross sections are preserved.

The removal of defects by welding requires the con-sent of GL as a matter of principle and may only be considered if the defects cannot be eliminated by the aforementioned measures.

5. Testing

5.1 Tensile test

The mechanical properties shall be verified by tensile test. For preparing the tensile specimens, test samples shall be cast integrally with the casting at a point stipulated in the specification. Each casting shall be tested individually.


Notched bar impact specimens shall be taken from every casting and tested. The location of the speci-mens shall be as described in 5.1. The specimen shape prescribed in the specification (Charpy V-notch or Charpy U-notch specimen) shall be used.


Crank shafts and connecting rods shall be subjected to non-destructive tests according to the requirements stipulated in G. to J.

By agreement between the foundry and the crankshaft or connecting rod manufacturer, the tests may be per-formed both at the foundry and at the manufacturer's works.

D. Steel Castings for Steam Boilers, Pressure Vessels and Pipelines

1. Scope

1.1 These Rules are applicable to castings made from unalloyed and alloyed grades of cast steel and used for the manufacture of valve and pump housings, endplates, flanges, nozzles and pipe fittings. Cast steels for use at low temperatures are subject to E.


The following grades of cast steel may be used:

2.1 Grades of cast steel for use at room tempera-ture and high temperatures conforming to EN 10213-2 "Technical Specifications relating to Cast Steel for Pressure Vessels", Part 2.

The chemical composition of the commonly used grades of cast steel is given in Table 4.5 and the me-chanical properties are stated in Table 4.6.

2.2 Ferritic grades of cast steel GS–38 and GS–45 conforming to DIN 1681 up to a wall temperature of 300 °C.

2.3 Heat resistant ferritic, ferritic-austenitic and austenitic grades of cast steel as well as Nickel and cobalt based alloys conforming to EN 10295.



D

Table 4.5 Chemical composition (%) of the commonly used grades of cast steel conforming to EN 10213-2

Grade of cast steel C

Si max. Mn

P max.

S max. Cr Mo

GP240GH 0,18 – 0,23 0,60 0,50 – 1,20 0,030 0,020 1 –– ––

GP280GH 0,18 – 0,25 2 0,60 0,80 – 1,20 2 0,030 0,020 1 –– ––

G20Mo5 0,15 – 0,23 0,60 0,50 – 1,00 0,025 0,020 1 –– 0,40 – 0,60

G17CrMo5-5 0,15 – 0,20 0,60 0,50 – 1,00 0,020 0,020 1 1,00 – 1,50 0,45 – 0,65

G17CrMo9-10 0,13 – 0,20 0,60 0,50 – 0,90 0,020 0,020 1 2,00 – 2,50 0,90 – 1,20

1 In the case of castings having a standard wall thickness of < 28 mm, 0,030 % is permissible.

2 For each 0,01 % reduction in the specified maximum carbon content, a 0,04 % increase of Manganese above the specified maximum content is permissible up to a maximum of 1,40 %.

Table 4.6 Mechanical properties of the commonly used grades of cast steel conforming to EN 10213-2

Tensile test Notched bar impact test

Grade of cast steel

Heat treatment symbol 1

Thickness [mm] max.

Rp0,2 [N/mm2]

min.

Rm [N/mm2]

A [%] min.

KV 2 [J]

min.

N 27 GP240GH

QT 100 240 420 – 600 22

40

N 27 GP280GH

QT 100 280 480 – 640 22

35

G20Mo5 QT 100 245 440 – 590 22 27

G17CrMo5-5 QT 100 315 490 – 690 20 27

G17CrMo9-10 QT 100 400 590 – 740 18 40

1 N = denotes normalising

QT = denotes quenching and tempering

2 Testing temperature = room temperature (individual value not less than 70 %)

2.4 Other grades of cast steel conforming to other standards or material specifications, provided that they are comparable with the grades of cast steel stated in paragraphs 2.1 to 2.3 and proof has been furnished of their suitability for the intended application. An initial test of product suitability may be required for this pur-pose.

2.4.1 In addition, ferritic grades of cast steel shall satisfy the following minimum requirements:

– The elongation A shall have the characteristic minimum elongation values of the steel grade as specified by GL, but shall be not less than 15 %.

– The impact energy shall be at least 27 J at room temperature in tests performed with Charpy V-notch specimens. Ductile fracture behaviour is a fundamental requirement.

– Where necessary, the yield strength at elevated temperature and the long-time rupture stress properties at elevated temperature shall be veri-fied by the manufacturer, specifying the guide values for the chemical composition.

Proof of weldability shall be furnished by the manu-facturer.

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All steel castings shall be supplied in a heat-treated condition appropriate to the grade of cast steel.

4. External and internal condition

The requirements pertaining to the external and inter-nal condition are specified in TRD 103. For this pur-pose, the cast steel shall be classed into quality levels according to the intended working temperature and pressure, see the Technical Rules for Steam Boilers TRD 103 and "AD-Merkblatt" W5 (AD Data Sheet W5).



With regard to the chemical composition, mechanical and technological properties, required impact energy values and hardness of the grades of cast steel, the data contained in the standards mentioned in 2.1 and 2.2 or in the approved specifications shall be applica-ble.

5.2 Weldability

Grades of cast steel conforming to these Rules shall be weldable by established workshop methods. Preheat-ing and/or post-weld heat treatments may be required for this purpose, depending on the chemical composi-tion.

6. Testing

The castings shall be presented for testing in finished condition (condition of supply) and shall undergo the following tests.

6.1 Tensile test

The mechanical properties shall be verified by tensile test. The tests shall be performed on a heat-by-heat basis, parts undergoing the same heat treatment being grouped into test batches in accordance with A.10.2.2. A tensile specimen shall be taken from each test batch and tested. Castings with unit weights > 1000 kg shall be tested individually.


The castings shall be subjected to the notched bar impact test. The number of sets of specimens (3 Charpy V-notch specimens per set) shall be deter-mined in the same way as the number of tensile specimens.

6.3 Hardness test

All quenched and tempered steel castings which are tested on a heat-by-heat basis shall be subjected to a

comparative hardness test. The result of the hardness test shall show that quenching and tempering has been carried out homogeneously (the difference in hardness between the hardest and the softest tested component in the test batch shall not exceed 30 HB).


The manufacturer shall ensure by non-destructive tests on his products that the requirements pertaining to the external and internal condition according to 4. are met. Unless otherwise agreed, the scope of testing shall conform to TRD 103 or AD data sheet W5, whichever is appropriate. Valves and fittings are subject to TRD 110. In addition the Rules as stated in Chapter 1 –Principles and Test Procedures, Section 3 shall be observed.

E. Steel Castings for Use at Low Tempera-tures

1. Scope

These rules are applicable to steel castings which are to be used for cargo and processing equipment on gas tankers at design temperatures below 0 °C, e.g. flanges, valve parts, weld-on and socket-welding pieces.

2. Approved grades of cast steel

The grades of cast steel stated in Table 4.7 may be used within the limits for the minimum design tem-peratures, provided that they satisfy the requirements of 5.

2.1 Grades of cast steel for use at low tempera-tures conforming to EN 10213-3 "Technical Specifica-tions relating to Cast Steel for Pressure Vessels" Part 3. The chemical composition of commonly used grades of cast steel is shown in Table 4.8 and the me-chanical properties are stated in Table 4.9.

2.2 Other grades of cast steel

Other grades of cast steel conforming to other stan-dards or material specifications, provided that they are comparable to the grades of cast steel described in 2.1, that they meet the requirements of 3. to 5. and that proof has been furnished of their suitability for the intended application. An initial test of product suit-ability may be required for this purpose.


All steel castings shall be supplied in a heat-treated condition appropriate to the grade of cast steel, see Table 4.9.



E

Table 4.7 Approved grades of cast steels for use at low temperatures

Grades of cast steel Permitted minimum design temperature

Designation or material No. Standard

–20 °C 1 G17Mn5 EN 10213-3 Weldable cast carbon-manganese steel –40 °C 1 G20Mn5 EN 10213-3

1,5 % cast nickel steel –40 °C 1 GS-10Ni6 SEW 685

2,25 % cast nickel steel –65 °C G9Ni10 EN 10213-3

3,5 % cast nickel steel –90 °C G9Ni14 EN 10213-3

1.4308 2 EN 10213-4

1.4408 EN 10213-4 Austenitic grades of

cast steel –165 °C

1.4581 3 EN 10213-4

1 A minimum design temperature down to – 55 °C is possible if this is verified by an approval test. 2 In addition EN 10283 does apply. 3 Unsuitable for carriage of ammonia.

Table 4.8 Chemical composition [%] of the commonly used grades of cast steel conforming to EN 10213-3

Grades of cast steel C

Si max. Mn

P max.

S max. Ni

G17Mn5 0,15 – 0,20 0,60 1,00 – 1,60 0,020 0,020 1 ––

G20Mn5 0,17 – 0,23 0,60 1,00 – 1,60 0,020 0,020 1 max. 0,80

G9Ni10 0,06 – 0,12 0,60 0,50 – 0,80 0,020 0,015 2,00 – 3,00

G9Ni14 0,06 – 0,12 0,60 0,50 – 0,80 0,020 0,015 3,00 – 4,00

1 For castings having a standard wall thickness of < 28 mm, 0,030 % S is permissible.

Table 4.9 Mechanical properties of the commonly used grades of cast steel conforming to EN 10213-3

Tensile test at room temperature Notched bar impact test 2

Grade of cast steel

Heat treatment symbol 1

Thickness [mm] max.

Rp0,2 [N/mm2]

min.

Rm [N/mm2]

A [%] min.

KV [J]

min.

Test temp. [°C]

G17Mn5 QT 50 240 450 – 600 24 27 – 40

N 30 480 – 620 20 – 30 G20Mn5

QT 100 300

500 – 650 22 27

– 40

G9Ni10 QT 35 280 480 – 630 24 34 – 70

G9Ni14 QT 35 360 500 – 650 20 34 – 95

1 N = denotes normalizing, QT = denotes quenching and tempering 2 Required impact energy value shown in Table 3.11 shall be complied with!

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The external and internal condition shall be subject to quality levels in accordance with Table 4.10 depend-ing on the minimum design temperature.

If the evaluation is carried out according to other stan-dards, the requirements shall be equivalent to those specified in Table 4.10.

If castings are required to undergo final inspection in accordance with the AD data sheets, proof of the qual-ity levels and scopes of testing is to be furnished in accordance with these Rules.

Table 4.10 Assignment of quality levels

Minimum design temperature

t

Quality level according to:

1, 2, 3, 4

≥ –105 °C SM4, LM4, AM4 1,

SP4, CP3, LP4, AP4 2, UV4 3, RV4 4

< –105 °C SM3, LM3, AM3 1,

SP3, CP3, LP3, AP3 2, UV3 3, RV3 4

Welding edges 5 SM011 CP01 2

1 EN 1369 2 EN 1371-1 3 EN 12680-2 4 EN 12681 and former DIN 1690-2 5 For surface crack detection linear indications are not

allowed.



The chemical composition and the mechanical proper-ties are subject to the requirements specified in the standards or the approved specifications (see Tables 4.8 and 4.9).

5.2 Weldability

Grades of cast steel conforming to these rules shall be weldable by established workshop methods.

5.3 Impact energy at low temperatures

The required impact energy values specified in Table 4.11 for the relevant grades of cast steel shall be met at the test temperatures stated in the table, using Charpy V-notch specimens.

6. Testing

The castings shall be presented for testing in finished condition (condition of supply) and shall undergo the following tests.

Table 4.11 Required impact energy values at low temperatures

Notched bar impact test

Grade of cast steel Test temp. [°C]

Impact energy

KV [J] 1 min.

Weldable cast carbon manganese steel

27 (19)

1,5 % cast nickel steel

5 K below minimum

design temp.,

not exceeding

–20 °C 34 (24)

2,25 % cast nickel steel –70 °C 34 (24)

3,5 % cast nickel steel –95 °C 34 (24)

Austenitic grades of cast steel 2

–196 °C 41 (27) 3

1 Average value for 3 specimens. Figures in parentheses indicate lowest individual value.

2 For design temperatures of – 105 °C and above, verification of the impact energy may be dispensed with.

3 Some austenitic grades of cast steel are subject to higher required impact energy values, see Table 4.13, Part F.

6.1 Tensile test

The mechanical properties shall be verified by tensile test. The tests shall be performed on a heat-by-heat basis, parts undergoing the same heat treatment being grouped into test batches in accordance with A.10.2.2. A tensile specimen shall be taken from each test batch and tested. Castings with unit weights > 1 000 kg shall be tested individually.


The castings shall be subjected to the notched bar impact test in compliance with the prescribed test temperature according to Table 4.11. The number of sets of test specimens (3 Charpy V-notch specimens per set) shall be determined in the same way as the number of tensile specimens.

The test may be dispensed with in the case of austenitic

steel castings with design temperatures of ≥ 105°C.

6.3 Hardness test

All quenched and tempered steel castings which are tested on a heat-by-heat basis shall be subjected to a comparative hardness test. The result of the hardness test shall show that quenching and tempering has been carried out homogeneously (the difference in hardness between the hardest and the softest tested component in the test batch shall not exceed 30 HB).



E


The manufacturer shall ensure by non-destructive tests on his products that the requirements pertaining to the external and internal condition according to 4. are met. Unless otherwise agreed, the scope of testing shall conform to AD data sheet W5; valves and fittings are subject to AD data sheet AD-W10. In addition the Rules as stated in Chapter 1 – Principles and Test Procedures, Section 3 shall be observed.

F. Stainless Steel Castings

1. Scope

These Rules are applicable to steel castings made from austenitic and austenitic-ferritic grades of steel which are intended for use in cargo and processing equip-ment for chemical tankers and other equipment for which chemical stability in relation to the cargo or the operating fluid is required. These Rules also apply to sleeves and bushes for propeller shafts and rudder stocks.

The Rules are also applicable in conjunction with E. for austenitic grades of cast steel which are designed for use in cargo and processing systems for gas tank-ers.


The following grades of casting may be used, pro-vided that they satisfy the requirements stated in 6.

2.1 Austenitic and austenitic-ferritic grades of steel conforming to EN 10213-4, "Technical Specifi-cations relating to Cast Steel for use in pressure Ves-sels" as well as the grades indicated in EN 10283, Corrosion resistant steel castings. The chemical com-position of these grades of cast steel is shown in Table 4.12 and the mechanical properties are given in Table 4.13.

2.2 Other stainless steels conforming to other standards or specifications after their suitability has been established by GL. An initial test of product suitability on the manufacturer's premises may be required for this purpose.

3. Selection of grades of cast steel

As regards their chemical resistance, the grades of steel shall be selected in accordance with the opera-tor's list of substances, which provides information on the nature of the substances to be transported or stored.

3.1 Where austenitic grades of cast steel are in-tended for cargo and process equipment for gas tank-ers, the requirements applicable to castings as stated in E., "Steel castings for use at low temperatures" shall apply.


All steel castings shall be supplied in a heat-treated condition appropriate to the grade of cast steel, i.e. the grades specified in Table 4.13 shall be solution-annealed and quenched in water.


Requirements to the external and internal condition shall be agreed on by the orderer and the manufac-turer. Requirements to welding edges and special rim zones shall be agreed on separately. In case no agree-ments were made G.3. does apply.



6.1.1 The limits stated in Table 4.12 and/or the specifications approved by GL are applicable.

6.1.2 For steel castings for the cargo and process-ing equipment of chemical tankers, the composition shall be selected so as to ensure the chemical stability required for the particular application, having regard to the intended heat-treated condition of the material. Furthermore, where steel castings are to be used for welded structures, the composition shall be selected so as to ensure that the material is suitable for the pro-posed welding process and that it remains chemically stable after welding and any post-weld heat treatments which may be applied. In the case of austenitic and austenitic-ferritic grades of cast steel, 6.2 shall be complied with. The manufacturer shall prove the weldability of the material if requested to do so.

6.1.3 If compliance with a minimum value for the aggregate effective chromium value W is required for a particular application, this is calculated as follows:

[ ] [ ] [ ]W % % Cr 3,3 % Mo= + ⋅

Note

This formula is applicable for austenitic cast steel which has a molybdenum content of < 3 %.


Austenitic grades of cast steel shall be resistant to intercrystalline corrosion in the condition in which they are supplied. If it is intended to weld castings without post-weld heat treatment, only grades of cast steel that are corrosion-resistant in this condition as well shall be used, e.g. cast steels stabilized with Nb or containing not more than 0,03 % C.

6.3 Mechanical properties and impact energy

The requirements specified in Table 4.13 or in the approved specifications are applicable.

II - Part 1 GL 2009


F

Table 4.12 Chemical composition [%] of suitable grades of cast steel in dependence on EN 10213-4 and EN 10283

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Table 4.13 Mechanical properties of suitable grades of cast steel

Tensile test at room temperature

Notched bar impact

test Thick-ness

[mm] Rp1,0 4

[N/mm2]

A [%]

KV 6 [J]

Designation Material No. Heat treatment

+ AT 1 [°C]

max. min.

Rm

[N/mm2] min. min.

GX2CrNi19-11 1.4309 1050 – 1150 150 210 440 – 640 30 80

GX5CrNi19-10 1.4308 1050 – 1150 150 200 440 – 640 30 60

GX5CrNiNb19-11 1.4552 1050 – 1150 150 200 440 – 640 25 40

GX2CrNiMo19-11-2 1.4409 1080 – 1150 150 220 440 – 440 30 80

GX5CrNiMo19-11-2 1.4408 1080 – 1150 150 210 440 – 640 30 60

GX5CrNiMoNb19-11-2 1.4581 1080 – 1150 150 210 440 – 640 25 40

GX2NiCrMo28-20-2 1.4458 1100 – 1180 150 190 430 – 630 30 60

GX2CrNiMoN22-5-3 1.4470 1120 – 1150 2, 3 150 420 5 600 – 800 20 30

GX2CrNiMoCuN25-6-3-3 1.4517 1120 – 1150 2, 3 150 480 5 650 – 850 22 50

GX2CrNiMoN26-7-4 1.4469 1140 – 1180 2, 3 150 480 5 650 – 850 22 50

1 The heat treatment applicable to all grades of steel is + AT + QW (solution annealing + quenching in water). 2 Following solution annealing at high temperature, the castings may be cooled to between 1 040 °C and 1 010 °C before quenching

in water to improve corrosion resistance and prevent cracks in the event of complex shapes. 3 In the case of cast steel intended for pressure vessels, the precipitation-hardened condition is not applicable to austenitic-ferritic steels. 4 Rp0,2 may be estimated by reducing the Rp1,0 value by 25 N/mm2.

5 Rp0,2

6 Test temperature = room temperature RT (individual value not less than 70 %)

7. Testing

The castings shall be presented for testing in finished condition (condition of supply) and shall undergo the following tests:

7.1 Tensile test

The mechanical properties shall be verified by tensile test. The tests shall be performed on a heat-by-heat basis, parts undergoing the same heat treatment being grouped into test batches in accordance with A.10.2.2. A tensile specimen shall be taken from each test batch and tested. Castings with unit weights > 1000 kg shall be tested individually.


The castings shall be subjected to the notched bar impact test. The number of sets of test specimens (3 Charpy V-notch specimens per set) shall be deter-mined in the same way as the number of tensile specimens.

7.3 Test of resistance to intercrystalline corrosion

Austenitic and austenitic-ferritic steel castings shall be tested per heat and heat treatment batch for their resis-tance to intercrystalline corrosion in accordance with ISO 3651-1 or -2. Austenitic-ferritic grades of cast steel shall be tested in accordance with Iron and Steel Test Specification SEP 1877, Method I, or an equiva-lent method. The test shall be confirmed by the manu-facturer by means of a certificate.


The manufacturer shall ensure by non-destructive tests on his products that the requirements pertaining to the external and internal condition according to 5. are met. Unless otherwise agreed, the scope of testing shall conform to AD Data Sheet W5. Valves and fittings are subject to TRD 110. In addition the Rules as stated in Chapter 1 – Principles and Test Procedures, Section 3 shall be observed.

II - Part 1 GL 2009


F

G. Non-destructive Testing of Cast Steel Components


1.1 These Rules apply to the non-destructive testing of cast steel components for which in B. to F. and H. appropriate requirements are prescribed, and for which no other regulations or manufacturer speci-fications are agreed upon.

1.2 A list containing the cast steel components for which non-destructive testing is required and the specific tests to be performed is contained in H. For propellers made of stainless cast steel the specifica-tions in Chapter 5 – Materials for Propeller Fabrica-tion, Section 2 do apply.

1.3 The general requirements for inspection bod-ies, inspection personnel, testing methods and certifi-cation of the results are prescribed in Chapter 1 – Principles and Test Procedures, Section 3 and are mandatory for all tests.

1.4 These Rules apply for the following testing methods defined according to EN 473, see Table 4.14:

1.5 Methods and testing, criteria indicated in G. are to be employed by the foundries, companies per-forming the further processing and the GL Surveyors.

1.6 For testing, the cast steel components shall be classified in inspection zones with different require-ments for the severity levels.

For classifying one or several of the following princi-ples is/are decisive:

– the operating loads to be expected

– the effects of the defects on the reliability of the component

– possible risk of damage if the component fails

– required welding security for the welding edges

– freedom of defects and surface condition after machining


Testing of 1 Symbol

Visual testing VT

Magnetic particle testing MT


Ultrasonic testing UT

Radiography testing RT

1 For testing of stainless austenitic cast steel only the methods VT, PT and RT are applicable.

For the most important cast steel components of the hull structure and of the propulsion plant the inspec-tion zones are prescribed in I. and J.

2. Performing the tests

2.1 After the inspector of the internal or external inspection body in charge of testing has performed the prescribed tests, the cast steel components shall be presented to the GL-Surveyor for visual testing.

2.2 Concerning the tests it shall be differentiated between pre-testing and acceptance testing. With pretests, where decisions concerning the testability and the employability of the cast steel component are made, they are in general the business of the foundry.

Acceptance tests shall be performed preferably on the final machined cast steel component after the heat treatment appropriate for the required properties has been performed. The Surveyor shall be informed in time about the intended tests. It is up to the discretion of the Surveyor to attend the tests.

2.3 The tests shall be performed for the zones described in the specification or in the test plan. In case the results indicate that further defects are present in the cast steel component, the test scope shall be extended according to agreement with the Surveyor.

2.4 The cast steel components for which testing is prescribed are listed in H. Concerning the test scope and the severity level requirements for specific hull structural parts and for machinery parts test instruc-tions are prescribed in I. and J. which shall be ob-served in addition to the manufacturer specifications.

3. Classifying in severity levels

3.1 The classifying in severity levels for the inner and outer condition is performed in accordance with the criterias indicated in the tables for the specific test meth-ods. Table 4.15 sums up the various severity levels.

3.2 The selection of severity levels shall be agreed upon in accordance with EN 1559-1 and EN 1559-2 within the order.

As a rule this is business of the orderer, in doing so the inspection zones shall be specified in accordance with 1.6 and the following requirements shall be observed:

3.2.1 Special rim zones such as welding edges shall be classified in the severity levels SM1, LM1, AM1, SP1, CP1, LP1, AP1, UV1 and RV1 over their entire length and over a width of 3 × wall thickness, but at least of 50 mm.

For welding edges with thickness larger than 50 mm the severity levels SM2, LM2, AM2, SP2, CP2, LP2, AP2, UV2 and RV2 are sufficient.

For valve casings DIN 1690 part 10 does apply.



G

Table 4.15 Overview of the severity levels

Testing of Test

method Description of severity levels 1

VT V1, V2, V3, V4

MT SM1, SM2, SM3, SM4 LM1, LM2, LM3, LM4 AM1, AM2, AM3, AM4 Outer

condition

PT

SP1, SP2, SP3, SP4, CP1, CP2, CP3 LP1, LP2, LP3, LP4 AP1, AP2, AP3, AP4

UT UV1, UV2, UV3, UV4 Inner

condition RT RV1, RV2, RV3, RV4

1 according to EN 12454, EN 1369, EN 1371-1, EN 12680-2, EN 12681 and DIN 1690-2

3.2.2 For fabrication weldings as a basic principle the same requirements as for the base material do apply.

3.2.3 For zones of steel castings for machinery parts, for valve casings as well as for dynamically loaded hull structural parts where no higher require-ments are prescribed at least the severity levels SM3, LM3 and AM3 are to be met.

3.2.4 Apart from the specifications in 3.2.1 to 3.2.3, and if in the purchasing documents no higher classifying is required, for not specified zones at least severity level V2 does apply.

3.2.5 For the inner and outer condition of cast steel components equivalent severity levels as well as dif-ferent severity levels may be determined.

3.3 Before testing is commenced the position and dimension of the zones to be tested and the severity levels to be met shall be specified in test plans, draw-ings or specifications taking into account 1.6, 3.1 and 3.2. These documents are shall be provided to GL.

4. Special agreements for the surface rough-ness

For the surface roughness limit values such as e.g. comparators 2 may be agreed upon if requested by the orderer or necessary due to technical reasons. Re-

–––––––––––––– 2 Reference to standards:

– "Technische Empfehlung (technical recommendation) 359-1

des Bureau de Normalisation de l' Industrie de la Fonderie"

– "SCRATA comparators for the definition of surface quality of steel castings"; Steel castings Technology International; 7, East Bank road, Sheffield, S2 3PL United Kingdom

quirements for the surface condition of surfaces of cast steel components depending on the smallest indi-cation to be registered are listed in Tables 4.16 and 4.17 for the magnetic particle testing and for the pene-trant testing. Concerning the surface roughness for non-destructive testings then the following applies:

– Cast steel components where requirements for the surface roughness were specified are to be tested visually in accordance with 5.

– Cast steel components which are subjected to radiographic, magnetic particle or ultrasonic testing shall comply at least with the compara-tors 3 S1 or 4 S2.

– Cast steel components which are subjected to penetrant testing shall comply at least with the comparators 3 S2.

Table 4.16 Recommended surface condition for magnetic particle testing

Surface comparators 1 Dimension

of the smallest

indication [mm] BNIF 2 SCRATA 2

1,5 1 S1 – 2 S1 3 S2 – 4 S2

––

2 2 S1 – 3 S1 4 S2 – 5 S2

A 2 H 2

≥ 3 not specified

(rough surface) A 3 – A 4

H 3

1 see EN 1370. 2 see Annex A of EN 1369.

Table 4.17 Recommended surface condition for penetration testing

Surface comparators 1 Dimension

of the smallest

indication [mm] BNIF 2 SCRATA 2

1,5 1 S1 – 2 S1 3 S2 – 4 S2

A 1 H 1

2 2 S1 – 3 S1 4 S2 – 5 S2

A 2 H 2

≥ 3 not specified

(rough surface) A 3 – A 4

H 3

1 see EN 1370. 2 see Annex A of EN 1371-1.

II - Part 1 GL 2009


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5. Visual testing (VT)

5.1 The manufacturer shall verify for each pro-duction stage of the cast steel components the external condition and the compliance of the dimensions. Mi-nor casting defects such as small sand and slag inclu-sions, small cold shuts and small hot tears are to be cleaned out in case they may affect the testability.

5.2 Discontinuities which may affect the employ-ability and the processability appropriate for the mate-rial more than irrelevant, such as larger non-metallic inclusions, cavities, gas holes or cracks, are not al-lowed and shall be repaired.

5.3 After special agreement with GL or if speci-fied in the order the evaluation of the surface condition may be performed by means of comparators in accor-dance with Table 4.18 (cf. EN 12454 "Visual examina-tion of surface discontinuities – Steel sand castings").

5.4 The Surveyor certifies the visual inspection on the GL acceptance test certificate. E.g. the follow-ing text can be typed in the test certificate:

“The aforementioned cast steel components were visually tested.

The prescribed requirements are fulfilled.”

5.5 On demand of the orderer the manufacturer shall issue a test report containing the details of the tests, the prescribed severity levels and the test results.

6. Magnetic particle testing (MT)

6.1 The surfaces of the cast steel component to be tested shall be free of oil, grease, and remnants of

the moulding material and the blackening, as well as scale, dust and other contaminations.

The required surface condition may be achieved by shot-blasting, grinding or machining. A specific sur-face roughness that shall be complied with may be agreed upon (cf. 4.).

6.2 The magnetic particle testing is to be per-formed in accordance with Chapter 1 – Principles and Test Procedures, Section 3, I. In case black magnetic particles are employed the surface to be tested shall be coated with a permanent white paint, applied as thinly as possible (max. 20 μm). A decrease of the test sensi-bility shall be observed.

6.3 In order to avoid burn marks on the surface of cast steel components in quenched and tempered con-dition when magnetization is performed by means of prods with alternating current only fusible supply electrodes made of tin-aluminium alloys shall be em-ployed.

Contact points visible on the surface are to be ground if necessary and to be retested by yoke magnetization.

On already machined surfaces of the cast steel com-ponent testing is only allowed with yoke magnetiza-tion.

6.4 The indications of magnetic particle testing shall be evaluated concerning their type, size and number in accordance with Tables 4.19, 4.20 and 4.21. The reference area for this shall be a rectangle with 105 mm × 148 mm (size DIN A6) and shall be placed on the specific most unfavourable area for each case (area with the highest number of indications). In addi-tion for the evaluation the reference figures according to EN 1369 are to be consulted.

Table 4.18 Allocation of severity levels to the selected comparators 1 for the surface condition

Severity Levels

V 1 V 2 V 3 V 4 Category

Designation according to the "Technischen Empfehlung 359-1" 2

Inclusions close to the surface B 1 B 2 B 4 B 5

Gas porosity C 1 C 2 C 3 C 4

Cold shuts D 1 D 2 D 5 ––

Hot tears E 3 E 5 –– ––

Inserts F 1 F 3 –– ––

Welds J 1 J 2 J 3 J 5

1 The required severity level can be different for each category. 2 See references to standards in 4.



G

Table 4.19 Nature of discontinuities and the corresponding indications for magnetic particle testing

Types of magnetic particle inspection indications

Nature of discontinuities Symbol non-linear

SM

non-linear

LM

aligned

AM

Gas porosity A X –– X

Sand and slag inclusions B X –– X

Cracks D –– X X

Chill chracks E –– X X

Inserts F –– X X

Cold shuts H –– X X

Table 4.20 Severity levels for magnetic particle testing - non-linear indications isolated (SM)

Severity level Characteristic

SM 1 SM 2 SM 3 SM 4

Inspection means eye

Magnification for observation of magnetic particle indication. 1

Length L1 of the smallest indication to be considered [mm]. 1,5 2 3 5

maximum total surface area allowed [mm2] 10 35 70 200 Non-linear indications (SM) maximum individual length L2 allowed [mm] 2 1 4 1 6 1 10 1

1 At maximum 2 indications of the designated maximum dimension are permitted.

Note

Only values expressed in this table are valid. The reference figures according to EN 1369 Annex B and C are for information only.

6.5 Definition of indications of magnetic parti-cle testing

6.5.1 Non-linear indications (SM)

Indications are to be assessed as non-linear if the length L is smaller than 3 times the width W.

The symbol for non-linear indications is SM (S for surface and M for magnetic particle).

6.5.2 Linear indications (LM)

Indications are to be assessed as linear if L is equal or larger than 3 times W.

The symbol for linear indications is LM (L for linear and M for magnetic particle).

6.5.3 Aligned indications (AM)

In the following cases the indications are assessed as aligned:

– non-linear: the distance between the indications is less than 2 mm and at least 3 indications are registered.

– linear: the distance between 2 indications is smaller than the length L of the longest discon-tinuity in a line.

Aligned indications are assessed as one single indica-tion. Its length equals the total length L of this line, see Fig. 4.1.

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II - Part 1 GL 2009


G

Table 4.21 Severity levels for magnetic particle testing - linear (LM) and aligned (AM) indications

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The total length L equals the distance between the start of the first indication and the end of the last indication.

Example: + +1 2 3 4 5L = + +

6.6 Defects which concerning their size and number exceed the requirements for the prescribed severity levels as well as cracks are not allowed and shall be removed. Repaired zones shall be retested.

7. Penetrant testing (PT)

7.1 Testing is to be performed with an inspection system consisting of penetrant remover, penetrant and developer in accordance with Chapter 1 – Principles and Test Procedures, Section 3, J.

7.2 The surface of the cast steel component to be tested shall correspond to the requirements for the surface condition specified in 6.1 and 4.

7.3 The indications shall be evaluated concerning their type, size and number in accordance with Tables 4.22, 4.23 and 4.24. The reference area for this shall be a rectangle with 105 mm × 148 mm (size DIN A6) and shall be placed on the specific most unfavourable area for each case (area with the highest number of indications). In addition for the evaluation the refer-ence figures according to EN 1371-1 part 2, or another recognized standard, may be consulted.

7.4 Definition of indications of penetrant testing

7.4.1 Linear indication (LP)

Indication where the largest dimension equals at least 3 times the smallest dimension (i.e. L ≥ 3 W).



G

Table 4.22 Nature of discontinuities and type of corresponding indications for penetrant testing

Type of corresponding indications for penetrant testing

non-linear Nature of discontinuities Symbol

isolated SP

clustered CP

linear

LP

aligned

AP

Gas porosity A X X –– X

Sand and slag inclusions B X X –– X

Cracks D –– –– X X

Chill cracks E –– –– X X

Inserts F X –– X X

Cold Shuts H –– –– X X

Table 4.23 Severity levels for penetrant testing - non-linear indications 1, isolated (SP) or clustered (CP)

Severity Levels

Characteristic SP1 CP1

SP2 CP2

SP3 CP3

SP4

Inspection means eye

Magnification for observation of penetrant indication 1

Diameter of the smallest indication to be considered [mm] 1,5 2 3 5

Maximum number of non-linear indications allowed 8 8 12 20

Maximum size of discontinuity indication A, B and F [mm]

– isolated indications SP 3 6 9 14

– clustered indications CP 10 16 25 ––

1 Such that L ≤ 3 W where L is the length and W is the width of the indication.

Note

Only values expressed in this table are valid. The reference figures according to EN 1371-1 Annex B and C are for information only.

7.4.2 Non-linear indication

Indication where the largest dimension is smaller than 3 times the smallest dimension (i.e. L < 3 W).

– isolated (SP)

– cumulative (CP): area with many indications, the distance between the indications can not be measured (seemingly they form only one single indication)

7.4.3 Aligned indications (AP)

– linear: the distance between 2 indications is smaller than the length of the largest defect in the line; or

– non-linear: the distance between 2 indications is less than 2 mm and at least 3 indications are reg-istered.

7.5 Defects which concerning their size and number exceed the requirements for the prescribed severity levels as well as discontinuities in the mate-rial (cracks) are not allowed and shall be removed.

Repaired zones shall be retested. For this the same inspection system as before shall be employed.

8. Ultrasonic testing (UT)

8.1 Ultrasonic testing is preferably performed for cast steel components with larger wall thickness and for examination of fabrication weldings as well as in addition to radiographic testing for determining the position in thickness and the dimension of defects, and shall be performed in accordance with Chapter 1 – Principles and Test Procedures, Section 3, K.

II - Part 1 GL 2009


G

Table 4.24 Severity Levels for penetrant testing - linear (LP) and aligned (AP) indications 1

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8.2 All cast steel components shall be presented for testing in heat treated condition. As a rule ultra-sonic testing may not be considered for austenitic and austenitic-ferritic cast steel grades.

8.3 In the areas to be tested an appropriate condi-tion of the surface of the cast steel component shall be achieved which enables a faultless coupling of the probe. For this the surface shall be clear of remnants of the moulding material and the blackening, scale, dust and other contaminations which may affect the coupling.

A specific surface roughness that shall be complied with according to 4. may be agreed upon.

8.4 Ferritic cast steel components shall only then be subjected to ultrasonic testing if disc shaped reflec-tors of 3 mm, 4 mm and 6 mm diameter can be veri-

fied definitely for the specific wall thickness regime, cf. Table 4.25. The echo height of these smallest disc shaped reflectors to be verified shall be at least 6 dB higher than the spurious echo at the end of the thick-ness regime to be evaluated. The fulfilment of the aforementioned conditions shall be proven to the GL-Surveyor within the testing.

8.5 If possible zones to be tested shall be tested from both sides. In case only one side is accessible near resolving probes, SE probes, shall be used in order to detect inhomogeneities close to the surface. Testing with SE probes is convenient only for thick-nesses up to 50 mm.

8.6 If not otherwise agreed on by the purchaser and the manufacturer for all cast steel components in addition the following zones shall be tested with SE- straight beam and/or angle probes up to 50 mm depth:



G

Table 4.25 Ultrasonic testability requirements according to EN 12680-1

Wall thickness

[mm] Smallest flat-bottom hole diameter detectable

[mm]

≤ 300 3

> 300 to ≤ 400 4

> 400 to ≤ 600 6

Table 4.26 Registration levels for ultrasonic testing of ferritic steel castings in accordance with EN 12680-1

Wall thickness

[mm]

Inspected area

Reflectors without measurable dimension

diameter of the equivalent

flat-bottomed hole 1

min. [mm]

Reflectors with measurable dimension

diameter of the equivalent

flat-bottomed hole 1 min. [mm]

Attenuation of back wall echo

min. [mm]

≤ 300 – 4 3

> 300 to ≤ 400 – 6 4

> 400 to ≤ 600 – 6 6

12

– Severity level 1

areas 3 3 6

– special rim zone 3 3 –

1 Formula for converting the flat-bottomed hole diameter into the side-drilled hole diameter, see EN 12680-1.

– Grooves, transitions in wall thickness, zones with outer cooling webs

– Fabrication weldings, welding edges and special rim zones

– Fabrication weldings with depths exceeding 50 mm shall be tested in addition with other ap-propriate angle probes.

8.7 All echo indications and attenuations of the back wall echo shall be registered which are equal to the registration levels indicated in Table 4.26 or ex-ceed them.

8.8 Indications exceeding the acceptance limits contained in Table 4.27 or Fig. 4.3 are not allowed and will result in rejection of the cast steel component by the Surveyor. Nevertheless acceptance of the cast steel component is possible on condition that after further evaluation of the indications performed by the orderer and GL proof has been furnished that in case no repair will be performed the employability of the cast steel component will not be effected considerably, or repair

will be performed. In the later case the testing shall be repeated.

8.9 For determining the acceptance criteria ac-cording to Table 4.27 the cast wall is to be divided in rim and core zones according to Fig. 4.2.

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Fig. 4.2 Deviation of wall section into zones

II - Part 1 GL 2009


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Table 4.27 Acceptance limits for ultrasonic testing for volumetric discontinuities following EN 12680-1

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II - Part 1 GL 2009


G

9. Radiographic testing (RT)

9.1 Radiographic testing of cast steel components is to be performed in accordance with Chapter 1 – Principles and Test Procedures, Section 3, L.

9.2 Selection of radiation source depends on the required testing category and the wall thickness to be penetrated, see Table 4.28. If necessary radiographic testing shall be performed in addition to ultrasonic testing if doubts exist concerning the evaluation of indications of ultrasonic testing.

9.3 Indications which concerning their type and dimension exceed the maximum permissible values indicated in Table 4.29 for the required test category are not allowed and will result in rejection of the cast steel component by the Surveyor. Nevertheless accep-tance of the cast steel component is possible on condi-tion that after further evaluation of the indications performed by the orderer and GL proof has been fur-nished that in case no repair will be performed the employability of the cast steel component will not be affected considerably, or repair will be performed. In the later case the testing shall be repeated.

Table 4.28 Radiation source in dependence of the test class and the penetrated thickness following EN 444 and EN 12681

Penetrated thickness ω [mm] Radiation source

Class A Class B

TM 170 w 5≤ w 5≤

Yb 169 1 w 15≤ ≤ 2 w 15≤ ≤

Se 75 10 w 40≤ ≤ 14 w 40≤ ≤

Ir 192 20 w 100≤ ≤ 20 w 90≤ ≤

Co 60 40 w 170≤ ≤ 60 w 150≤ ≤

X-ray equipment with energy from 1 MeV to 4 MeV 30 w 200≤ ≤ 50 w 180≤ ≤

X-ray equipment with energy from 4 MeV bis 12 MeV w 50≥ w 80≥

X-ray equipment with energy above 12 MeV w 80≥ w 100≥



G

Table 4.29 Maximum permissible defects for radiographic testing

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II - Part 1 GL 2009


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H. List of Cast Steel Components for which Non-destructive Tests are Required

Table 4.30 Test methods to be employed

Test methods to be employed 1 Name of the component

VT MT PT UT RT

Structural parts concerning the hull

Stern × × (×) 2 × × Propeller shaft-nut × × (×) 2 × × Rudder horn × × (×) 2 × × Rudder bearing × × (×) 2 – –

Rudder coupling × × (×) 2 × × Shaft bracket × × (×) 2 × –

Ruder shaft × × – × –

Tiller × × (×) 2 × –

Diesel engine parts

Piston crowns × × 5 – × 5 – Cylinder covers × × 5 – × 5 – Camshaft drive gear wheels and chain wheels × × 5 – × – Crank webs and throws × × – × – Connecting rods × × – × – Bearing transverse girders × × – × – Main bearings and bearing covers for main, crossheads and piston rod bearings × × – × –

Starting valve casings × × – – ×

Further components of the propulsion plant

Turbine casings × × – × × Gear wheels × × – × ×

Valve casings

Valve casings for pipe class I 3 with NW ≥ 100 × × – – × 4

1 Testing in the prescribed areas. 2 PT may be employed instead of MT. 3 Compare GL Rules for Classification and Construction I – Ship Technology, Part 1 – Seagoing Ships, Chapter 2 – Machinery

Installations, Section 11, A.3. 4 Random testing according to testing plan 5 For diesel engines with cylinder diameter > 400 mm.



H

I. Testing Instructions for Hull Structural Parts

In the figures 4.4 to 4.11 the specifications for the non-destructive testings are prescribed.

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Fig. 4.4 Testing instruction for stern

II - Part 1 GL 2009


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Fig. 4.5 Testing instruction for rudder stock



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Fig. 4.6 Testing instruction for stern nut

II - Part 1 GL 2009


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Fig. 4.7 Testing instruction for rudder horn



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Fig. 4.8 Testing instruction for upper rudder coupling

II - Part 1 GL 2009


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Fig. 4.9 Testing instruction for lower rudder coupling



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Fig. 4.10 Testing instruction for stern frame

II - Part 1 GL 2009


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Fig. 4.11 Testing instruction for tiller



I

J. Testing Instruction for Diesel Engine Parts

In the figures 4.12 and 4.13 the specifications for the non-destructive testings are prescribed.

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Fig. 4.12 Testing instruction for connecting rods

II - Part 1 GL 2009


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Fig. 4.13 Testing instruction for main bearing support



J

Section 5

Cast Iron

A. General Rules

1. Scope

General Rules to be applied in the manufacture and testing of nodular and grey cast iron are contained in A.

2. Selection of grades of cast iron

2.1 All castings shall be suitable for their in-tended purpose and satisfy the minimum requirements specified in the following individual Rules. Subject to these conditions, grades conforming to the relevant standards or to material specifications approved by GL may be used.

2.2 The grades of cast iron shall be identified by the standardized designations or the designations in the specifications.

3. Requirements to be met by foundries

3.1 Foundries wishing to supply castings in ac-cordance with these Rules shall be approved by GL. This is conditional upon their fulfilling the manufac-turing and quality control requirements stated in Chapter 1 – Principles and Test Procedures, Section 1, C. and furnishing proof of this to GL prior to the commencement of supplies.

3.2 Irrespective of the requirements stated in 2.1, the manufacturer shall himself prove by qualification tests carried out on the products that these can be manufactured in accordance with the conditions im-posed. The scope of these tests will be determined by GL on a case to case basis.

4. General characteristics of castings

4.1 All castings shall have a clean surface com-patible with the conditions of manufacture. Minor casting defects such as sand and slag marks, small cold shuts and scabs may be trimmed off within the negative tolerance on the wall thickness. Castings shall be free from defects liable to impair machining operations and their subsequent use to a more than insignificant extent.

In this respect orderer and manufacturer have to agree on specific grade levels according to EN 1369, EN 1371-1, EN 12680-3 and EN 12681.

4.2 Feeders and other excess material shall be removed by suitable methods. Where the method of

removal causes a change of structure, e.g. in the case of flame cutting, the cut faces shall afterwards be machined.

4.3 Fabrication and repair welds, be it dissimilar welding by means of fillers with high nickel content or similar welding, i.e. using similar fillers, have to be in any case subject to a welding procedure test at the presence of the Surveyor. GL decides about a cast- or component-specific application of the above men-tioned procedure.

4.4 With the consent of the Surveyor, local po-rous areas on castings not subjected to internal pres-sure may be corrected applying appropriate proce-dures, such as inserting filler pieces of similar mate-rial. It is a condition that the serviceability of the cast-ings shall not be impaired by this.


The dimensions and the dimensional and geometrical tolerances are governed by the values specified in the drawings relating to the order or in the relevant stan-dards, as applicable. Appropriate details shall be given in the order documents and shall be made known to the Surveyor.

6. Resistance to leakage

All castings which are subjected to internal pressure by the operating medium or for which special proof of impermeability is required shall be tightness tested at the specified test pressures.

7. General requirements applicable to cast materials


Unless otherwise agreed or specified in the standards, the chemical composition shall be selected by the manufacturer. The manufacturer shall determine the composition in such a way that the required character-istics are achieved.


The values shown in the Tables in B. and C. or in the standards, where applicable, shall be met under test.

The impact energy specified for special quality nodu-lar cast iron grades shall be met by the average value measured on 3 specimens.

II - Part 1 GL 2009

Section 5 Cast Iron Chapter 2Page 5–1

A

8. Tests

The following tests are to be carried out:


Where required, the manufacturer shall determine the composition of each treatment batch (ladle) and give the Surveyor a certificate confirming this composition.

8.2 Testing of mechanical properties and selec-tion of specimens

8.2.1 The mechanical properties shall be ascer-tained by tensile test. In the case of special quality nodular cast iron for which an impact energy is speci-fied, a notched bar impact test shall also be performed.

8.2.2 For each casting or unit test quantity, as ap-plicable, a sufficient quantity of sample material shall be provided to enable the necessary tests and possible retests to be performed.

8.2.3 For proof of the mechanical properties sepa-rately cast samples, integrally cast samples or samples taken from the casting unit may be used.

8.2.4 Type, quantity and location of the respective samples are to be agreed between orderer and manu-facturer until acceptance of the order, unless otherwise specified.

8.2.5 For casting units with cast weights of maxi-mum 2000 kg and a determining wall thickness of up to 200 mm integrally cast samples are to be used. If the weight of the casting unit exceeds 2000 kg and the determining wall thickness is larger than 200 mm integrally cast samples or samples taken from the casting unit are to be used. The latter is to be agreed between the manufacturer and the orderer as well as GL under consideration of 8.2.4.

8.2.6 Where separately cast samples are used, these shall be cast in moulds made of the same mould mate-rial as that used for the casting itself. The samples may not be removed from the moulds until their tempera-ture has dropped to below 500 °C. In the case of chill casting, centrifugal casting and continuous casting, special agreements shall be reached with GL regarding the selection of samples.

8.2.7 All samples are to be marked in such a way that they can be clearly related to the castings which they are intended to represent.

8.2.8 Where castings are supplied in a heat-treated condition, the samples shall be heat treated together with the castings concerned.

8.2.9 Where castings are manufactured in series, the manufacturer may, with the agreement of GL, use other, equivalent methods of testing. In this case, the manufacturer shall have proved the characteristics of the products by a preliminary type test and shall en-

sure by continuous quality control that the characteris-tics remain constant.

9. Test of surface finish and dimensions

The manufacturer shall inspect each casting with re-gard to its surface finish and compliance with the dimensional and geometrical tolerances and shall then present the castings to the Surveyor for final inspec-tion. For this purpose, the surface of the castings shall be free from moulding material and shall be properly prepared for inspection.

10. Non-destructive tests

Generally, a non-destructive test shall be performed only where this is specified in the order according to 4.1. Apart from this, the Surveyor may call for suit-able non-destructive tests if there are justified doubts that the castings are free from defects.

11. Hydraulic pressure test

Where specified, castings shall be submitted to a hy-draulic pressure test. The test is to be performed in the presence of the Surveyor, wherever possible on the rough-machined castings. Where no other test pressure is specified, the test pressure shall be equal to 1,5 times the operating pressure.

12. Retests in the event of failure

If specimens fail to meet the required values in the tensile or notched bar impact test, or if, in the notched bar impact tests, one value is below the level permit-ted by the specification, then, before the unit test quantity or the casting is rejected, the procedures for retests prescribed in Chapter 1 – Principles and Test Procedures, Section 2, H. may be applied. The addi-tional test specimens shall be taken either from the same test sample as the original specimen or from other samples which are representative of the casting or of the unit test quantity.

13. Identification and marking

13.1 The manufacturer shall institute a monitoring system enabling all castings to be traced back to the original heat, and this shall be demonstrated to the Surveyor on request.

13.2 Prior to final inspection, all castings shall be provided by the manufacturer in at least one place with the following marks:

13.3 Grade of cast iron, material symbol and/or material number of the cast material:

– heat number or mark enabling the manufactur-ing process of the casting to be traced back

– manufacturer's name or mark

– test pressure, where applicable


Section 5 Cast Iron II - Part 1GL 2009

A

13.4 In the case of series-manufactured castings, agreement may be reached with the Surveyor to apply marks other than those specified above.

14. Certificates

For each consignment, the manufacturer shall supply to the Surveyor a certificate containing at least the following details:

– orderer and order number

– newbuilding or project number, where known

– item number and quantity

– type of casting units and grade of cast iron

– application and drawing number, if necessary



– heat number or identifying mark



– details of heat treatment, if necessary

– marking

– test pressures, if necessary

– results of mechanical tests

B. Nodular Cast Iron

1. Scope

These Rules are applicable to nodular cast iron for the manufacture of machinery and pipeline components, e.g. fittings, flanges, housings, hubs, bed-plates and similar parts designed for use and testing at normal ambient temperatures.

The requirements for the use of castings at higher operating temperatures or at low temperatures gener-ally below 0 °C are subject to the special agreement of GL.

2. Suitable grades of cast iron

The following grades of cast iron may be used:

2.1 Nodular cast iron conforming to DIN EN 1563 with the characteristics stated in the standard.

2.2 Nodular cast iron grades conforming to other standards, provided that they are equivalent to the grades specified in 2.1 and satisfy the requirements stated in 4.2 to 4.4.


3.1 Apart from the exceptions provided for in 3.2, the castings may be supplied in as cast or heat-treated condition. The method of treatment shall be specified at the time of the approval test.

3.2 Cast iron of grades EN-GJS-350-22-LT/-22-U-LT to EN-GJS-400-18-LT/-18U-LT or the special qualities according to Table 5.1 with nominal strengths of 350 and 400 N/mm2 shall undergo ferri-tizing treatment.

3.3 Where castings are subject to special re-quirements in respect of their dimensional or geomet-rical stability, any heat treatments needed shall be carried out before the castings are machined.

Heat treatments to eliminate casting stresses or for straightening may only be carried out at temperatures up to 550 °C because of the danger that the character-istics might be changed.


4.1 Nodular cast iron conforming to DIN EN 1563

The requirements specified in the standard and given in Table 5.2 for separately cast samples and in Table 5.3 for integrally cast samples are applicable.

In case of requirements regarding impact energy, the minimum values specified in Tables 5.4 and 5.5 are to be proven.

In addition the requirements in 4.3 and 4.4 apply re-garding graphite- or metallic matrix structure respec-tively.

4.2 Other grades of cast iron

4.2.1 The castings shall achieve the mechanical properties specified in Table 5.1 in testing, depending on their minimum tensile strength. The Brinell hard-ness data are only guide values.

4.2.2 Special quality castings shall meet the re-quired energy impact values specified in Table 5.1.

4.3 Graphite structure

The manufacturing process shall ensure that 90 % of the graphite is precipitated in nodular form according to Form VI of EN ISO 945. The remaining graphite shall have a structure at least of form V according to the above mentioned standard.

4.4 Structure of metallic matrix

The metallic matrix shall have the structure indicated in Table 5.1. The proportion of pearlite in the ferritic grades may not exceed 10 %. The graphite- and metal-lic matrix structures are to be demonstrated by micro-graphs.

II - Part 1 GL 2009


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Table 5.1 Mechanical properties and structure of nodular cast iron

Impact energy Minimum tensile

strength Rm 1

[N/mm2]

Rp0,2 [N/mm2]

min.

A [%] min.

Hardness

HB 10 2

min.

Test temp.

[°C]

KV 3 [J]

min.

Structure of metallic matrix

Ordinary

qualities

370

400

450

500

600

700

800

230

250

310

320

370

420

480

17

15

10

7

3

2

2

120 – 180

140 – 200

160 – 210

170 – 240

190 – 270

230 – 300

250 – 350

––

––

––

––

––

––

––

––

––

––

––

––

––

––

Ferrite

Ferrite

Ferrite

Ferrite/pearlite

Ferrite/pearlite

Perlite

Perlite/sorbite

Special qualities

350 400

220 250

22 4 18 4

110 – 170 140 – 200

- 20 - 20

17 (14) 14 (11)

Ferrite Ferrite

1 Where the minimum tensile strength of the casting falls between the graduated values indicated, the requirements may be determined by interpolation.

2 The values are intended only as a guide and are not test requirements. 3 The average value measured on 3 Charpy V-notch specimens. One result may be below the average value but not less than the

minimum shown in brackets. 4 In the case of integrally cast samples, the elongation may be 2 percentage points less.

Table 5.2 Mechanical properties determined from samples of separately cast test specimens

Material designation

Material code Number

Tensile strength Rm

[N/mm2] min.

0,2-proof stress Rp0,2

[N/mm2] min.

Elongation A

[%] min.

Main structure of metallic

matrix

EN-GJS-350-22-LT 1 EN-JS1015 350 220 22 Ferrite

EN-GJS-350-22-RT 2 EN-JS1014 350 220 22 Ferrite

EN-GJS-350-22 EN-JS1010 350 220 22 Ferrite

EN-GJS-400-18-LT 1 EN-JS1025 400 240 18 Ferrite

EN-GJS-400-18-RT 2 EN-JS1024 400 250 18 Ferrite




ENGJS-500-7 EN-JS1050 500 320 7 Ferrite/Perlite

EN-GJS-600-3 EN-JS1060 600 370 3 Perlite/Ferrite

EN-GJS-700-2 EN-JS1070 700 420 2 Perlite

EN-GJS-800-2 EN-JS1080 800 480 2 Perlite

1 LT for low temperatures 2 RT for room temperature

Note

The values for these materials apply to units cast in sand moulds with comparable temperature conductibility.



B

Table 5.3 Mechanical properties determined from samples of integrally cast test specimens

Material designation


Determining wall thickness

t [mm]

Tensile strength

Rm

[N/mm2] min.

0,2 % Proof stress

Rp0,2

[N/mm2] min.

Elongation

A [%] min.

t ≤ 30 350 220 22

30 < t ≤ 60 330 210 18 EN-GJS-350-22U-LT 1 EN-JS1019

60 < t ≤ 200 320 200 15

t ≤ 30 350 220 22

30 < t ≤ 60 330 220 18 EN-GJS-350-22U-RT 2 EN-JS1029

60 < t ≤ 200 320 210 15

t ≤ 30 350 220 22

30 < t ≤ 60 330 220 18 EN-GJS-350-22U EN-JS1032

60 < t ≤ 200 320 210 15

t ≤ 30 400 240 18

30 < t ≤ 60 390 230 15 EN-GJS-400-18U-LT 1 EN-JS1049

60 < t ≤ 200 370 220 12

t ≤ 30 400 250 18

30 < t ≤ 60 390 250 15 EN-GJS-400-18U-RT 2 EN-JS1059

60 < t ≤ 200 370 240 12

t ≤ 30 400 250 18

30 < t ≤ 60 390 250 15 EN-GJS-400-18U EN-JS1062

60 < t ≤ 200 370 240 12

t ≤ 30 400 250 15

30 < t ≤ 60 390 250 14 EN-GJS-400-15U EN-JS1072

60 < t ≤ 200 370 240 11

t ≤ 30 450 310 10

30 < t ≤ 60 EN-GJS-450-10U EN-JS1132

60 < t ≤ 200 to be agreed

t ≤ 30 500 320 7

30 < t ≤ 60 450 300 7 EN-GJS-500-7U EN-JS1082

60 < t ≤ 200 420 290 5

t ≤ 30 600 370 3

30 < t ≤ 60 600 360 2 EN-GJS-600-3U EN-JS1092

60 < t ≤ 200 550 340 1

t ≤ 30 700 420 2

30 < t ≤ 60 700 400 2 EN-GJS-700-2U EN-JS1102

60 < t ≤ 200 660 380 1

t ≤ 30 800 480 2

30 < t ≤ 60 EN-GJS-800-2U EN-JS1112

60 < t ≤ 200 to be agreed

1 LT for low temperatures

2 RT for room temperature

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B

Table 5.4 Minimum values for impact energy determined from samples with V-notch from separately cast test specimens

Minimum values for impact energy [J]

Material designation at RT

(23 ± 5) °C at

(–20 ± 2) °C at

(–40 ± 2) °C

Material code Number Average

value from 3 tests

Individual value

Average value from

3 tests

Individual value

Average value from

3 tests

Individual value

EN-GJS-350-22-LT 1 EN-JS1015 –– –– –– –– 12 9

EN-GJS-350-22RT 2 EN-JS1014 17 14 –– –– –– ––

EN-GJS-400-18-LT 1 EN-JS1025 –– –– 12 9 –– ––

EN-GJS-400-18-RT 2 EN-JS1024 14 11 –– –– ––– ––


Note

The values for these materials apply to units cast in sand moulds with comparable temperature conductibility.

Table 5.5 Minimum values for impact energy determined from samples with V-notch from integrally cast test specimens

Minimum values for impact energy [J]

Material designation RT (23 ± 5) °C

at (–20 ± 2) °C

at (–40 ± 2) °C


Determining wall thickness

t [mm]

Average value from

3 tests

Indivi-dual value

Average value from

3 tests

Indivi-dual value

Average value from

3 tests

Indivi-dual value

t ≤ 60 12 9 EN-GJS-350-22U-LT 1 EN-JS1019

60 < t ≤ 200 –– –– –– ––

10 7

t ≤ 60 17 14 EN-GJS-350-22U-RT 2 EN-JS1029

60 < t ≤ 200 15 12 –– –– –– ––

30 < t ≤ 60 12 9 EN-GJS-400-18U-LT 1 EN-JS1049

60 < t ≤ 200 –– ––

10 7 –– ––

30 < t ≤ 60 14 11 EN-GJS-400-18U-RT 2 EN-JS1059

60 < t ≤ 200 12 9 –– –– –– ––


Note The values for these materials apply as a rule to casting units with thicknesses between 30 and 200 mm.



B

5. Testing



The manufacturer shall determine and make known to the Surveyor the chemical composition of each heat treatment batch. The analysis report shall cover at least the following elements:

C, Si, Mn, P, S and Mg together with Ni and Cu, where these are added to achieve the required charac-teristics.


5.2.1 The mechanical properties such as tensile strength, 0,2 % proof stress and elongation shall be determined by tensile test. In the case of ferritic grades, the yield point revealed by the curve plotted by the testing machine may be stated instead of the 0,2 % proof stress.

5.2.2 For the tensile test, one test specimen each shall be taken from a separately cast U- or a Y-shaped sample piece according to Fig. 5.1 and 5.2 respec-tively or from an integrally cast sample piece accord-ing to Fig. 5.3. The shape of the sample piece shall normally correspond to the standard U or Y2 type with a thickness of 25 mm. In special cases, samples having different dimensions may be agreed. The provision of samples is governed by the following requirements:

– For heavy casting units with gross weights of minimum 1000 kg one sample plus one sample per treatment batch shall be provided.

– For casting units with gross weights of less than 1000 kg one sample per treatment batch shall be provided. In case of testing by batch one sample per 1000 kg gross weight of the test batch shall be provided and one additional sample for each further 2000 kg gross weight of the test batch. Precondition is that all casting units are from a series of the same type and have been cast from the same treatment batch and heat treated, where applicable.

– Where heat treatments are carried out, integrally cast samples may be removed from the casting only after heat treatment. Separately cast sam-ples shall be heat treated together with the cast-ing.


Where an impact energy is specified for a grade of cast iron, this shall be verified by the notched bar impact test performed on Charpy V-notch specimens at the prescribed test temperature. The requirements regarding impact energy are specified in Table 5.1, 5.4 and 5.5 for the respective grades of cast iron. To carry out the test, one set of specimens shall be taken from each of the samples called for in 5.2.2.

��

�

��

�

��

Dimensions Location of specimen

a = 25 mm Z = tensile test specimen b = 90 mm K = impact test specimen c = 40 mm h = 100 mm Lt ≥ 200 mm

Fig. 5.1 U-type sample piece

��

�

�

�

�

�

Location of specimen

Z = tensile test specimen K = impact test specimen

Sizes in [mm] for samples of type Dimen-

sion Y 1 Y 2 Y 3 Y 4

a b c h

12 40 25 135

25 55 40 140

50 100 50 150

75 125 65 175

Lt ≥ 200

Fig. 5.2 Y-type sample piece


The manufacturer shall inspect each casting with re-gard to its surface finish and compliance with the dimensional and geometrical tolerances and shall then present the casting to the Surveyor for final inspection.

II - Part 1 GL 2009


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�

� ��

��

��

Location of specimen Z = tensile test specimen K = impact test specimen

A) Casting unit (or cast system) Dimensions in mm

Type

Determining wall thickness of casting unit

t

a b c h Lt

I 30 < t ≤ 60 40 30 20 40 to 60 ≥ 200

II 60 < t ≤ 200 70 52,5 35 70 to 105 ≥ 200

If smaller dimensions are agreed, the following correlations apply: a

b 0, 75 a and c2

= ⋅ =

Fig. 5.3 Integrally cast test specimens

C. Grey Cast Iron

1. Scope

These Rules are applicable to grey cast iron for the manufacture of machinery and pipeline components, e.g. fittings, flanges, housings, hubs, wheel bodies, bed-plates, cylinders, and similar parts.

2. Suitable grades of cast iron

The following grades of cast iron may be used:

2.1 Grey cast iron conforming to DIN EN 1561, with the exception of grades EN-GJL-100 and EN-GJL-150.

2.2 Grades of cast iron conforming to other stan-dards, provided that they are equivalent to the grades specified in 2.1 and meet the requirements of 4.


Castings may be supplied in the as cast or heat-treated condition at the manufacturer's option unless a heat treatment is specified because of special requirements in respect of machinability or geometrical and dimen-sional stability.


4.1 Mechanical characteristics

Castings shall normally be supplied with one of the following minimum tensile strengths Rm:

200 N/mm2

250 N/mm2

300 N/mm2

350 N/mm2

Castings with minimum tensile strength values of < 200 N/mm2 are not allowed. The requirements are applicable to specimens with a diameter of 20 mm in accordance with 5.2.4. The requirements regarding minimum tensile strength for separately and integrally cast specimens are specified in Table 5.6. The re-quirements for specimens taken from the casting (e.g. core specimens) shall be specially agreed between manufacturer and orderer as well as GL.

4.2 Graphite and matrix structure

The method of manufacture shall ensure that the graphite is present in uniformly distributed flakes and



C

Table 5.6 Tensile strength of grey cast iron

Material designation Determining wall thickness

[mm]

Tensile strength Rm

values to comply with

Material code Number over up to

in separately cast test specimens

[N/mm2]

in integrally cast test specimens

[N/mm2] min.

2,5 2 5 ––

5 10 ––

10 20 ––

20 40 170

40 80 150

80 150 140

EN-GJL-200 EN-JL1030

150 300

200 – 300 3

130 1

5 2 10 ––

10 20 ––

20 40 210

40 80 190

80 150 170


150 300

250 – 350 3

160 1

10 2 20 ––

20 40 250

40 80 220

80 150 210


150 300

300 – 400 3

190 1

10 2 20 ––

20 40 290

40 80 260

80 150 230


150 300

350 – 450 3

210 1 1 These values are guidances. 2 This value is included as lower limit of the range of determining wall thickness. 3 The values refer to test specimens with 30 mm diameter of rough casting. This corresponds to a determining wall thickness of 15 mm.

that a saturation level Sc of 1,0 is not exceeded. The level of saturation shall be determined by applying the following formula:

c% C

S4,3 0,33 (% Si % P)

=− +

The fracture of tested tensile specimens shall have a uniform grey crystalline appearance.




The manufacturer shall constantly monitor the chemi-cal composition and the saturation level of each treat-ment unit (ladle) and shall pass this information on to the Surveyor on request. Determination of at least the following elements is required: C, Mn, Si, P and S.


5.2.1 The tensile strength is to be determined by a tensile test. For this purpose, separately cast speci-mens with 30 mm diameter of rough casting and 200 mm minimum length according to Fig. 5.4 may be used as well as integrally cast specimens of type 2 according to DIN EN 1561, see also Fig. 5.5.

II - Part 1 GL 2009


C

50 50∅30+20

5050

L ≥

200

∅50Moulding material

Fig. 5.4 Mould for separately cast test specimen

5.2.2 The test sample type shall be so selected that about the same conditions for cooling down apply as for the casting unit.

5.2.3 For casting units which determining wall thickness exceeds 20 mm and which gross weight is larger than 200 kg, integrally cast test specimens shall be used.

5.2.4 A test specimen of 20 mm diameter is to be taken from each sample for testing. Thereby the frac-ture surfaces of the test specimens shall be assessed. For test specimen shape, refer to Chapter 1 – Princi-ples and Test Procedures, Section 2, D.1.3.6.

5.2.5 The following number of samples is to be provided:

– For heavy casting units with gross weights of minimum 1000 kg one sample plus one sample per treatment batch shall be provided.

– For casting units with gross weights of less than 1000 kg one sample per treatment batch shall be provided. In case of testing by batch one sample per 1000 kg gross weight of the test batch shall be provided and one additional sample for each further 2000 kg gross weight of the test batch. Precondition is that all casting units are from a series of the same type and have been cast from the same treatment batch and heat treated, where applicable.

5.3 If casting units are supplied in heat treated condition, the samples shall be heat treated together with the respective casting units.

Dimensions in mm

��3�

��3�

7��$7��8��

��$�

��

The numbers in brackets apply to casting units

with wall thickness larger or equal 80 mm

Fig. 5.5 Integrally cast test specimen

The details of 5.2.2 shall be observed in this connec-tion.

Integrally cast sample pieces may be removed from the casting unit only after heat treatment.


The manufacturer shall inspect each casting with re-gard to its surface finish and compliance with the dimensional and geometrical tolerances and shall then present the casting to the Surveyor for final inspection.



C

Section 6

Fittings and Pressed Parts, Bolts and Nuts

A. Pressed Parts

1. Scope

1.1 These Rules are applicable to the testing of pressed parts for pressure vessels, e.g. pressed heads and shell components fabricated from ferritic or aus-tenitic steel plates by hot forming or by cold forming followed by heat treatment. They are also applicable to the method of heat treatment which may be required after forming has been carried out.

1.2 These Rules are also applicable to pressed parts made from individual parts by welding and sub-sequent forming. Testing of these welded joints before and after forming is to be carried out according to GL Rules Part 3 – Welding.


Manufacturers wishing to supply products in accor-dance with these Rules shall be approved by GL. This is conditional upon their fulfilling the manufacturing and quality control requirements specified in Chapter 1 – Principles and Test Procedures, Section 1, C. and furnishing proof of this to GL prior to the commence-ment of supplies. Tests of product suitability shall additionally be performed on selected products.

3. Requirements applicable to the starting plates

3.1 The grades of steel from which the starting plates are made shall be specified in the order. In selecting them, care shall be taken to ensure that they fulfil the requirements to be met by the base material concerned after forming and, where applicable, heat treatment.

3.2 The plates may be supplied in the stipulated final heat-treated condition or in another condition which facilitates the subsequent forming. In the latter case, testing of the starting plates - if required - shall be performed using test specimens which have under-gone the heat treatment intended for the finished part. The condition of supply of the plates and the method of heat treatment of the test specimens shall be indi-cated in the test certificate.


These are governed by the relevant standards and/or the information in the order documents. The manufac-turer shall keep relevant documents ready for the test-ing.

5. Principles governing hot forming and heat treatment

5.1 The manufacturer of the finished part shall have available suitable equipment for the proper exe-cution of the necessary heat treatments. Preliminary proof of this shall be submitted to the Surveyor.

5.2 The heat treatment equipment shall be fitted with a sufficient number of calibrated temperature measuring devices, and fixed items of plant shall be additionally equipped with automatic recording in-struments which are to be recalibrated at regular inter-vals.

5.3 As far as possible, all parts shall be heated or annealed in their entirety. With the consent of the Surveyor, this Rule may be waived where only local forming is performed. In these cases the heat treatment shall, however, embrace the whole area of deforma-tion.

5.4 The temperatures, holding times and heating and cooling rates shall be determined by reference to the data contained in the standards or manufacturer's specifications in accordance with the material and the component concerned. The manufacturer is required to guarantee compliance with the conditions.

5.5 Where the testing of finished parts is allowed to be carried out on separate test sections, provision shall be made to ensure that these receive the same heat treatment as the finished part. For this purpose, the test sections shall be laid on top of the correspond-ing finished parts for the annealing operation.

6. Heat treatment after hot forming

6.1 Ferritic steels

6.1.1 Hot forming shall normally be followed by renewed heat treatment as prescribed for the base material concerned.

This Rule may be waived in the case of normalized and air-quenched and tempered steels with the excep-tion of the steels tough at sub-zero temperatures, pro-vided that the hot forming operation is begun and ended within the temperature range specified for this purpose in the standard or the manufacturer's material specification. In this case, the renewed heat treatment can be dispensed with for normalized steels while tempering can suffice for air quenched and tempered steels.

II - Part 1 GL 2009

Section 6 Fittings and Pressed Parts, Bolts and Nuts Chapter 2Page 6–1

A

6.1.2 For the steels tough at sub-zero temperatures, preliminary proof shall be furnished that the intended heat treatment imparts to the finished part the neces-sary impact energy at the specified test temperature. If this is the case, then, subject to the conditions men-tioned in 6.1.1, subsequent heat treatment may be dispensed with for normalized steels, while subse-quent tempering may suffice for air quenched and tempered (normalized and tempered) steels, and in the case of 5 % and 9% nickel steels calling for triple heat treatments (12 Ni 19 and X 8 Ni 9), the second nor-malizing and tempering operation may be sufficient.

6.1.3 For water-quenched and tempered steels, the nature of the heat treatment to be applied after hot forming shall be specially determined.

6.1.4 The exceptional provisions set out in 6.1.1 and 6.1.2 may also be applied where local hot forming is performed, provided that, prior to forming, the plates were in a heat-treated condition appropriate to the material.

6.2 Austenitic steels 1

After hot forming, parts made of austenitic steels shall be subjected to renewed heat treatment which shall normally comprise solution annealing and quenching. This Rule may be waived where the forming operation is begun in the temperature range from 1150 to 1000 °C and is ended above 750 °C for stabilized steels and steels with a carbon content of C ≤ 0,03 % or above 875 °C for non-stabilized steels with a car-bon content of C ≤ 0,08, followed by rapid cooling to ambient temperature.

6.3 Clad plates

Where parts are made of clad plates, the nature of the heat treatment is governed by the base material, see 6.1. Where the cladding material requires a heat treatment different from that of the base material, the details of this shall be specified by the manufacturer of the material and made known to GL.

7. Heat treatment after cold forming

7.1 Ferritic steels

All plates shall be in the prescribed condition of sup-ply before cold forming is carried out, see the individ-ual Rules in Section 1. Due to the changes in material properties which may result from cold forming and ageing, the following procedure applies:

7.1.1 Pressed parts for pressure vessels operated at ambient temperatures or feedstock temperatures down to – 10 °C shall, if the degree of deformation exceeds 5 % (wall thickness s > 0,05 ⋅ Dm for cylindrical shell rings and sphere segments), be subjected to heat

–––––––––––––– 1 For further details on heat treatment of austenitic steels, see

AD-Merkblatt (AD Data Sheet) HP/7.3.

treatment (normalizing or quenching and tempering) in accordance with the relevant standards or material specifications.

7.1.2 Pressed parts for pressure vessels operated at charging media temperatures below – 10 °C shall,

– if the degree of deformation exceeds 2 % in the case of steel grades conforming to EN 10028-2, EN 10028-3, EN 10028-4 and EN 10028-6, with the exception of 12Ni14, 12Ni19, X7Ni9 and X8Ni9,

– if the degree of deformation exceeds 5 % in the case of steel grades 12Ni14, 12Ni19, X7Ni9 and X8Ni9 conforming to EN 10028-4,

be subjected to heat treatment (normalizing or quench-ing and tempering) in accordance with the relevant standards or material specifications.

7.1.3 Pressed parts for gas tanks with design tem-peratures below 0 °C shall be treated in accordance with 7.1.2.

7.1.4 Cold-formed heads, including those fabri-cated from welded round blanks, shall be heat treated (normalized or quenched and tempered) in accordance with the relevant standards or material specifications.

7.1.5 The stipulations of 7.1.1, 7.1.2 and 7.1.4 may be relaxed if proof is furnished that the properties of the materials make them able to withstand the stresses prevailing while the pressure vessel is in service.

7.1.6 Cold-formed dished heads made of steel grades S235 JR, S235 J0, S235 J2 and S235 J2+N according to EN 10025-2, P235 GH and P265 GH to EN 10028-2, P275 N according to EN 10028-3, as well as of other steel grades of comparable strength, do not require heat treatment if the temperature of the charging media is –10 °C or above, the design tem-perature does not exceed 120 °C according to GL Construction Rules and the nominal wall thickness is ≤ 8 mm.

7.1.7 If the acceptable degrees of deformation are exceeded in cold forming, heat treatment shall as a rule be performed before welding.

7.1.8 In the case of clad pressure vessels or pres-sure vessel components, heat treatment shall be per-formed in accordance with the base material, unless special conditions have to be agreed with regard to the cladding.

7.2 Austenitic steels

7.2.1 Acceptable heat treatments are solution an-nealing with quenching or, for stabilized steels (excep-tion: Mo-alloyed stabilized steels with more than 0,03 % C) and steels with carbon contents of C ≤ 0,03 %, stabilization annealing.


Section 6 Fittings and Pressed Parts, Bolts and Nuts II - Part 1GL 2009

A

Note

See AD Data Sheet HP 7/3.

7.2.2 Heat treatment of solution annealed and quenched or stabilization annealed material after cold forming may be dispensed with if:

7.2.2.1 in the case of austenitic steels with required minimum elongation values A of ≥ 30 % in respect of the initial material, the degree of deformation does not exceed 15 % or proof is furnished that the residual elongation capacity A after cold forming is at least 15 %. For size ranges in which the required minimum elongation values A are less than 30 %, proof that the residual elongation capacity A is 15 % is deemed to have been furnished if an elongation A of ≥ 30 % is shown in the acceptance test certificate;

7.2.2.2 in the case of degrees of deformation higher than 15 %, proof is furnished that the residual elonga-tion capacity A after cold forming is at least 15 %;

7.2.2.3 in the case of dished, ellipsoidal and hemi-spherical heads, the following elongations A are shown in the acceptance test certificates for the start-ing materials:

– ≥ 40 % for nominal wall thicknesses ≤ 15 mm at design temperatures down to –196 °C,

– ≥ 45 % for nominal wall thicknesses > 15 mm at design temperatures down to –196 °C,

– ≥ 50 % at design temperatures below –196 °C;

7.2.2.4 in the case of pressure vessel components, except heads, which are operated at design tempera-tures below –196 °C, the degree of deformation does not exceed 10 %.

7.3 Clad plates

Cold-formed finished parts made of clad plates are subject to the conditions stated in 7.1 for the base material concerned.

8. Testing

8.1 Test of mechanical and technological properties

8.1.1 The testing of pressed parts shall comprise tensile and notched bar impact tests performed on specimens taken from the finished parts after the final heat treatment transverse to the original rolling direction of the plate. A tolerance of up to 20° from the required specimen orientation can be tolerated. The necessary test sections, the quantity of which is specified in Table 6.1, shall be taken from surplus material at the edges of the pressed parts or from cut-outs.

8.1.2 Where stress relief heat treatment is sufficient after forming, the test section may be removed from the test piece beforehand and subjected to the same annealing treatment.

8.1.3 Where Table 6.1 specifies testing by test batches, a test batch may only comprise items made from plates originating from the same heat which have been pressed and heat treated in the same way. The wall thicknesses of items within a test batch may vary by 20 % from the mean wall thickness. The number of sets of specimens shall be determined as follows:

– up to 10 items: 1 set of specimens

– up to 25 items: 2 sets of specimens

– over 25 items: 3 sets of specimens.

8.1.4 Where individual testing of the pressed parts is prescribed, testing of the starting material by GL may be dispensed with.

8.1.5 Instead of individual testing of the pressed parts, GL may agree to testing by rolled plate (1 set of specimens per starting plate) provided that the manu-facturer of the pressed parts demonstrates to GL by a preliminary test of the manufacturing method used that the requirements can be met and products with constant characteristics can be manufactured. In this case, the starting plates shall be tested.


The surface finish and dimensions of each finished part shall be checked by the manufacturer. The parts shall then be submitted to the Surveyor for final test-ing and verification of the dimensions.

For this purpose, the manufacturer shall give the Sur-veyor the measuring records.

9. Marking

Each part shall be marked by the manufacturer with the manufacturer's mark, the material designation, the heat number and the specimen number.

10. Certificates

10.1 In the case of pressed parts which are heat treated after forming, the manufacturer shall certify the proper execution of the heat treatment stating the temperatures, the holding times and the type of cool-ing applied.

10.2 In the case of pressed parts which may be supplied in the hot pressed condition, the manufac-turer shall certify that the forming operation was be-gun and ended within the specified temperature limits and shall indicate the standard or material specifica-tion applicable. In addition, the method of cooling and the condition in which the starting material was sup-plied shall also be stated.

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Table 6.1 Scope of tests on pressed parts made from plate

Grades of steel Base material according to Section 11

Test performed on Extent of tests on

pressed parts

All unalloyed steels with a minimum tensile strength ≤ 410 N/mm2

C, E starting plate not required

Unalloyed and fine-grained structural steels with a minimum tensile strength

410 < Rm ≤ 510 N/mm2, and ReH ≤ 355 N/mm2, also 0,3 %-Mo alloy steels

C, E starting plate pressed part

testing by batches

Fine-grained structural steels, ReH > 355 N/mm2 E pressed part 1 set of specimens from each pressed part 2

High-temperature CrMo alloy steels E pressed part 1 set of specimens from each pressed

part 2

Steels tough at sub-zero temperatures F pressed part 1 set of specimens from each pressed

part 2

Austenitic stainless steels:

≤ 20 starting plate not required

Thickness [mm]

> 20

G starting plate pressed part

testing by batches

Clad plates H The extent of the test depends on the base material

1 Pressed parts which are designed for the manufacture of tanks carrying pressure-liquefied ammonia are subject to F.8.2.2. 2 Testing by rolled plate may be agreed if the conditions specified in 8.1.5 are satisfied.

B. Pipe Fittings

1. Scope

These Rules are applicable to saddles, T-shaped fit-tings, tapered transition pieces and pipe elbows for welding into pipelines which are fabricated from pipe or plate sections made of ferritic or austenitic steels.

2. Starting materials

Suitable plates or pipes are to be selected as starting materials in accordance with Section 1 or 2. Unless otherwise stipulated by GL, the starting materials shall be ordered with inspection certificates conforming to EN 10204-3.1 from manufacturers approved by GL.

3. Manufacture

3.1 Pipe fittings may be hot or cold formed from sections of pipe. They may also be made from sections of plate hot or cold formed into one or more shells and welded together.

3.2 Proof shall be furnished to GL, as a prelimi-nary measure, of the suitability of the process and, for fittings welded together from individual components, the characteristics of the welded joints. For this pur-pose, the manufacturer shall send a process descrip-tion containing all the details required for evaluating the process to GL for consideration. The nature and scope of the procedure approval inspection shall be determined by GL from case to case.

4. Heat treatment

4.1 All fittings shall be in the heat-treated or hot-worked state specified for the material according to GL Rules or other relevant standards or material specifications.

4.2 In the case of ferritic steels for which normal-izing is prescribed and which undergo hot forming, subsequent heat treatment may be dispensed with if a corresponding structure can be achieved by the hot forming operation. In the same circumstances, temper-ing may be sufficient for steels for which quenching and tempering is prescribed.



B

4.3 Cold formed parts are generally required to undergo renewed heat treatment following the forming operation. If such treatment is not to be applied, the manufacturer shall prove that the finished part retains the required characteristics.

4.4 Where fittings are welded together from hot or cold formed components, the nature of the heat treatment shall be determined at the time of the proce-dure approval test.

4.5 If the starting material is in the prescribed heat-treated condition, in the case of pipe elbows manufactured from ferritic or austenitic steels the following procedure may be applied:

If these elbows are produced by cold bending with bending radii of rm ≥ 1,3 ⋅ da, subsequent heat treat-ment is not required if the outside diameter da is ≤ 133 mm. The same applies to all elbows manufac-tured with bending radii of rm ≥ 2,5 ⋅ da.

The exceptions are steel pipes tough at sub-zero tem-peratures with wall thicknesses > 2,5 mm and cold-bent pipes which have to be heat treated due to corro-sive attack or because stressed parts have to be welded on outside the neutral zone.

5. Requirements applicable to properties

In the finished state, the fittings shall possess all the required characteristics specified for the starting mate-rial used (pipe or plate).

6. Testing

6.1 Inspection and dimensional check

All fittings shall be inspected and their dimensions checked in the condition of supply. For this purpose, the surface of the fittings shall be in a condition ap-propriate for inspection which enables major defects to be detected.

6.2 Testing of materials

6.2.1 For performing the mechanical tests, the fittings shall be divided into test batches in accordance with Table 6.2.

A test batch in accordance with Table 6.2 consists of fittings made of the same materials and having the same dimensions, and, in the case of alloy steel fit-tings with a da > 100 mm, originating from the same heat. If final heat treatment is necessary, testing shall also be performed by heat treatment batches.

Unalloyed steel fittings from the same heats which have been heat-treated separately but in the same way may be tested together if the uniformity of the fittings has been proved to the Surveyor by means of a hard-ness test on 10 %, but at least 3, of the fittings.

Table 6.2 Test batches for fittings

Size da [mm]

No. of fittings per test batch 1

< 100 ≤ 200

≥ 100 < 225 ≤ 100

≥ 225 < 350 ≤ 50

≥ 350 ≤ 25

1 Test batches apply to 90-degree elbows.

The number of elbows per test batch is halved in the case of 180-degree elbows and doubled in the case of 45-degree elbows.

6.2.2 The scope of the mechanical tests is as shown in Table 6.3.

For preparing the test specimens, either additional fittings shall be provided or fittings of excess length shall be manufactured. Tensile and notched bar impact tests may be performed on either tangential or longi-tudinal test specimens depending on the geometry of the fittings; the specimens shall be prepared from the hardest and softest fittings determined in the hardness tests. The required values shall be the definitive values for the starting materials.

6.2.3 In the case of steels tough at sub-zero tem-peratures, the notched bar impact test shall be per-formed at the appropriate test temperature.

6.2.4 In the case of austenitic or austenitic-ferritic stainless steel fittings for use on chemical tankers, each heat and heat treatment batch shall be tested by the manufacturer for resistance to intercrystalline corro-sion in accordance with ISO 3651-2 or an equivalent standard and a test certificate shall be issued.

6.2.5 Alloy steel fittings shall be subjected to ap-propriate testing by the manufacturer to verify the use of the correct material.

6.2.6 Welded alloy steel fittings with nominal bores > 75 mm shall be subjected by the manufacturer to random radiographic inspection of the welds. Un-less stipulated in the specification or the order, the number of fittings to be tested shall be agreed with the Surveyor. These shall be selected in such a way that every size of fitting is included.

7. Marking

The fittings shall be marked as follows:

– manufacturer's symbol


– where applicable, quality level in the case of boiler tubes

– heat number or code, if the starting material had a corresponding marking

II - Part 1 GL 2009


B

Table 6.3 Classification into test groups and scope of tests

Scope of tests per test batch

Test groups

Size da

[mm] Material Hardness

test 1 Tensile test

Notched bar impact test 2

(set of specimens = 3 specimens)

I < 100 unalloyed 1 4

II < 100 alloyed 1 4

III ≥ 100 unalloyed Rm < 500

N/mm2

10 % 3 min. on

3 fittings

IV ≥ 100 ≤ 225 (DN ≤ 200)

unalloyed Rm ≥ 500

N/mm2

10 % min. on

3 fittings

V > 225 (DN > 200)

or alloyed

100 % 5

2 specimens, only if less than

10 fittings 1 specimen

2 sets, only if less than

10 fittings 1 set

1 With austenitic steels, the hardness test is dispensed with if the geometry allows tensile tests to be performed.

2 The notched bar impact test is only performed in the case of materials for which minimum values for the absorbed energy are stated for the starting material. Furthermore, specimens are only taken where the wall thickness is ≥ 6 mm and the geometry allows this to be done.

3 Starting with the second batch of a complete final inspection, the scope of hardness testing may be reduced by half if the hardness values measured for the first batch lie within the specified strength range.

4 The tensile test is to be carried out on the starting pipe.

5 For elbows made of 16 Mo 3, 13 Cr Mo 4-5 and 10 Cr Mo 9-10 conforming to EN 10028-2, the scope of hardness testing specified for test group IV is applicable.

C. Bolts and Nuts

1. Scope

1.1 These Rules are applicable to the manufac-ture, the mechanical properties and the testing of bolts and nuts for

– boilers, vessels, equipment and pipelines

– diesel engines, gears, shafting and propellers

– other components of the machinery plant for which proof of quality is required as specified in the Construction Rules

1.2 The choice of bolts and nuts, together with the form of the requisite material test certificate is set out in the individual Chapters of the Construction Rules and shall be stated in the purchase order.

2. Materials

2.1 Bolts and nuts are to be selected in accor-dance with recognized standards or the manufacturer's material specifications which have been approved by

GL. The steels used in the manufacture of bolts shall have a guaranteed impact energy. Under these condi-tions, the following materials may be considered:

2.1.1 Bolts and nuts conforming to ISO 898 (EN 20898-1 and -2) up to M39 threads. Exempted thereof are bolts of strength categories for which the standard gives no data in respect of impact energy.

2.1.2 Steels conforming to EN 10269 in conjunc-tion with DIN 267-13.

2.1.3 Steels conforming to DIN 267-13.

2.1.4 Stainless steels conforming to ISO 3506-1 and -2.

2.2 Bolts and nuts conforming to other standards or the manufacturer’s material specifications may be used, provided that GL has confirmed their suitability for the intended application. Unless otherwise speci-fied, the materials shall satisfy the requirements of 4.2.2, 4.2.3 and 4.2.4.

2.3 Free cutting steels with a high sulphur, phos-phorous or lead content may not be used.



C

3. Manufacture

3.1 Bolts and nuts may be manufactured by hot or cold forming or by machining. Cold formed bolts shall be subjected to subsequent heat treatment. The same applies to hot formed bolts and nuts with the exception of those made of quenched and tempered steels, provided that the latter are to be used at normal ambient temperatures and the hot forming process results in a uniform structure.

Surface smoothing and rolling of the thread are not regarded as cold forming within the meaning of this paragraph.

3.2 Bolts and nuts shall be in the heat-treated condition specified for the material in order to achieve the minimum values. The material shall not undergo unacceptable embrittlement up to the maximum tem-perature occurring in service. In the case of steels tough at sub-zero temperatures, it shall exhibit tough-ness even at the minimum design temperature. In the case of quenched and tempered steels, the tempering temperature shall always be a reasonable amount above the maximum in-service temperature.



The chemical composition shall satisfy the stipulations according to Section 3.B., Table 3.2 and the relevant standards or specifications respectively.


4.2.1 Bolts and nuts conforming to the standards specified in 2.1.1 to 2.1.4 shall meet the mechanical properties set out in these standards.

4.2.2 Steels tough at sub-zero temperatures for bolts and nuts which are to be used in the construction of gas tanks shall achieve an impact energy of at least 41 Joules at the prescribed test temperature using longitu-dinal Charpy V-notch specimens. The test temperature is to be determined in accordance with Section 3, F.

4.2.3 Steels for bolts and nuts with threads exceed-ing M39 as well as according to 2.2 shall have the characteristic values of the material and shall satisfy the following conditions in testing at room tempera-ture with longitudinal specimens.

– Elongation A ≥ 14 %,

– impact energy using Charpy V-notch specimens ≥ 52 Joules for quenched and tempered steels and ≥ 40 Joules for unalloyed steels.

4.2.4 Steels for bolts and nuts intended for engine foundation and with threads exceeding M39 as well as according to 2.2 shall have the characteristic values of the material and shall meet the requirements in testing at room temperature with longitudinal specimens according to Section 3, Table 3.5 and Table 3.6.

4.2.5 Steels or semi-finished products for founda-tion bolts of propulsion plants may be rolled as well as forged, but shall meet the requirements of 4.2.4.

For threads exceeding M39 forged semi-finished prod-ucts are to be used.

4.2.6 The impact energy values shall be average values obtained with three test specimens. Of these only one specimen may have a value which is below the average value but not less than 70 % of the aver-age value.

5. Testing of bolts

5.1 The manufacturer shall demonstrate the chemical composition of each heat according to C.7.

5.2 Tensile testing shall be performed on bolts and, for thread diameters ≥ 16 mm, the notched bar impact test shall also be carried out.

For preparing the specimens, bolts of the same type and strength category or made from the same material shall be grouped into test batches in accordance with Table 6.4.

If proof is furnished that the bolts in a delivery origi-nate from one heat and have undergone the same heat treatment, testing of four sets of specimens is suffi-cient, regardless of the quantity supplied.

Table 6.4 Batch sizes for the testing of mechani-cal properties

Quantity No. of sets of specimens for

mechanical testing

≤ 200 1

> 200 to ≤ 400 2

> 400 to ≤ 800 3

> 800 to ≤ 1200 4

> 1200 to ≤ 1600 5

> 1600 to ≤ 3500 6

> 3500 7

5.3 For the tensile test, specimens may be ma-chined from the sample material, or turned specimens of the type shown in Fig. 6.1 may be used.

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Fig. 6.1 Turned specimen

II - Part 1 GL 2009


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5.4 Where no heat treatment is performed follow-ing machining and the starting material is in the final heat treated condition, testing of the starting material with regard to demonstrating mechanical properties shall suffice. In this case steel bars from the same heat and with the same diameter and heat treatment are to be grouped into test batches of 5000 kg maximum. The performance of the tensile and notched bar impact tests require one set of test specimens to be taken from each test batch.

5.5 Where machining is followed by heat treat-ment, testing shall be performed in the same way as on the corresponding formed bolts as per 5.2.

5.6 The surface finish, dimensions and compli-ance with tolerances shall be verified by the Surveyor on at least 20 bolts and on at least 10 bolts in the case of batch sizes of ≤ 200. The manufacturer shall supply the gauges and callipers necessary for this purpose.

5.7 The uniformity of the delivery is to be dem-onstrated by the manufacturer by means of hardness tests. For this purpose, at least 20 bolts from each test batch are to be tested, and at least 10 bolts in the case of quantities ≤ 200. The results of the test are to be submitted to the Surveyor.

5.8 For bolts calculated for elevated temperature application on the basis of their high-temperature mechanical characteristics, the 0,2 % or 1 % proof stress shall be proved by a high-temerature tensile test performed on one specimen from each batch. The test shall be performed at the temperature which approxi-mates most closely to the level of the operating tem-perature, rounded off to the nearest 50 °C. The test may be dispensed with in the case of bolts to recog-nized standards, the high-temperature mechanical properties of which are regarded as proven.

6. Testing of nuts


The chemical composition shall satisfy the stipulations according to Section 3, B., Table 3.2 and the relevant standards or specifications respectively.

6.2 Nuts with nominal thread diameters of up to and including 39 mm are to be subjected to the expan-sion test using a mandrel with a 1:100 taper, see Fig. 6.2. Before testing, the nuts are to be drilled out to the thread outside diameter. The expansion shall be at least 6 % for nuts with a depth of ≥ 0,8 ⋅ nominal thread diameter d (at least 4 % for nuts with a depth of ≥ 0,5 to < 0,8 d). The numbers of test specimens shown in Table 6.4 are applicable, but for quantities of ≤ 200 at least 2 nuts shall be tested.

6.3 Nuts with nominal thread diameters > 39 mm are to be subjected to testing of the starting material as specified in 5.2 rather than the expansion test.

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Fig. 6.2 Expansion testing of nuts



C

6.4 The uniformity of the delivery is to be dem-onstrated by the manufacturer by means of hardness tests. For this purpose, at least 20 nuts from each test batch are to be tested, and at least 10 nuts in the case of quantities ≤ 200. The results of the test are to be submitted by the Surveyor.

6.5 The surface finish, dimensions and compli-ance with tolerances shall be verified by the Surveyor in the same way as described in 5.6.

7. Proof of chemical composition

7.1 For each delivery, the manufacturer shall provide the surveyor with a certificate giving the re-sults of the chemical analysis, heat numbers, dimen-sions and the as-delivered condition of the starting material processed by him. The name of the steel producer shall also be indicated in the certificate.

7.2 Alloy steel bolts and nuts shall be subjected by the manufacturer to appropriate tests for use of the correct material.


The manufacturer shall apply a suitable method of crack detection to the following bolts:

– turbine casing bolts

– bolts in main steam lines with temperatures > 350 °C

– propeller blade fixing bolts

and, for diesel engines with cylinder diameters > 400 mm, the following bolts:

– main bearing bolts

– connecting rod bolts

– cross-head bearing bolts

– cylinder cover bolts

9. Retests

9.1 Where one of the test specimens required for carrying out testing of mechanical properties does not satisfy the specified conditions, two additional test specimens or test sets of each are to be taken which shall satisfy the requirements. If these test samples also fail to meet the requirements, the test batch shall be regarded as unacceptable. The manufacturer may, however, heat treat the batch again and present it for retesting. If, however, these test specimens still fail to meet the requirements, the test batch shall be rejected for once and for all.

9.2 Where one of the test specimens required for carrying out hardness testing, non-destructive testing to check for surface defects, or for carrying out a di-mensional check fails to meet the requirements, a further random sample of 20 specimens (or 10 speci-mens in the case of batch sizes of ≤ 200) shall be taken of which all the test specimens shall satisfy the requirements. Otherwise the entire test batch shall be regarded as unacceptable. For the hardness test, the manufacturer may present this batch for retesting once he has carried out a further heat treatment. If these test specimens still fail to satisfy the requirements, the entire batch shall be rejected for once and for all.

10. Marking

10.1 Bolts and nuts are to be marked with the manufacturer's symbol and with the strength category or the steel grade, as well as with the heat number in the case of bolts of M52 size and above. Bolts of M52 size and above are to be individually marked with the GL stamp, which in all other cases is to be applied to the packing label.

10.2 Steel bars over 25 mm in diameter for the machining of bolts and nuts are to be marked at one end with the manufacturer's symbol, the steel grade and the GL stamp, and alloy steel bars are to be addi-tionally marked with the heat number. Where the diameter of the steel bars is 25 mm or less, it is suffi-cient to apply the corresponding markings to the label attached to the bundle of bars.

II - Part 1 GL 2009


C

Rule Change Notice regarding Section 1 of the GL Rules for Steel and Iron Materials (II-1-2) The following paragraphs of Section 1 have been subject to a Rule Change due to the IACS Unified Requirement W13:

Paragraph Edition 2009 Rules Change, effective 1 December 2011

A.6.1 Plates, strips and wide flats may be delivered with the minus tolerances shown in Table 1.1 or with no minus tolerance. Where no stipulations are made in the following individual rules, e.g. for shipbuilding steels in accordance with B., flat products for cargo tanks in accordance with F. and clad plates in accordance with H. the permitted minus tolerance is to be agreed when the order is placed.

Plates, strips and wide flats may be delivered either with the minus tolerances shown in Table 1.1 or with no minus tolerance. Where no stipulations are made in the following individual rules, e.g. for shipbuilding steels in accordance with B., flat products made from high-strength steels in accordance with D., flat products for cargo tanks in accordance with F. and clad plates in accordance with H. the permitted minus tolerance is to be agreed when the order is placed.

A.6.2 The thickness is to be measured at points located at least 25 mm from the edge of the product. Local depressions due to flaws and grinding marks arising from the remedying of defects are not taken into account, provided that they do not exceed the tolerances.

The thickness is to be measured at points located at least 25 mm from the edge of the product, if not stipulated otherwise in the individual rules, e.g. for shipbuilding steels in accordance with B. and flat products made from high-strength steels in accordance with D. Local depressions due to flaws and grinding marks arising from the remedying of defects are not taken into account, provided that they do not exceed the tolerances.

B.8. The provisions of A.6. are applicable. With regard to flat products (plates and steel wide flat) for shipbuilding use, Class B given in Table 1.1 may be considered as the permitted lower deviation from the nominal thickness. This means that the permitted lower deviation for all product thicknesses is a uniform – 0,3 mm.

The provisions of A.6. are applicable. With regard to flat products (plates and wide flats) for shipbuilding use, the permitted lower deviation from the nominal thickness for all product thicknesses is uniformly – 0,3 mm. However, the average thickness, calculated as arithmetic mean from the measurements made in accordance with 10.5.3, shall not be less than the nominal thickness. Alternatively Class C given in Table 1.1 may be considered as the permitted lower deviation from the nominal thickness. In this case the provisions of 10.5.3 are not applicable.

B.10.5 Inspections of surface finish and dimen-sional checks are the responsibility of the rolling mill. Acceptance testing by the Surveyor does not release the manufacturer from this responsibility.

10.5.1 Inspections of surface finish and dimensional checks are in the responsibility of the rolling mill. Acceptance testing by the Surveyor does not release the manufacturer from this responsibility. 10.5.2 The procedure and the records of measurements are to be made available to the Surveyor and copies provided on request. 10.5.3 For plates and wide flats, at least two lines along the longitudinal edge of the product are to be selected for the thickness measurements and at least three points on each selected line are to be selected for thickness measurement. If more than three points are taken on each line the number of points shall be equal on each line.

1 of 2

2 of 2

Paragraph Edition 2009 Rules Change, effective 1 December 2011

B.10.5 For automated methods, the measuring points at sides are to be located not less than 10 mm but not more than 300 mm from the transverse or longitudinal edges of the product. For manual methods, the measuring points at sides are to be located not less than 10 mm but not more than 100 mm from the transverse or longitudinal edges of the product.

D.3.6 A.6. applies, with the following addition: For the minus tolerance applicable to the nominal thickness, the values stated under Class A in Table 1.1 apply, unless otherwise specified in the order

The provisions of A.6. are applicable. Unless otherwise specified in the order, the permitted lower deviation from the nominal thickness for all product thicknesses is uniformly – 0,3 mm. However, the average thickness, calculated as arithmetic mean from the measurements made in accordance with 4.5.3, shall not be less than the nominal thickness. Alternatively Class C given in Table 1.1 may be considered as the permitted lower deviation from the nominal thickness. In this case the provisions of 4.5.3 are not applicable.

D.4.5 The manufacturer shall inspect the condition of the surface and the dimensions of the product and shall then submit the products to the Surveyor for inspection.

4.5.1 Inspections of surface finish and dimensional checks are in the responsibility of the rolling mill. Acceptance testing by the Surveyor does not release the manufacturer from this responsibility. 4.5.2 The procedure and the records of measurements are to be made available to the Surveyor and copies provided on request. 4.5.3 For plates and wide flats, at least two lines along the longitudinal edge of the product are to be selected for the thickness measurements and at least three points on each selected line are to be selected for thickness measurement. If more than three points are taken on each line the number of points shall be equal on each line. For automated methods, the measuring points at sides are to be located not less than 10 mm but not more than 300 mm from the transverse or longitudinal edges of the product. For manual methods, the measuring points at sides are to be located not less than 10 mm but not more than 100 mm from the transverse or longitudinal edges of the product.


3 Welding

1 General Requirements, Proof of Qualifications, Approvals

Edition 2000

The following Rules come into force on July 1st , 2000




Phone: +49 40 36149-0 Fax: +49 40 36149-200

[email protected]

www.gl-group.com




Table of Contents

Section 1 General Rules

A. General ....................................................................................................................................... 1- 1

B. Other Rules, Standards and Specifications ................................................................................. 1- 1

C. Information in Working Documents ........................................................................................... 1- 2

D. Materials, Weldability ................................................................................................................ 1- 2

E. Welding Consumables and Auxiliary Materials ......................................................................... 1- 2

F. Quality Assurance, Responsibility .............................................................................................. 1- 3

G. Inspection Tests, Liability .......................................................................................................... 1- 4

Section 2 Requirements for Welding Shops, Approval

A. Approval of Welding Shops ....................................................................................................... 2- 1

B. Requirements for Welding Shops ............................................................................................... 2- 2

C. Inspection of Welding Shops ..................................................................................................... 2- 3

D. Welding Procedure Tests ........................................................................................................... 2- 3

E. Certification of Approvals, Certificates according to EN 729/ISO 3834 ................................... 2- 4

Section 3 Welder´s Qualification Tests

A. General ....................................................................................................................................... 3- 1

B. Testing Bodies, Certificates ....................................................................................................... 3- 2

C. Scope of Testing and Range of Approval ................................................................................... 3- 2

D. Performance of Welder's Qualification Tests ............................................................................. 3- 3

E. Period of Validity, Repeat Tests ................................................................................................ 3- 3

F. Other Welder's Tests .................................................................................................................. 3- 4

Section 4 Welding Procedure Tests, Production Tests

A. General ....................................................................................................................................... 4- 1

B. Performance of Welding Procedure and Production Tests ......................................................... 4- 2

C. Evaluation of Test Results, Requirements, Repeat Test Specimens, Test Reports ..................... 4- 5

D. Limits of Application, Period of Validity ................................................................................... 4- 5

Section 5 Welding Consumables and Auxiliary Materials

A. General ....................................................................................................................................... 5- 1

B. Covered Electrodes for Manual Metal-Arc Welding of Hull Structural Steels .......................... 5- 8

C. (Flux-cored) Wire-Gas Combinations and Flux-Cored Wire Electrodes for Semi-Mechanized Welding of Hull Structural Steels .......................................................................... 5- 15

D. Wire-Flux Combinations for Submerged-Arc Welding of Hull Structural Steels ...................... 5- 18

E. Welding Consumables and Auxiliary Materials for Electrogas and Electroslag Welding of Hull Structural Steels ................................................................................................................. 5- 23

F. Welding Consumables and Auxiliary Materials for High-Strength (Quenched and Tempered) Structural Steels ....................................................................................................... 5- 25

G. Welding Consumables and Auxiliary Materials for Steels Tough at Subzero Temperatures ........ 5- 28

H. Welding Consumables and Auxiliary Materials for High-Temperature Steels ........................... 5- 29

II - Part 3 GL 2000


I. Austenitic and austenitic-ferritic welding consumables and auxiliary materials for stainless steels, non-magnetic steels and nickel alloy steels tough at subzero temperatures ..................... 5- 33

J. Welding Consumables and Auxiliary Materials for Aluminium Alloys ...................................... 5- 38

K. Welding Consumables and Auxiliary Materials for Copper and Copper Alloys ........................ 5- 41

L. Welding Consumables and Auxiliary Materials for Nickel and Nickel Alloys ........................... 5- 44

Section 6 Overweldable Shop Primers

A. General ........................................................................................................................................ 6- 1

B. Testing and Approval of Shop Primers ....................................................................................... 6- 1

C. Supervising the Use of Shop Primers, Production Tests ............................................................. 6- 2

Annex A Application for Approval

Annex B Description of Welding Shop

Annex C Assessment Form for Welder Qualification Test Certification

Annex D Welding Procedure

Annex E Welding Consumables and Auxiliary Materials

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Table of Contents II - Part 3GL 2000

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Section 1 General Rules Chapter 1Page 1–1

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Section 1

General Rules

A. General

1. Scope

1.1 These Rules apply to all welding work per-formed in the course of new construction, conversionor repairs carried out on ships and their machineryinstallations, including steam boilers, pressure vesselsand pipelines, for which an application for classifica-tion has been submitted to Germanischer Lloyd (GL)or which have been classified by GL.

Note:

The terms "welding", "welding work", “welding proc-ess” etc. used in these rules also cover all other ther-mal and/or mechanized joining processes such asbrazing which, because they are deemed as “specialprocesses” under the terms of the quality assurancestandards, require pre-qualification which has to becarried out by qualified personnel and constantlymonitored. These rules shall be applied in an analo-gous manner to these processes. Where no specialprovisions are made in the following paragraphs, thenature and scope of the quality assurance measuresrequired will be specified by the Society on a case-by-case basis.

1.2 They also apply to all welding work on com-ponents, installations or implements for which theSociety has issued rules, regulations or other technicaldirections in which reference is made to these Weld-ing Rules.

1.3 These Welding Rules shall be applied inanalogous manner where other rules, regulations ortechnical directions issued by the Society contain nospecial instructions with regard to welding work.

2. Application in other fields

These Welding Rules may be applied in analogousmanner to welding work carried out on structures andcomponents other than those mentioned under 1., thesupervision and inspection of which is the concern ofthe Society. Where necessary, appropriate arrange-ments shall be made with the Society.

3. Exceptions to these Rules

Exceptions to these Welding Rules require the consentof the Society's head office in each individual case.

4. Alterations and additions

The Society reserves the right to alter or add to theseRules from time to time, should this prove necessaryon the basis of more recent knowledge or operatingexperience.

B. Other Rules, Standards and Specifications

1. Other relevant standards

1.1 The standards or other technical directionsmentioned in the following sections form an integralpart of these Welding Rules and shall also be com-plied with. The same applies to the working docu-ments, e.g. drawings, welding specifications, etc.approved by the Society.

1.2 Where the following sections refer to stan-dards in which a date is specified, the current versionshall apply. Where no dates are specified, the versionof the standards which shall be applicable shall be theone valid at the time that these rules were issued. Theuse of later versions of these standards is subject to theconsent of the Society.

1.3 Where the following sections and chaptersrefer to both EN and ISO standards, and if, where theyare both specified, the standards are not identical, theEN standards shall take precedence. Where the twostandards are identical, either the EN or the ISO stan-dard may be used.

1.4 The application of other rules, standards,regulations or other technical directions is subject tothe consent of the Society's head office in each indi-vidual case. The Society may make any such approvalconditional upon construction and dimensioning alsobeing subject to these directions.

2. Differences in requirements

2.1 If there are differences in requirements be-tween these Rules and other relevant standards orspecifications, the requirements of these WeldingRules shall take precedence, unless otherwise stipu-lated.

2.2 If there are differences between the differentlanguage versions of these rules or difficulties in in-terpretation, the German language version shall takeprecedence in each case.

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C. Information in Working Documents

1. Drawings, other working documents

1.1 The drawings and other working documentsto be submitted before commencing the fabricationwork must contain all the necessary details for thepreparation, execution and, where applicable, theinspection of the welds.

This information shall in particular include details of:

– Base materials, shapes and dimensions of prod-ucts

– Welding processes, welding consumables andauxiliary materials

– Shapes and dimensions of welds

– Preheating and heat input during welding

– Heat treatment after welding

– Subsequent treatment of the welds

– Nature and scope of inspections

– Requirements applicable to the welded joints(e.g. quality grade, weld performance, evalua-tion category or the like).

1.2 Provided that in the fabrication of ship'sstructures, the materials, welding processes, weldingconsumables, auxiliary materials and the shapes anddimensions of welds conform to normal shipbuildingpractice, these Rules and the approvals, these detailsneed not be specified.

2. Additional information and documentation

For particular structures (e.g. liquefied gas tanks),materials (e.g. quenched and tempered structural steelsand clad plates) or welding processes, the followingadditional information and documentation shall beprovided as necessary:

– Weld preparation, assembly, auxiliary (tack)welds

– Welding positions, welding sequence (drawings)

– Weld build-up, number of passes

– Heat input during welding (heat input per unitlength of weld)

This information shall be combined in a weldingspecification (see Annex D). For test schedules andspecifications for non-destructive testing, please referto Chapter 2, Section 4.

D. Materials, Weldability

1. All materials shall be of proven weldability.They shall be chosen in accordance with the intendedapplication and the conditions of service and shallcomply with the requirements stated in Part 1, Metal-lic Materials. Their properties shall be documented tothe specified extent by test certificates, e.g. in confor-mity with EN 10204.

Note:

The hull structural steels and rolled products de-scribed in Part 1, Metallic Materials, for the manu-facture of steam boilers, pressure vessel, pipelines andmachinery are deemed to be of proven weldability.

2. If, not withstanding para. 1., materials are tobe welded whose properties are not described in theSociety's Rules for Materials, the welding shop con-cerned shall furnish proof of their weldability (e.g. byreference to existing standards) or submit special ma-terial specifications for approval. If there is doubt as tothe weldability of a material, the welding shop shallspecially demonstrate this in the course of the weldingprocedure tests.

3. The welding shop shall ensure that only ma-terials which meet the requirements of 1. and 2. areused for both original and replacement supplies, andshall furnish proof thereof to the Surveyor on request.

E. Welding Consumables and Auxiliary Ma-terials

1. The welding consumables and auxiliary ma-terials shall enable a welded joint to be made which issuited to the base material and the operating condi-tions. They shall have been tested for product suitabil-ity in accordance with Section 5 and approved for theapplication in question. This provision applies in ananalogous manner to brazing metals.

2. Approval shall as a rule have been given bythe Society. If, in special cases, e.g. repairs, no weld-ing consumables which have been tested by the Soci-ety are available, welding consumables approved byother recognized testing bodies may be used with theSociety's consent. Relevant proof of this must besubmitted to the Society’s surveyor.

3. The welding shop's supervisors shall ensurethat only tested welding consumables and auxiliarymaterials which have been approved by the Societyare used and shall furnish proof thereof to the Sur-veyor on request.

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Section 1 General Rules Chapter 1Page 1–3

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F. Quality Assurance, Responsibility

1. Compliance with Rules, Quality Inspec-tions

1.1 Shipyards or welding shops are responsiblefor ensuring that the welding work conforms to theseand any supplementary rules as applicable, the ap-proved working documents, any conditions as may bestated in the approvals, good shipbuilding practice,and also the state of the art technology relating towelding.

1.2 Shipyards or welding shops must ensure, bymeans of regular in-house quality inspections duringthe production process and at the end of the weldingwork, that such work has been properly and expertlyexecuted. The responsibilities of the welding supervi-sors are also covered in EN 719/ISO 14731. The teststo be performed by GL surveyors shall not relieve thewelding shop of this responsibility.

1.3 The range and extent of the quality inspec-tions required is determined by the structure in ques-tion. In each case, however, it is necessary to ensurethat the specified materials, welding consumables andauxiliary materials are used and that weld preparation,assembly, performance of tack and welding work,together with the accuracy to size and completeness ofthe components and welded joints meet the require-ments.

1.4 Following inspection by the welding shopand any repairs which may be necessary, the compo-nents must be presented to the Society’s Surveyor forinspection at appropriate stages of construction, easilyaccessible and as a rule unpainted. The Surveyor mayreject those components which have been inade-quately inspected by the welding shop and specify thata component be presented again after a successfulinspection by the welding shop and, where necessaryrepairs.

2. Placing subcontracts

2.1 When placing orders with subcontractors,independent branch companies or suppliers as well asoutside companies working in the welding shop whoare themselves approved (so-called "contract compa-nies", cf. note to paragraph A.1.1 in Section 2) the"prime contractor" must ensure that the provisionsstated in 1. are also complied with by the "subcon-tractors".

2.2 Where the outside companies working in thewelding shop are not themselves approved or wherecontract labour is used, the welding shop placing thecontract shall be responsible for ensuring that theconditions stated in 1. are complied with and that thequality inspections are performed. The Society shall

be notified of the placing of subcontracts or the use ofcontract labour.

3. Deviation from approved working docu-ments, repairs

3.1 If alterations to the design compared with theapproved drawings or deviations from approved fabri-cation procedures become necessary, the welding shopshall promptly obtain the Society’s consent thereto.The Society’s Surveyor shall be notified of any repairswhich become necessary during fabrication.

3.2 If, due to inadequate or incorrect informationin the production documents (e.g. workshop draw-ings), the quality or functional capability of a compo-nent cannot be guaranteed or is doubtful, the Societymay require appropriate repairs to be carried out.

3.3 This shall apply in an analogous manner tosupplementary or additional components (e.g. rein-forcements) even if these are not specified during theexamination of the drawing or could not be specifiedowing to a lack of detail shown in the "class plans"(cf. Construction Rules I – Part 1, Chapter 1, Section1, G.).

4. Marking and identification of materials

4.1 The materials shall be marked in such a waythat they can be identified and matched up with thetest certificates even during and after fabrication.

4.2 If the marking is likely to be erased duringmanufacture, the welding shop shall promptly see to itthat it is transferred to another part of the product.This can be dispensed with in the case of small partsof minor importance such as ribs or bracings, providedthat any confusion of materials can be prevented byoperational means.

5. Marking of welds

5.1 In the fabrication of steam boilers and vesselsunder internal pressure, each weld section shall bemarked with the symbol of the welder who executedit. This may be dispensed with if the welding shopsupervisory staff keep a record of the names of thewelders who execute the individual weld sections.

5.2 In special cases, the Society may also requiremarking or record-keeping as described in 5.1 forother components or their welded joints.

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G. Inspection Tests, Liability

1. Presentation of components

The welding shop shall be obliged to present the com-ponents to the Surveyor for the required intermediateand final inspections. Steps shall be taken to ensureunimpeded access to the welds. The welds shall not betreated with coatings or preservatives which make itdifficult or impossible to assess the condition of thewelds.

2. Supplying of test documentation

For the inspections, all the manufacturer's records anddocuments concerning the quality assurance measuresundertaken by him shall be submitted. These includein particular:

– Drawings (approved if required) and otherworking documents

– Material test certificates

– Welder's and welding procedure test certificates

– Test reports and films of the non-destructivetests

– Certificates of hot-forming and heat treatment,where applicable

– Results of production tests, intermediate resultsif necessary.

3. Subsequent defects

3.1 The Society gives no guarantee that the prod-ucts, welded structures or components tested by itsSurveyor to the extent laid down (normally randomtests) conform to the requirements in every respectand that their manufacture has been performed cor-rectly and in accordance with the tested procedures.

3.2 Products or welded structures which provedefective in subsequent use or in the operation orprocesses which exhibit deficiencies in use may berejected even if an earlier inspection was satisfactory,if it is not possible to remedy the defect or deficiency.

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Section 2 Requirements for Welding Shops, Approval Chapter 1Page 2–1

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Section 2

Requirements for Welding Shops, Approval

A. Approval of Welding Shops

1. General

1.1 Shipyards and welding shops, includingbranches and subcontractors, wishing to performwelding work covered by these Rules must have beenapproved for this work by the Society (cf. Chapter 3).The preconditions for this approval are that the shopssatisfy the requirements under B., have been inspectedby the Society in accordance with C. and, where nec-essary, have carried out welding procedure tests inaccordance with D.

Note:

The term “welding shop” used in the following para-graphs is understood to mean the welding productionplant which, due to its space and organisational fa-cilities, can be regarded as an independent unit.Branches and subcontractors shall generally be re-garded as “independent” facilities which have to meetthe requirements stated below. In particular, eachwelding shop must have available its own permanentin-house welding supervisory staff (cf. B.2.) Outsidecompanies working in welding shops may be approvedas independent companies. For details of this andcontract labour, cf. Section 1, F.2.

1.2 Any approval in accordance with 1.1 coversthe most essential welding quality requirements inaccordance with the standards EN 729/ISO 3834. Forcertification under the terms of these standards, therequirements set out in 2.2 and 3.2 must also be met.These additional requirements shall be regarded ashaving been met when the welding shop has in place acertified quality assurance system in accordance withthe series of standards EN 29000/ISO 9000.

1.3 In individual valid exceptions, e.g. in the caseof repairs, the Society may grant approval for weldingwork to be executed even without approval beinggranted to the welding shop, subject to a time limitand restricted to a specific structure, if the weldingshop pre-conditions have been specified for such workand the quality of the welds performed is demon-strated by relevant tests, e.g. non-destructive and/orproduction tests.

2. Application for approval

Introductory remark:

Where no special provisions are given in the followingparagraphs or, in an individual case, no other ar-rangements are made, the provisions for "Approval"set out in accordance with these rules shall also applyin an analogous manner to "Certification" in accor-dance with EN 729/ISO 3834.

2.1 Approval shall be applied for in writing to theSociety's head office. The application shall contain thefollowing details, which shall be related to each otheras far as possible, (cf. Description of Welding Shop,Annex B, item 2.), of the scope of the desired ap-proval:

– Nature of the structure and/or components

– Materials and dimensional ranges

– Welding procedures and positions

– Heat treatments (if necessary)

– Weld factor (for pressure vessels).

2.2 If a certificate of compliance with the weld-ing quality requirements stipulated in EN 729/ISO3834-2, -3 or -4 is required over and above approval inaccordance with these Rules for Welding, this must beexpressly noted in the application for approval.

3. Approval documents

3.1 Welding shops applying for approval to carryout welding work must submit the following docu-ments to the Society's head office with their applica-tion for approval (cf. Annex A):

– A description of the welding shop; cf. the formin Annex B.

– Copies of the qualification documents of thewelding supervisor(s)

– Copies of the valid welder's certificates or a listof the qualified welders (testing standard, testingbody, date of testing, test category, date of lastretest) signed by the Surveyor.

– Copies of documentation as proof of the qualifi-cation of supervisory and test personnel, as ap-propriate.

– Copies of reports of welding procedure testsperformed elsewhere, including the approvalsgranted, as appropriate.

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3.2 For certification in accordance with 2.2, in-formation and documents relating to the elementsspecified in Annex B to EN 729-1/ISO 3834-1 for therespective grade of requirement (EN 729-2/ISO 3834-2 = full, -3 = standard, or -4 = basic quality require-ments) must also be enclosed with the application forapproval (e.g. in the form of relevant procedure in-structions):

– contract review

– design review

– treatment of subcontractors

– equipment maintenance

– quality inspections

– nonconformances

– calibration

– identification

– traceability

If the welding shop operates a certified quality assur-ance system conforming to the series of standards EN29000/ISO 9000, the QA manual and - if specified inAnnex B to EN 729-1/ISO 3834-1 - documentationrelating to the quality assurance measures performed(quality reports) must be submitted to the Society forinspection in place of the above information anddocuments.

4. Period of validity of approval, renewal

4.1 An approval granted according to these Rulesor certification in accordance with EN 729/ISO 3834shall be valid for three years. Provided that weldingwork is constantly performed under the Society's su-pervision during the validity of the approval and thatthe preconditions on which approval was granted havenot changed, approval may be extended on applicationby the welding shop for further three years subject toan appropriate inspection.

4.2 If no welding work has been carried out un-der the Society's supervision for more than a year, anapplication for renewal of the approval, enclosingupdated information as specified in 3., must be madeno later than the end of the 3-year period of validity.Approval may only be renewed if the necessary pre-conditions continue to apply, which shall be verifiedby a re-inspection of the welding shop. The approvalmay then be renewed for a further period of threeyears.

5. Changes, revocation

5.1 If the preconditions under which approvalwas granted change, e.g. through the use of untestedwelding procedures, materials and/or welding con-

sumables, or if changes are made to the welding shopsupervisory staff, the Society shall be notified volun-tarily. As a rule, this necessitates a revision of theapproval.

5.2 An approval shall cease to be valid if thepreconditions under which it was granted cease toapply. If serious defects are detected in the compo-nents or the welds, the Society is entitled to carry outinterim re-inspections of the production facilities andmay, if necessary, revoke the approval.

B. Requirements for Welding Shops

1. Technical equipment

1.1 Welding shops must have at their disposalsuitable workshops, equipment, machinery and jigs ona scale necessary for proper performance of the weld-ing work. This includes, for example, the provision ofstorage facilities and baking equipment for the weld-ing consumables and auxiliary materials, preheatingand heat treatment equipment, testing appliances andequipment, and means of weather protection for car-rying out welding work in the open air.

1.2 Equipment and facilities not belonging to thewelding shop itself, e.g. testing appliances, may betaken into account when evaluating the capabilities ofa welding shop, provided that the preconditions neces-sary to proper fabrication and testing are satisfied andthat such equipment is available without restriction.

2. Welding shop supervisory staff

2.1 Welding shops or branches (cf. note to A.1.)shall have at least one fully qualified welding supervi-sor, who is responsible for ensuring that the weldingwork is competently performed. Welding supervisorsshall have training and experience corresponding tothe scope of the fabrication work and shall provide theSociety with the necessary documentary proof thereof.

2.2 The names of the welding supervisor incharge and his deputy must be notified to the Society,cf. Annex B "Description of the Welding Shop", 3. Ifthe supervision role is carried out by more than oneperson, the responsibilities and tasks of each personmust be established and specified. The welding super-visor in charge and his deputy shall be recognised bythe Society as part of the approval for the weldingshop.

2.3 The following persons shall be appointed aswelding supervisors depending on the nature andscope of the work:

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Section 2 Requirements for Welding Shops, Approval Chapter 1Page 2–3

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– Welding engineers 1 for fabrication of impor-tant components of the hull structure and of off-shore installations, also of handling equipment,steam boilers, pressure vessels, pressure linesand engine and transmission components

– Welding specialists 2 for fabrication of simpleror less heavily stressed components.

For information relating to the qualification of thewelding supervisory staff, their tasks and responsibili-ties, cf. EN 719/ISO 14731.

2.4 The welding supervisor(s) shall be perma-nently employed by the welding shop. Supervision ofthe welding work by outside staff is not acceptable.

3. Welders and operators

3.1 Welding shops shall be staffed with qualifiedwelders and, for fully mechanized and automaticwelding equipment, adequately trained operators. Therequired number of qualified welders is determined bythe size of the welding shop and the scope of thewelding work to be performed under the Society'ssupervision. However, a minimum of two qualifiedwelders are required for each welding process.

3.2 Welders for manual and semi-mechanizedwelding must have passed a test in accordance withSection 3 and in conformity with a recognized stan-dard (e.g. DIN 8561, EN 287/ISO 9606 or ASMESection IX as applicable). The test shall cover theconditions likely to occur in the fabrication work withregard to the process(es), base material, welding con-sumable and welding position(s). The production oftest pieces in a successfully completed welding proce-dure or production test may be taken as proof of man-ual skill for testing of welders, cf. Section 3, B.4.

3.3 Operators of fully mechanised or automaticwelding equipment and of welding robots must havebeen trained in the use of the equipment. They mustalso be capable of setting or programming and oper-ating the equipment in such a way that the requiredweld quality is achieved. The qualification of suchpersonnel must be demonstrated in accordance withEN 1418/ISO 14732 on welded test pieces, e.g. inwelding procedure or fabrication tests or by means ofrandom tests and operational tests as applicable(please refer to the standards).

––––––––––––––1 e.g. professional welding engineers as defined in the guidelines

of the European Welding Federation (EWF) or engineers withan equivalent level of knowledge

2 e.g. welding technicians or welding experts as defined in theEWF guidelines or, if necessary, other persons with suitableknowledge

4. Test supervisory staff and test personnel

Where the welding shop has its own test supervisorystaff and test personnel (cf. Chapter 2, Section 4, C.),documentary proof of their qualification (e.g. certifi-cates conforming to EN 473/ISO 9712) shall be sub-mitted to the Society.

C. Inspection of Welding Shops

1. Shop inspection

Before starting fabrication work, it shall be proved tothe Society's Surveyor in the course of an inspectionof the welding shop that the requirements applicableto the technical equipment as stated in B.1. are satis-fied. For this purpose the Surveyor shall be givenaccess to all departments and laboratories relevant tofabrication and testing. The fabrication and qualitycontrol procedures shall also be described and ex-plained to him if he so requests. For certification ac-cording to EN 729/ISO 3834, compliance with theadditional quality requirements stated in the standardsshall be demonstrated to the Surveyor (cf. A.3.2).

2. Submission of documentation

As part of the welding shop inspection procedure,originals of all documents necessary in order to evalu-ate the fabrication and quality assurance proceduresshall be submitted to the Surveyor. These especiallyinclude the welding supervisor’s qualification docu-ments, welder's certificates, reports on previouswelding procedure tests, and results of quality testsand welder's retests. For certification according to EN729/ISO 3834, compliance with the additional qualityrequirements stated in the standards shall be demon-strated to the Surveyor (cf. A.3.2).

D. Welding Procedure Tests

1. General provisions

1.1 If welding procedure tests are required, theirsuccessful performance shall be a further preconditionfor the approval of a welding shop or for extending itsapproval. Requirements for the performance of thesetests and requirements applicable to test results aregiven in Section 4 and in Chapter 3, Section 1 to 5.

1.2 Welding procedure tests shall be performedin such a way that the conditions of fabrication can becovered with regard to materials, welding processes,welding positions, welding consumables and auxiliarymaterials, wall thicknesses, shapes of welds and heattreatments. The properties of the base materials for thetest pieces shall be documented by test certificates.

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2. Scope of the welding procedure test

Note:

Please refer to the detailed information given inSection 4, D.

2.1 In general, a welding procedure test is validonly within the limits specified in the approval and isnot transferable from the welding shop where it isperformed to a different welding shop. The Societymay permit exceptions in the case of a nearby branchwelding shop which is under the constant supervisionof the main welding shop, where the same fabricationconditions prevail and where the same welding proc-esses are used.

2.2 Welding procedure tests performed in aworkshop are in general not simultaneously valid forwelding in the field. In such cases, the welding proce-dure test must be repeated in whole or in part underfield conditions as determined by the Society. TheSociety may waive the repeat testing by prior agree-ment if the properties of the field welds are docu-mented by production tests.

3. Recognition of other tests

Welding procedure tests performed under the supervi-sion of other testing bodies which are independent ofthe works may be recognized in full or in part by theSociety at the welding shop's request if this is accept-

able on the basis of the test results. In such a case, thecomplete test reports and the approval certificate ofthe other testing body shall be submitted to the Societyfor evaluation.

E. Certification of Approvals, Certificatesaccording to EN 729/ISO 3834

1. The Society issues certificates for the ap-proval of welding shops to carry out welding work andfor welding procedure tests if the requirements set outin these rules are satisfied in the tests. These weldingshop and welding procedure approvals are valid withinthe limits stated in the certificates.

2. Where proof has been furnished that the ad-ditional requirements listed in A.3.2 according to EN729/ISO 3834 have been met, the Society issues acertificate based on this in accordance with this stan-dard.

3. If previously issued approval certificates arereplaced or supplemented by more recent ones (cf.A.5.1) and the details in the more recent approvalcertificates contradict those of previous approvals, thedetails in the more recent certificate shall be valid.This applies especially to the range of application, e.g.for a specific welding process.

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Section 3 Welder´s Qualification Tests Chapter 1Page 3–1

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Section 3

Welder´s Qualification Tests

Preliminary remarks:

The following rules for the testing of welders conformto or make use of the standards EN 287 resp. ISO9606, Parts 1 (Steel) and 2 (Aluminium). For othernon-ferrous metals, DIN 8561 shall continue to applyuntil the corresponding parts of EN 287 and ISO 9606come into force.

Where no details of the tests are specified in thefollowing Rules, the tests shall be performed inaccordance with these standards. References in thetext also refer to these standards unless otherwisespecified.

Some deviations from the standards have been madewith regard to the testing of steel welders (EN 287-1resp. ISO 9606-1), especially in relation to the rangesof approval for base materials and weld types whichhave been somewhat narrowed down compared withthe standards. As far as the testing of non-ferrousmetal welders is concerned, it is chiefly the weld formswhich differ from those of the standard.

A. General

1. Required testing (welding processes)

1.1 Welder's qualification tests are required forall welders who are to perform welding work usingmanually guided welding appliances (as for manualmetal arc welding or semi-mechanized gas-shieldedmetal arc and/or welding using flux-cored electrodes)and where the quality of the welded joints dependsmainly on the manual skill of the welder.

1.2 For welders who are required to performwelding work on steam boiler installations, the "Tech-nische Regeln für Dampfkessel" (Technical Rules forSteam Boilers) TRD 201, Annex 2, Guidelines fortesting and supervising boiler welders, shall also becomplied with. The inclusions and exclusions speci-fied in these Regulations shall apply hereto.

1.3 The qualification of operators of fully mecha-nized and automatic welding equipment and of weld-ing robots, shall be demonstrated in accordance withEN 1418/ISO 14732 on welded test pieces e.g. as partof the welding procedure or fabrication tests or by

means of random tests and operational tests (cf. thestandards).

2. Training, manual skill, knowledge

2.1 Welder's qualification tests may only be takenby welders who have received appropriate previoustraining (both practical and theoretical) and who havehad sufficient opportunity to practise the craft.

2.2 Besides the necessary manual skill, thewelder shall also possess the professional knowledgeenabling him to perform the welding work compe-tently and safely. Cf. the relevant information in thestandards.

Note:

In accordance with the foreword to DIN EN 287 re-lating to German practice, the job knowledge testsdescribed in Annex D of the standard (for informationpurposes) are required for welders taking the test (andemployed) in the Federal Republic of Germany.Welders who work in the Federal Republic of Ger-many and who have not taken a job knowledge testmust demonstrate that they at least have knowledge ofthe area of health and safety at work and accidentprevention in accordance with the legislation applica-ble at the time. Such proof is the responsibility of thewelding shop.

3. Lists of welders, symbols

3.1 Welding shops are required to maintain listsor files which furnish information about the number,names (code number) and test scope of the weldersand the dates of their initial and repeat tests (cf. AnnexC "Assessment Form"). These lists shall be submittedto the Society for examination on demand togetherwith the relevant original documentation or, whereappropriate, together with the description of the weld-ing shop (cf. Section 2, A.3.).

3.2 Each welder shall be assigned an unmistake-able symbol, which shall be recorded in the testingdocumentation (certificates, lists, etc.). The Societymay in addition - depending on the application - re-quire the components and welds to be marked with thesymbol of the welder who performed the work; cf. alsoSection 1, F.5.

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B. Testing Bodies, Certificates

1. Initial tests in the welding shop

The initial testing of welders in the welding shop is tobe conducted by the welding supervisory staff in thepresence of the Society's representative. Followingsubmission of the assessment forms completed by thewelding shop and initialled by the Surveyor (cf. AnnexC), these tests will be confirmed by the Society’s headoffice in the form of test certificates.

2. Repeat tests in the welding shop

2.1 Repeat tests taken by welders who have beencertified by the Society or by those certified by otherrecognized testing bodies and recognized by the Soci-ety may be conducted independently by the weldingengineer recognized by the Society in conjunctionwith the approval granted to the welding shop. Testsconducted by other welding supervisors shall be car-ried out in the presence of the Society's representative.

2.2 The extension of the validity of a test certifiedby the Society by a further two years may, however,only be authorised by the Society. For this purpose, afull set of test documentation (welding procedurespecification, assessment form and test certificate)must be submitted to the Surveyor. Cf. E.4.

3. Tests conducted by other testing bodies

Welder's qualification tests conducted by other testingbodies (e.g. welding training and testing establish-ments or welding training establishments, cf the fore-word to DIN EN 287) which are independent of thewelding shop and which are recognized by the Societywill be recognized by the Society subject to the testcategories specified below. Such recognition is subjectto the submission to the Society of a full set of testdocumentation, as described in 2.2 above.

4. Tests conducted as part of the weldingprocedure tests

The testing of welders may be included in the weldingprocedure tests (cf. Section 4, B.5.3) and their nameswill then be included in the welding procedure ap-proval. A welder’s qualification test certificate con-forming to the standards may, however, only be issuedprovided that all the provisions of the standards, e.g.scope of test and jobknowledge testing, have been metand that this is recorded in an assessment form whichhas been completed accordingly (cf. Annex C).

C. Scope of Testing and Range of Approval

1. Base materials

1.1 In the case of base materials - and in contrastto the provisions of the standards EN 287-1 resp. ISO9606-1 - higher-strength (hull structural) steels with aminimum yield strength ReH of up to 355 [N/mm²] (upto 360 [N/mm²] in the case of pipe-grade steels) shallonly be considered, following testing, as being in-cluded in the material category W 01 if the test (usingthe appropriate welding consumables) was also per-formed on a higher-strength steel.

1.2 Unless otherwise stipulated by the Society ina particular case, the test categories conforming to thestandards shall also apply to the base materials. TheSociety may, however, require a more precise subdivi-sion of the categories in accordance with the note toChapter 3, Section 1, F.2.

2. Joint types

2.1 In the case of joint types - and in contrast tothe provisions of the standards - the test performed onbutt welds does not also includes fillet welds. Wherewelders are required to lay down butt welds as well asfillet welds, both weld forms must be included in thetest.

2.2 Unless otherwise stipulated by the Society ina particular case, the test categories conforming to thestandards shall also apply to the weld forms.

3. Other inclusions and exclusions

Unless otherwise specified by the Society in a par-ticular case, the inclusions and exclusions stipulated inthe standards shall otherwise apply.

4. Deviations, special features, particularapplications

4.1 If deviations from the standards or theserules for testing are to be included in the welder’squalification test, this shall be agreed with the Societybeforehand. The kind of the deviation or special fea-ture is to be indicated on the assessment form under"Remarks" and will be noted in the test certificate.

4.2 Welder's qualification tests for particularapplications (particular materials, shapes of weld,welding processes) which are not covered by the testsand work assignments described above and in thestandards (e.g. for clad plates or offshore pipe junc-tions) shall be carried out according to a test scheduleto be agreed with the Society on a case-by-case basis.

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Section 3 Welder´s Qualification Tests Chapter 1Page 3–3

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D. Performance of Welder's QualificationTests

1. Welding of test pieces, Welding ProcedureSpecification (WPS)

For welding test pieces, a "Manufacturer’s" WeldingProcedure Specification (WPS) shall be produced bythe welding shop - a separate one for each weldingtask - in accordance with the Annex C of the standardsEN 287 resp. ISO 9606. The welding conditions fortesting shall match those during fabrication.

2. Test pieces, specimen types and tests

The test pieces, the specimen types and the perform-ance of the tests shall conform to the standards.

3. Evaluation of test pieces and specimens,recording of results

3.1 Depending upon the kind and scope of thetests, test pieces and specimens shall be evaluated,conforming to the specifications of the standards,according to the following criteria:

– Thickness, reinforcement and appearance ofweld (external results)

– Radiograph (internal results)

– Appearance of fracture (internal results)

– Mechanical properties, where applicable

– Metallographic specimen, if required.

3.2 A welder shall be regarded as having passedthe test provided that the imperfections fall within thelimits of assessment category B conforming toEN 25817 resp. ISO 5817. Exceptions to this ruleinclude the following imperfections: weld reinforce-ment too large (butt and fillet welds), excessive filletweld thickness and excessive root reinforcement, towhich assessment category C applies.

3.3 A test shall only be passed as successful if allthe requirements stated in the standards relating to thetest piece in question and the specimens taken from itcan be evaluated as having been met. Repeat testpieces and specimens are subject to the specificationsof the standards EN 287 resp. ISO 9606.

3.4 The assessment form provided at Annex C isto be used to record the details and results of the tests(p = passed, np = not passed). Additional sheets shallbe used as necessary.

E. Period of Validity, Repeat Tests

1. Standard period of validity

A welder's qualification test remains valid for twoyears with effect from the test date, provided that dur-ing this period welding work is constantly performedin the range of approval of the test and the work of thewelder is monitored by the welding supervisors at alltimes. This is to be confirmed by the welding supervi-sors on the welder’s qualification test certificate atintervals of no more than six months. The provisionsgiven in the standards in this regard shall also apply.

2. Reduced period of validity

2.1 The Society may reduce the validity of thetest (e.g. to one year) if the supervision of the welder'swork mainly takes the form of visual inspections.

2.2 A repeat test relating to an individual weldingprocess is required where a welder who has beentested in more than one welding process has not usedthe process in question for longer than six months.

2.3 A repeat test is in any case necessary where awelder has not performed any welding work as definedin para 1. for longer than six months.

2.4 The Society may demand a repeat test at anytime should reasonable doubts arise as to a welder'sskill.

3. Continuous supervision

3.1 A repeat test may be dispensed with wherethe quality of the work performed by the welder in thework assignment range corresponding to his test cate-gory is systematically and verifiably monitored duringfabrication by the welding shop's welding engineerrecognized by the Society and this is confirmed, asdescribed above in paragraph 1 above, at intervals ofno more than six months.

3.2 For this purpose the following measures shallbe implemented at times of which the welder has noprior knowledge and which shall occur at intervals ofnot more than three months:

– Destructive tests on test welds or sections ofweld produced by the welder (wherever possi-ble, in the most difficult positions), and/or

– Non-destructive tests for defects on productionwelds provided that these tests can be docu-mented (e.g. by means of radiographs).

3.3 The results of these tests are to be noted inthe lists of welding personnel (cf. A.3.1) and are to besubmitted to the Society for examination and confir-mation at intervals of not more than one year. Pleaserefer to the standards.

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4. Extensions to the period of validity, repeattests

4.1 The validity of a welder’s qualification testcertified by the Society may be extended by a furthertwo years at a time only if specified by the Society onthe test certificate provided that the preconditionsrelating to this as stated above resp. in the standardshave been met and provided that this was confirmedby the employer (welding supervisor) on the test cer-tificate for the six month period as applicable.

4.2 An extension may only be certified for therange of approval in which the initial test took place.

4.3 If the conditions under which an extension isgranted, as specified above, are not met a repeat test isto be carried out conforming in scope to the initial test.If a repeat test is carried out with a restricted scope oftesting compared with the initial test, the subsequentrange of approval is determined by scope of testing ofthe repeat test.

F. Other Welder's Tests

1. Other rules and standards

1.1 The Society may consent to the performanceof welder's qualification tests in accordance with othercomparable recognized rules, standards or codes. The

work assignments of welders tested in accordance withthese tests will be specified in analogous manner to theabove Rules, depending on the scope of testing. Theperiod of validity is as specified in E.

1.2 Welder's tests conforming to other rules,standards or codes which have been conducted by anindependent testing body in analogous manner to B.3.may be recognized by the Society subject to the fore-going provisions. The relevant welding procedurespecifications, test reports, test certificates and, uponrequest, the relevant rules, standards or codes shall besubmitted to the Society for this purpose.

2. Exceptions

In justified exceptional circumstances (e.g. repairs),the Surveyor may, subject to a specified time limit andto limitation to a particular structure, authorise theemployment of well-trained and experienced welderswithout the documentary qualifications stipulatedabove, provided that he has reason to believe that thewelders concerned are competent to perform the workenvisaged and that the quality of the welds producedby them can be verified by suitable, e.g. non-destructive tests.

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Section 4

Welding Procedure Tests, Production Tests

A. General

1. Welding procedure tests in the user'sworks

1.1 Welding procedure tests shall be carried outunder the Society's supervision in the user's worksbefore starting the fabrication work according to thescope described in the relevant sections of Chapter 3for the different areas of application under workshopconditions. Workplace conditions (weather protection,welding equipment, operating jigs, welders, produc-tion allowances etc.) and any intended extreme cold-forming operations as well as heat treatments of thematerials and/or the welds where applicable shall forman integral part of the welding procedure tests.

1.2 The Society may dispense with a weldingprocedure test for certain "standard" processes onmaterials which are easy to weld where the quality ofthe welded joints essentially depends on the choice ofthe welding consumables and the manual skill of thewelder, e.g. manual metal arc welding (SMAW) orsemi-mechanised gas-shielded metal arc welding(GMAW), of normal-strength hull structural steels,comparable construction steels, forgings or steel cast-ings, except for vertical-down (PG) welding.

Table 4.1 gives a summary of the documentary proofrequired for recognition of welding processes in thedifferent areas of application. The provisions in theindividual sections of Chapter 3 do, however, takeprecedence.

1.3 Welding procedure tests which have alreadybeen carried out under the supervision of other inde-pendent testing bodies and certified by them are sub-ject to the provisions of Section 2, D.3. In such casesthe Society reserves the right to demand that supple-mentary production tests be carried out before the startof fabrication or during production.

1.4 In individual, technically justified exceptionalcircumstances (e.g. repairs), the Surveyor may, subjectto a specified time limit and to limitation to a particu-lar structure, authorise the use of particular weldingprocesses without carrying out a welding proceduretest beforehand, provided that proof is furnished bymeans of other suitable tests (e.g. non- destructiveweld tests and/or production tests) that the weldingprocess in question is being applied correctly andsafely.

2. Preliminary welding procedure test

2.1 A preliminary welding procedure test shall becarried out on the premises of manufacturers of weld-ing equipment or welding consumables or at researchinstitutions if, for special reasons, an immediatewelding procedure test in the user's works appearsinappropriate.

In this test, the welding parameters and, where appli-cable, the post-weld heat treatments shall conform tothe conditions prevailing in the user's works. In allother respects, the provisions governing welding pro-cedure tests in the user's works apply.

2.2 The preliminary welding procedure test doesnot relieve the user's works of the obligation to carryout a definitive welding procedure test. On the basis ofthe preliminary test, a simplified test schedule for thedefinitive welding procedure test may be accepted.

3. Production tests

3.1 Production tests shall be performed to theextent described in the relevant sections of Chapter 3in the course of fabrication to monitor the quality ofthe welded joints. Test pieces welded at the same timeas the production welds (e.g. in the course of a longi-tudinal weld of a plate, pipe or vessel shell ring) orsections of production welds may be used for thispurpose. Where applicable, the test pieces shall as faras possible be heat-treated together with the compo-nent. As a rule, the production tests shall compriseboth non-destructive tests and mechanical and tech-nological tests.

3.2 Production tests are also required if a par-ticular welding process has not been used under theSociety's supervision for a long time or if processesand/or materials to be welded require constant verifi-cation of the weld quality. The nature and scope ofsuch production tests shall be established on a case-by-case basis.

3.3 In addition, the Society may require produc-tion tests to be carried out if the way in which thewelding work is performed gives rise to doubts as tothe quality of the welded joints or if individual weld-ing parameters, welding consumables or auxiliarymaterials have been changed or changes have beenmade in the welding shop personnel. The scope ofsuch production tests will be established on a case-by-case basis.

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3.4 For production tests in conjunction withoverweldable shop primers, please refer to Section 6,C.

B. Performance of Welding Procedure andProduction Tests

1. Application for approval

1.1 Application for approval of a welding processand for the performance of a welding procedure testshall be made to the Society's head office, with simul-taneous notification of the competent Surveyor, givingthe following details (to be specified in Annex B,item 2 "Description of Welding Shop":

– Range of application (components, materials,plate/wall thicknesses, pipe diameters, weldfactor where applicable)

– Welding process

– Welding positions

– Welding equipment and parameters

– Weld shapes, weld build-up

– Welding consumables and auxiliary materials

– Joint preparation

– Cold- or hot-forming operations prior to welding

– Overweldable shop primers

– Welding jigs and weather protection

– Preheating and heat input during welding

– Post-weld heat treatment, other after-treatment

– Welders (qualification tests)

– Date of test.

Note:

Annex D contains a form to specify the welding pro-cedure (WPS) and recording the test results (WPAR)in conformity with DIN EN 288/ISO 9956.

1.2 Where possible, the application should en-close a proposal for a test schedule in accordance withthe rules set out in Chapter 3 with sketches and dimen-sions of the test pieces, describing the intended speci-mens and tests. If the information and parametersstipulated in 1.1 are based on in-house standards orother (welding) specifications, these are also to beenclosed with the application.

2. Scope of testing, requirements, testschedule

2.1 The scope of testing (test pieces, specimens,etc.), tests and requirements for the individual fields ofapplication (shipbuilding, steam boiler and pressure

vessel fabrication, pipeline fabrication, etc.) are de-scribed in the relevant sections of Chapter 3 of theseRules, while details of the non-destructive tests aregiven in Section 4 and details of the mechanical andtechnological tests in Section 5 of Chapter 2.

2.2 If a test schedule appropriate to the intendedfield and range of application has already been drawnup by the applicant in accordance with 1.2 and 2.1 asapplicable, this must be agreed with the Society beforestarting the tests. Otherwise such a test schedule mustbe drawn up by the applicant - with the agreement ofthe Society - and submitted to the Society’s HeadOffice for final authorisation.

3. Materials, welding consumables and aux-iliary materials

3.1 The materials used in the welding proceduretests must be unambiguously identifiable on the basisof their marking and certificates. The direction ofrolling of the test pieces must be ascertainable. If not,check specimens shall be prepared and tested.

3.2 The welding consumables and auxiliary mate-rials should if possible have already been tested andapproved by the Society; however, they may be testedand approved at the same time as the welding process.Cf. Section 5, A.1.4. Approvals of this type are gener-ally restricted to the user's works and are valid for amaximum of one year, unless repeat tests are per-formed in accordance with Section 5, A.3.

3.3 Welding consumables and auxiliary materialsused in the welding procedure tests may only be re-placed in the subsequent fabrication work by others ofthe same kind which bear the Society's approval if thisis expressly stated in welding procedure approvalcertificate; cf. also A.3.3.

4. Test pieces, dimensions, direction of roll-ing, weld form, welding positions

4.1 The shape and size of the test pieces shall becompatible with the welding procedure concerned andthe number of specimens. The most commonly usedtest pieces are described in the relevant sections ofChapter 3. The dimensions of the test pieces may bechanged if this does not adversely affect the test and isnecessary for evaluating the process. Unless otherwisestipulated in an individual case both butt welded andfillet weld test pieces shall be welded in the specifiedpositions for the fabrication process.

4.2 For vertical welding (e.g. electrogas or elec-troslag welding) the length of the test piece (length ofthe weld) shall conform to the production welding jig,while with appliances using a fusible wire-guide elec-

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trode, the length of the test piece shall be geared to thelength of the wire-guide electrode or the height of thecomponents to be welded, as applicable. Any specialfeatures affecting the application of these processes(e.g. welding operations performed through the deck)shall be allowed for in determining the shape of thetest piece.

4.3 The plate thicknesses shall be chosen in ac-cordance with the information on the limits of appli-cation in the relevant sections of Chapter 3 in line withthe intended range of application. Where possible, twodifferent plate thicknesses should be welded and testedfor each range of application. The weld form shall bethose to be used in subsequent practice in line with thewelding process.

4.4 Where the characteristics of the weldingprocess or the dimensions, and hence the number ofpasses which these entail, are likely to have a consid-erable effect on the results of the test, the thickness ofthe test pieces and the number of passes shall be madeto conform to the limit thicknesses for the range ofapplication concerned. In the case of vertical down-ward welding, the thickness of the test piece shall bethe upper limit thickness of the range of application,whereas with a variable number of passes dependingon the plate thickness (e.g. with single- and multi-passwelding) the scope of the test shall include the varioustechniques and the thickness of the test pieces shall bechosen accordingly. The same applies in analogousmanner to the weld thicknesses.

4.5 Normally, test pieces shall be welded in allthe positions occurring in subsequent practice. De-pending on the welding processes and materials con-cerned, it may be agreed to restrict the test to certainspecified welding positions, e.g. in the case of manualarc welding or semi-mechanised gas-shielded metalarc welding the test may be limited to the positionsapplicable to the corresponding welder's qualificationtests as stated in Section 3. The horizontal-verticalposition PC (h-v) is, however, always to be included inthe welding procedure test for single-side welding.Where overhead welding PE (o) is included, this maybe combined with the downhand position PA (d).

4.6 The direction of rolling of the plates shall beparallel to the direction of welding. The orientation ofthe rolling direction shall be stated in the test report.

5. Welding of test pieces

5.1 All welding procedure tests shall investigate,in accordance with workshop practice, the effects ofprior cold-forming operations, weld preparation aspractised in the welding shop and air gap exactness,restraints together with the use, where applicable, ofoverweldable production coatings (shop primers).

Difficult fabrication conditions (e.g. limited accessi-bility) shall be simulated in the welding procedure test.

5.2 Welding shop facilities, welding equipment,aids to assembly and tack welds used in the test shallconform to those used in actual production. In thedownhand and vertical positions, account is to betaken of the maximum anticipated angular deviationsfrom the theoretical welding position (e.g. slope ofslipway).

5.3 Where possible, several (at least two) weldersor two teams of operators shall participate in a weldingprocedure test. As part of the welding procedure test,each welder or team of operators, as applicable, shallcarry out anew the preparation (tack welding) of thetest pieces, the alignment of the welding appliances,and the setting of the current supply and feed rate.

5.4 Preheating, heat input per unit length of weld,interpass temperature, electrode changing and thestarting and stopping of welding appliances (startingpoints/end craters) shall conform to subsequent prac-tice. Covered electrodes are to be used down to theclamping butt.

5.5 In welding procedure tests, depositing abacking run on the root side (cap pass), with or with-out grooving of the root depending on the process, aregenerally permitted. In single-side welding, the sametypes of backing shall be used as in the subsequentfabrication work.

5.6 In the case of mechanised welding processesin shipbuilding, an interruption of the welding opera-tion followed by complete cooling of the test piece andrestarting of the equipment shall be demonstrated. Themachining of the end crater and the preparation of thenew starting point shall be carried out in accordancewith normal practice. The test results from these weldareas will be evaluated separately.

5.7 Minor welding defects occurring in the courseof a welding procedure test may, with the consent ofthe Surveyor, be repaired or ignored when preparingspecimens. In the case of serious defects, the causesshall be established and remedied, after which new testpieces shall be welded.

5.8 The following data shall be recorded whenwelding the test pieces:

– Shape of weld and method of preparation

– Weld build-up and number of passes

– Welding consumables and auxiliary materials(type, trade name, dimensions, quantities)

– Method of root grooving and interpass clean-ing/treatment

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– Preheating, interpass temperatures

– Welding equipment and parameters (amperage,voltage, welding speed, heat input per unitlength of weld)

– Interruptions/disturbances in the welding se-quence

– Names of welders/operators

– Special features applying to the tests (e.g. cli-matic influences, limited accessibility).

6. Post-weld heat treatment, other kinds ofafter-treatment

6.1 If post-weld heat treatment of the components(e.g. annealing to relieve stresses) is intended in thesubsequent fabrication work, the test pieces are to besubjected to the same post-weld heat treatment. Thisapplies in analogous manner to other types of after-treatment, e.g., TIG after-treatment of the weld inter-faces. If approval of the welding process is desired forboth the untreated and after-treated conditions, the testshall be carried out for both conditions.

6.2 Where possible, post-weld heat treatment ofthe test pieces should be carried out in the annealingfurnaces which are to be used for the fabricated com-ponents. The equipping of the annealing furnace with atemperature recorder is mandatory. The time-temperature curve shall be recorded. Other types ofafter-treatment shall be described in the test report.Further information on post-weld heat treatment isgiven in Chapter 2, Section 3.

7. Non-destructive testing

7.1 Prior to sectioning, each butt-welded testpiece shall undergo visual and non-destructive testingover the entire length of the weld to detect any exter-nal or internal welding defects. Unless otherwiseagreed, the test pieces shall be radiographed and thosewith a thickness of 30 mm or over (10 mm or over inthe case of single-side submerged-arc welded testpieces) shall additionally undergo ultrasonic testing.

7.2 Where the base materials or weld metals areliable to crack, surface testing for cracks shall be car-ried out in addition to the above. If the material ismagnetizable, this shall take the form of magneticparticle inspection; otherwise the dye penetrantmethod shall be used. The Society may require spe-cific testing intervals (e.g. 72 hours) to be adhered tobetween completion of the welding work and perform-ance of the crack tests.

7.3 Each K-shape or fillet-weld test piece (T-jointor cruciform test piece) shall undergo a visual inspec-

tion for external welding defects. Test pieces madefrom a material other than normal-strength hull struc-tural steel or comparable simple structural steels shallin addition be subjected to testing for surface cracks.

7.4 In contrast to the recording limits stated forthe production tests, all welding defects and indica-tions detected during non-destructive ultrasonic testingshall be recorded.

8. Sectioning of test pieces, preparation ofspecimens

8.1 Sectioning of the test pieces shall be carriedout as described in the relevant sections of Chapter 3.The test pieces shall be sectioned mechanically. Ifthermal cutting methods are employed, a sufficientmachining allowance shall be provided and the heat-affected zone must thereafter be machined off.

8.2 The individual specimens shall be markedbefore sectioning and during machining in a waywhich enables them to be identified at all times andtheir orientation in the test piece to be reconstructed.

8.3 From all butt-welded and fillet-welded (cruci-form) test pieces for manual and semi-mechanisedwelding processes, one set of specimens each shallnormally be taken and tested. From the test pieces forfully mechanised welding processes, one set of speci-mens each from the beginning and end of the weldshall be taken and tested. In the case of these latter testpieces, a third set of specimens from the middle of theweld may be additionally demanded in special circum-stances, e.g. where long seams are concerned or thewelding process has been recently developed. Wheresingle-side submerged-arc welding is performed withflux backing, a third set of specimens shall be sub-jected to test in every case.

9. Shapes and dimensions of test specimens,mechanical and technological tests

9.1 The shapes and dimensions of the specimens,the preparation and performance of the tests and thedetermination of the results are subject to the provi-sions of Chapter 2, Section 5. Furthermore, the corre-sponding provisions in the Rules for Materials (Part 1,"Metallic Materials", Chapter 1, Section 1 and 2) shallalso be complied with.

9.2 All tests shall be carried out by trained staffusing calibrated testing equipment. The testing equip-ment shall be maintained by its owners in fully func-tional condition and shall be calibrated at regular in-tervals by an independent testing body.

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9.3 Unless otherwise stipulated or agreed, allmechanical and technological tests shall be performedin the presence of the competent Surveyor. The micro-graphs shall be submitted to him for evaluation.

C. Evaluation of Test Results, Requirements,Repeat Test Specimens, Test Reports

1. Designation of test results

1.1 To ensure that the description and evaluationof welding processes and positions, test results, etc.are as clear and uniform as possible, use shall be madeof the terminology and symbols in the relevant stan-dards (e.g. ISO 857, EN ISO 6947, EN 26520/ISO6520, EN 25817/ISO 5817, EN 30042/ISO 10042)and, for internal defects, Table 4.1 in Chapter 2, Sec-tion 4. The position of a defect or fracture must beindicated and may be designated as follows:

– WM = in the weld metal

– FL = in the transition zone (fusion line)

– HAZ = in the heat-affected zone (of the basematerial)

– BM = in the base material.

2. Requirements, repeat test specimens

2.1 The requirements are specified in the relevantsections of Chapter 3.

2.2 If, in the tests, individual specimens fail tomeet the requirements or the failure of these specimensis due to localised defects in the specimen or deficien-cies in the testing equipment, it is sufficient to test tworepeat test specimens or sets of repeat specimens ineach case from the same test piece, which must thenmeet the requirements.

2.3 In the testing of notched bar impact testspecimens, unless otherwise specified in a particularcase, the average value of three specimens shall apply;none of the individual values may be less than 70 % ofthe required value. If these conditions are not met andthe average value is not less than 85 % of the requiredvalue, three repeat test specimens may be tested andthe results added to the values originally obtained. Thenew average value from these six specimens must thenmeet the requirements. If the average value of the firstthree specimens is less than 85 % of the requiredvalue, six repeat test specimens shall be tested, theaverage value of which must meet the requirements.

2.4 If the requirements are not met by a sizeablenumber of specimens and/or in several areas of testing,

the causes of the failures shall be investigated. Whenthe faults have been cured, new test pieces shall bewelded and fully tested.

3. Reports, storage times

3.1 Reports (cf. Annex B) shall be prepared of alltrial welds and tests and submitted to the Society induplicate, signed by the tester and the testing supervi-sor.

3.2 The debris of test pieces, specimens and thetest documentation are to be kept until all the tests andinspections are concluded by the confirmation of ap-proval issued by the Society. For the storage time ofdocuments relating to the non-destructive testing ofwelds (e.g. radiographs), see Chapter 2, Section 4.

D. Limits of Application, Period of Validity

1. Works and sub-works

1.1 Welding procedure approvals are generallynon-transferable. The Society may allow exceptions inthe case of a nearby branch works where the weldingwork is carried out under the constant supervision ofthe main works, provided that the fabrication work isperformed under the same conditions and the samespecified welding processes are used. The Societymay, however, require proof as to whether the weldingprocesses are being applied correctly and the mechani-cal properties are adequate by means of non-destructive tests and/or simplified production tests

1.2 Welding procedure tests performed in aworkshop are in general not simultaneously valid forwelding in the field. In such cases, the welding proce-dure test must be repeated in full or in part under fieldconditions as determined by the Society. The Societymay dispense with repeat testing by prior agreement ifthe qualitative properties of the field welds are demon-strated by production tests.

2. Range of application

2.1 The other materials included in a weldingprocedure approval on the basis of the testing of aparticular material are indicated in the relevant sec-tions of Chapter 3.

2.2 With regard to plate thicknesses, unless oth-erwise stated in the relevant sections of Chapter 3 or ina particular case a plate thickness range of approx.0,7 – 1,7 t (t = tested plate thickness) shall apply tohull structures according to Chapter 3, Section 1 and arange of 0,75 – 1,5 t shall apply in the other fields of

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application according to Chapter 3. The Society maylimit this range of application, in accordance with thestandards (EN 288/ISO9956), to 0,8 – 1,1 t or extendit to 0,5 – 2 t; cf. the Sections in Chapter 3. In the caseof vertical downward welding (PG), the thickness ofthe plate tested shall in each case be regarded as theupper limit of application.

2.3 The welding procedure approval is generallyvalid for the welding positions tested. Depending onthe welding process, particular welding positions maybe included; these are stated in the approval documentwhere applicable.

2.4 The welding procedure approval is valid forthe welding process, the weld form and weld build-uptested.

2.5 The welding procedure approval is valid forthe heat treatment condition for which the test wasperformed, e.g. untreated, annealed to relieve stresses,normalised.

2.6 Any minimum or maximum design or oper-ating temperatures taken into account during testingare stated in the procedure approval document. Theformer is generally 5° C above the test temperature.

3. Period of validity

3.1 A welding procedure approval is generallyvalid without limit of time or with a time limit - de-pending upon the range of application; cf. Table 4.1

and the relevant sections of Chapter 3. This is, how-ever, always provided that the conditions under whichit was granted do not change significantly.

3.2 The welding procedure approval is tied to theapproval of the welding shop to perform welding workand expires when the approval of the welding shopexpires. For renewal of the welding shop approvaldocument (cf. Section 2, A.4.), it must be demon-strated to the Society that the approved welding proc-esses have not be changed in the current productionrun and have been used without any significant de-fects.

3.3 For the production tests necessary in individ-ual fields (e.g. steamboiler, pressure vessel) of appli-cation to maintain the validity of a welding procedureapproval, please refer to A.3. The Society will checkthe aforementioned conditions in the course of thethree-yearly renewal of the welding shop approval; cf.Section 2.

3.4 The Society may revoke part or all of awelding procedure approval and require a fresh weld-ing procedure test or fresh production tests if doubtsarise as to whether a welding process is being appliedcorrectly or safely or if defects in or damage to thewelds made by this process lead to the conclusion thatthe quality of the welded joints is inadequate.

II - Part 3GL 2000


D

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II - Part 3GL 2000

Section 5 Welding Consumables and Auxiliary Materials Chapter 1Page 5–1

A

Section 5

Welding Consumables and Auxiliary Materials

A. General

1. Approval procedure, marking

1.1 All welding consumables and auxiliary mate-rials (welding wires and rods, covered electrodes, fluxcored wires, (flux cored-) wire-gas or wire-flux com-binations, etc.) which are to be used within the rangeof approval of the Welding Rules or other Rules,regulations, etc. issued by Germanischer Lloyd mustbe tested and approved by the Society for that purposein accordance with the following provisions. The samealso applies an analogous manner to brazing materials,the tests and requirements for which will be specifiedon a case-by-case basis.

1.2 Approval is normally granted on the basis ofspecimen welds and tests carried out on the weldmetal and the weld joints on the manufacturer’spremises under the Society’s supervision with eachindividual product (individual manufacturer’s brand)in accordance with 1.1, for which approval was ap-plied for. For details of transfers of approvals, cf. 2.

1.3 An inspection of the manufacturer’s produc-tion facilities (production workshops, stores etc.) andespecially the internal quality assurance measuresapplied shall be carried out in the course of normalproduction in conjunction with the approval tests.

Note:

The quality requirements relating to the manufacture,supply and marketing of welding consumables and theprocesses applied are described in EN 12074/ISO14344. Unless other or contrary provisions relating tothis are stipulated in the following paragraphs, thequality requirements stated in this standard may beused as a basis for the inspection of the manufac-turer’s facilities.

1.4 For the approval of welding consumables andauxiliary materials in conjunction with a (preliminary)welding procedure test, see also Section 4, B.3.2. Theuser must have consented to the approval (on behalf ofthe manufacturer). In such cases the testing of the pureweld metal shall also be included in the scope of thewelding procedure tests. Testing of specimens takenfrom the welded joint is not regarded as testing of thepure weld metal.

1.5 Where approval is applied exclusively forauxiliary materials such as ceramic backing strips (i.e.not in conjunction with welding consumables), theirproperties shall be tested, and where appropriate theireffect on the quality of the welded joints establishedon the basis of the relevant product standards or themanufacturer’s specifications in accordance with a testschedule to be specified in each individual case.

1.6 If welding consumables and auxiliary materi-als are to be approved in exceptional cases on thebasis of approval tests conducted elsewhere by otherbodies recognized by the Society (e.g. other classifi-cation societies, Deutsche Bahn AG [German Rail-ways] or Technical Supervisory Authorities) the com-plete test reports shall be submitted (initial test notolder than 5 years and, if applicable, the last 3 annualrepeat tests) and - if nothing else has been stipulatedby the Society - tests at least corresponding to thecompulsory (annual) repeat tests shall be performed.

1.7 In isolated, urgent cases, consent may excep-tionally be given for the use of welding consumablesand auxiliary materials which have been approved byother recognized classification societies or neutraltesting authorities (e.g. Deutsche Bahn AG, TechnicalSupervisory Authorities), though such consent shall besubject to a time limit and shall be restricted to a par-ticular structure. In the case of larger projects, themanufacturer shall simultaneously apply for approval.

1.8 Applications for approval according to AnnexA shall be submitted in one copy to the Society's headoffice, with simultaneous notification of the competentSurveyor, giving the following information and ac-companied by the most recent catalogues resp. techni-cal data sheets with the properties guaranteed by themanufacturer (especially chemical composition,strength and toughness values):

– Manufacturer's name and manufacturing works(name of licensor, where appropriate)

– Nature of the welding consumables and auxil-iary materials

– Manufacturer's brand (licensor's designation,where applicable)

– Dimensions for which approval is applied for(diameters, lengths)

– Grades for which application is made, includingadditional symbols

Chapter 1Page 5–2

Section 5 Welding Consumables and Auxiliary Materials II - Part 3GL 2000

A

– Proposed range of application, including forexample base materials, welding processes,welding positions for which approval is sought,heat treatment condition and any special oper-ating conditions (e.g. low temperatures)

– Instructions for use (welding current, polarity,baking, heat treatment, etc.)

– Classification to DIN, EN, ISO or other stan-dards

– Marking, packaging

– Any previous approvals (e.g. from other classi-fication societies Deutsche Bahn AG [GermanRailways], Technical Supervisory Authority)

– Proposed testing laboratory and date of test.

The statements of conformity ("Affidavits") specifiedin 2.2 shall also be enclosed with any application fortransfer of approval. The form provided in Annex Emay be used to list the information specified above.

Note:

Classification to DIN, EN, ISO or other standards isperformed by the manufacturer and is included in theapproval certificate and in the list of weldingconsumables and auxiliary materials approved by theSociety. Where possible classification is performed toEN standards, but where these are not well-knownclassification shall be to other rules which have thewidest possible circulation. For space reasons,however, only the designation of the standard isgenerally given in the list (not the title of the relevantstandard). Classification is not normally covered bythe tests and is therefore not part of the approvalgranted by the Society; cf. 4. If the Society is alsorequired to check and confirm the classification inaccordance with the standards, a separate applicationshould be made to this effect

1.9 The applicant is generally the manufacturerof the welding consumables and auxiliary materials.The manufacturer is the firm which carries out thefinal quality-influencing stage of the manufacturingprocess (e.g. coiling in the case of wire electrodes).

1.10 In the case of applicants with several produc-tion facilities which have separate organisations andare in separate locations, approval of the weldingconsumables and auxiliary materials will generally begranted for the plant that manufactured them. If pro-duction is relocated, already existing approvals maybe transferred to the new plant. The conditions relatingto the transfer of approvals specified in 2. shall applyin an analogous manner hereto.

1.11 If the applicant is not the manufacturer of thewelding consumables and auxiliary materials, he shallgive the Society the names of his suppliers. Any

change of supplier shall be promptly notified to theSociety and generally necessitates a fresh approvaltest.

1.12 If welding consumables of the same compo-sition are manufactured by several suppliers and mar-keted by the applicant under a brand name, the in-house records and the printing on the packaging (e.g.fabrication number) must clearly identify the manu-facturer in question beyond all doubt. The relevantcode system used must be notified to the Society.

1.13 On the successful conclusion of the specimenwelds and tests, the Society's head office will issue anapproval certificate. The Society also maintains andpublishes a "List of Approved Welding Consum-ables".

1.14 With the approval, the manufacturer assumesresponsibility for ensuring that during fabrication, thecomposition and properties of the products conform atall times to those of the tested welding consumablesand auxiliary materials; see also Section 1, F.1., andunder 3.2.

1.15 Manufacturers are obliged to state in theircatalogues at least those items of information from theapproval certificate which appear in the "List of Ap-proved Welding Consumables".

1.16 Besides the brand name, identifying marksand the manufacturer’s details concerning the natureand use of the welding consumable or auxiliary mate-rial, the printing on the packaging or the adhesivelabel or the tag attached to reels, coils of wire etc.must at least indicate the Society’s full quality gradeand any additional symbols must be visible. The de-tails given in the current approval list published by theSociety in accordance with 1.13 shall, however, takeprecedence in each case.

1.17 Where possible each individual coveredelectrode, welding wire etc. shall be permanently anddistinctively identified by colour-coding, stamping orimpressed marking. The marking must match that onthe packaging.

2. Transfers of approval

2.1 On application, an "original approval" oncegranted may be transferred to welding consumablesand auxiliary materials manufactured in the sameworks but bearing a different brand designation or towelding consumables and auxiliary materials with thesame or a different brand designation and produced byother manufacturers (including subsidiary companies)under licence. An approval which has already beenbased on a transfer of approval cannot be transferred.

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2.2 For this purpose, manufacturing and market-ing companies as well as licensors and licensees mustconfirm that the welding consumables are identical incomposition, manufacture and the welding propertiesand quality factors on which approval was based ("Af-fidavits"), and they must constantly supervise that thisidentity is preserved in accordance with para. 1.14.Marketing companies are also required to confirm thatother welding consumables and auxiliary materials(from other manufacturers) are not marketed under thesame brand name; cf. paras. 1.9 to 1.1 and the note to3.3.

2.3 Transfer of approval is normally conditionalupon a previous test corresponding in scope to theprescribed (annual) repeat test. However, a test dif-fering from this in scope and timing may be agreed. Atest may be waived where the transfer relates towelding consumables and auxiliary materials manu-factured in the same works provided that the pre-scribed (annual) repeat tests were performed on themanufacturer's premises in the period stipulated.

2.4 The company (marketing company, licensee)in whose name the approval certificate has been issuedis responsible for the prescribed (annual) repeat tests.Where welding consumables and auxiliary materialsare produced in the same works, repeat tests need notbe duplicated, but where welding consumables of thesame composition are manufactured by several suppli-ers (cf. 1.12) repeat tests are required for all suppliers.

2.5 Changes to welding consumables and auxil-iary materials or their brand designations, the reloca-tion of manufacturing facilities, or changes in therelationship existing between companies (e.g. in thecase of transfers of approval) shall be brought to theSociety's attention by each of the companies con-cerned. The provisions of 1. are to be applied inanalogous manner.

3. Period of validity and repeat tests

3.1 Provided that the prescribed (annual) repeattests are performed, approvals of welding consum-ables and auxiliary materials remain valid indefinitelyuntil revoked. If welding consumables and auxiliarymaterials do not undergo the prescribed annual repeattests, the approval shall lapse and they shall be re-moved from the list of approved products. Equivalentalternative documentary proof may be recognized bythe Society by prior special agreement.

Note:

The Society may accept regular in-house tests per-formed as part of a recognized quality assurancesystem as equivalent alternative proof provided thatthis system meets the recommendations “Guidelinesfor the Acceptance of Manufacturer’s Quality Assur-

ance Systems for Welding Consumables” which havebeen jointly drawn up by the IACS classification so-cieties and that satisfactory quality assurance testrecords are submitted to the Society for inspection atnot more than yearly intervals. The Society may alsoperform interim tests on a random basis in order tosatisfy itself that the specified procedure is being fol-lowed and that the prescribed requirements are beingmet.

3.2 The continued validity of the approval isfurther conditional not only upon the brand designa-tion being retained, but also upon the composition andproperties of the starting and end products remainingunchanged in the intervening period, as well as uponthe constant monitoring of these products by themanufacturer in accordance with 1.14 and upon themaintenance of verifiable records of this monitoring.The Society may demand sight of these records at anytime, may inspect the current production and mayalso, in case of doubt, call for interim sampling ortesting, as appropriate.

3.3 Transfers of approval are generally valid for ayear at a time from the date of issue of the certificate,but at the most up to the (annual) repeat test at thepremises of the manufacturer (licensor) which followsthe issuing of the transfer certificate. Transfers ofapproval may be extended for a further year at a timeon application by the marketing company (licensee) ifboth the manufacturer (licensor) and the marketingcompany (licensee) submit appropriate confirmationsof identity (affidavits) in accordance with Section 2.

Note:

The Society may waive the requirement for the sub-mission of annual confirmations of identity (Affidavits)if, in conjunction with the first transfer of approval,the manufacturer (licensor) and marketing company(licensee) both expressly declare that they agree to theSociety continuing to certify the annual repeat test(s),(until revoked), i.e. extending the approval(s).

3.4 A transfer of approval to brand designationsused for marketing in accordance with 2.1 shall ceaseto be valid when the approval of the correspondingmanufacturer's product expires. A transfer of approvalfor a product made under licence by another manu-facturer may in such cases, on application, continue tobe valid, provided that the prescribed (annual) repeattests continue to be conducted by the licensed manu-facturer.

3.5 Repeat tests shall be performed under theSociety's supervision and shall be of the scope de-scribed for the various welding consumables and aux-iliary materials. Unless otherwise agreed, the testsshall be performed at yearly intervals. They relate to aperiod of one year calculated from the date of theapproval and are to be concluded by the end of this

Chapter 1Page 5–4


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period at the latest. If no welding consumable or aux-iliary material is manufactured within this period, i.e.is sold “ex stock” from a production run that the Soci-ety has already inspected, the Society may, on appli-cation, defer the repeat test. The Society issues collec-tive certificates covering these repeat tests.

Note:

If the scheduled repeat test is missed, the subsequentrepeat test shall apply retrospectively to the period inwhich it should have been performed and may besubject to a time limit. The manufacturer is then re-quired to perform subsequent repeat tests at shorterintervals to ensure that on average the prescribedannual test period is once again achieved. Approval isrevoked if repeat testing is not performed in two con-secutive years.

3.6 Repeat tests for welding consumables andauxiliary materials which have been approved for usein both untreated condition and for one or more heat-treated conditions (cf. para. 7.4) shall be carried outaccording to the prescribed scope for use in untreatedcondition and for use in each of the heat-treated con-ditions in question.

3.7 Welding consumables and auxiliary materialswhich have been tested and approved in conjunctionwith welding procedure tests conducted on the user'spremises (cf. Section 4, B.3.2) or in conjunction with apreliminary welding procedure test (cf. Section 4,A.2.) shall be subjected to annual repeat tests in linewith these provisions, which shall be carried out onthe premises of either the manufacturer or the user. Inthe case of welding consumables and auxiliary materi-als for special welding processes or materials, thescope of the tests applicable will be determined on acase-by-case basis.

4. Classification and designation (qualitygrades, added symbols)

4.1 Welding consumables and auxiliary materialsfor the welding of hull structural steels (includingthe corresponding grades of steel forgings and cast-ings) and of comparable structural steels are subject toclassification, designation and approval as follows:

– According to their nature (e.g. covered elec-trode, flux-cored wire electrode, wire-gas com-bination or wire-flux combination),

– According to quality grades 1, 2, 3 and 4 orhigher, depending on their notch impact energyand test temperature (cf. B. to E.),

– With the added symbol Y or Y 40 (= yield con-trolled) for welding of higher-strength hullstructural steels,

– With the added symbol H15(H), H10 (HH) orH5 (HHH) for controlled hydrogen content of

the weld metal (applies only to quality grades 2,3 and 4 or higher),

– With the added symbol S (= semi-automatic) forsemi-mechanized welding,

– With the added symbol T (= two run technique)for welding in one pass on each side, M desig-nating a multirun technique, or TM which cov-ers both (and is applicable only to welding con-sumables and auxiliary materials for fullymechanized welding),

– With the added symbol V (= vertical weldingprocess) for electrogas or electroslag welding.

Each higher quality grade includes the one (or those)below. Approval for higher-strength hull structuralsteels (added symbol Y or Y40) generally encom-passes approval for normal-strength hull structuralsteels; cf. Table 1.1 in Chapter 3, Section 1, E. Forwelding processes where a high base material contentmay influence the properties of the weld metal (e.g. insubmerged-arc welding using the two-run technique orin electrogas or electroslag welding), the Society mayrequire testing of both categories of material. Ap-proval for semi-mechanized welding (added symbolS) subsumes approval for fully mechanized multirunwelding (added symbol M) in flat positions.

4.2 Welding consumables and auxiliary materialsfor the welding of high-strength (quenched andtempered) structural steels with minimum yieldstrengths in excess of 390 N/mm2 are subject to classi-fication, designation and approval in analogous man-ner to para. 4.1, with the following differences:

– With the quality rating 3 or higher, dependingon their notch impact energy and test tempera-ture (see F.),

– With the added symbol Y and an appended codenumber designating the minimum yield strengthof the weld metal (e.g. Y46 for a minimum yieldstrength of 460 N/mm2).

Each higher quality grade includes the one (or those)below. Approval for steels having the minimum yieldstrength designated by the code number subsumesapproval for steels of similar type having the next twolower yield strengths (e.g. approval for a steel with thesymbol Y50 subsumes approval for steels with thesymbols Y46 and Y42). In the case of steels withminimum yield strengths of 550 N/mm2 and above(symbols Y55, Y62 and Y69), the approval only sub-sumes the steel with the next lower yield strength. Inspecial cases, welding consumables and auxiliarymaterials are approved only for specific materials.

4.3 Depending on their nature and condition(type of alloy), welding consumables and auxiliarymaterials for welding of steels tough at subzero tem-peratures are classed as equivalent to those for high-

II - Part 3GL 2000


A

strength (quenched and tempered) structural steels(see F.), for austenitic stainless steels (see I.), or fornickel and nickel alloys (see L.) and are subject toclassification, designation and approval as follows:

– For approvals in accordance with F., accordingto a quality grade which depends on their notchimpact energy and test temperature and, whereapplicable, with the added symbol Y and thecode number for the minimum yield strength (cf.4.2)

or

– For approvals in accordance with I., accordingto a quality grade consisting of the abbreviatedmaterial number of the material or materialcategory for which approval was granted (cf.4.5), also stating the test temperature used forthe approval test

or

– For approvals in accordance with L., accordingto a quality grade corresponding to the codedesignation shown in the standard applicable tothe welding consumable (cf. 4.8), also statingthe test temperature used for the approval test.

The inclusions and exclusions of the category ofwelding consumables and auxiliary materials accord-ing to which approval was granted apply, unless oth-erwise stated in the approval certificates.

4.4 Welding consumables and auxiliary materialsfor welding of high-temperature steels are subject toclassification, designation and approval as follows:

– According to a quality grade corresponding tothe code designation for the material or materialcategory for which the approval was granted(see H.).

The materials included in the respective approvals areshown in Table 5.18.

4.5 Austenitic welding consumables and auxil-iary materials for welding of stainless and non-magnetic steels and nickel alloy steels tough atsubzero temperatures are subject to classification,designation and approval as follows:

– For welded joints in (austenitic) stainless steels,according to a quality grade consisting of theabbreviated material number of the base mate-rial to be welded with the product (e.g. qualitygrade 4571 for the welding of steel with thematerial number 1.4571 X6CrNiMoTi17-12-2)

– For welded joints in (austenitic) non-magneticstainless steels, according to a quality gradeconsisting of the abbreviated material number ofthe welding consumable itself (e.g. quality grade

3954 for the welding of steel with the materialnumber 1.3964 X2CrNiMnMoNNb21-16-5-3)

– For welded joints between these steels and un-alloyed or low-alloy (hull) structural steels, forintermediate weld runs in clad plates and build-up welding, according to a quality grade con-sisting of the abbreviated material number ofthe welding consumable itself (e.g. qualitygrade 4370 for the welding consumable with thematerial number 1.4370 X15CrNiMn-18-8)

– For welding of nickel alloy steels tough at sub-zero temperatures, according to a quality gradeconsisting of the abbreviated material numberof the base material to be welded with theproduct in question (e.g. quality grade 5662 forwelding of steel with the material number1.5662 X8Ni9).

The steels also covered by the approval and informa-tion on the types of application are shown in I. (Tables5.21 to 5.24). In special cases, e.g. where the inclu-sions and exclusions differ, the relevant information isgiven in the approval certificates.

4.6 Welding consumables and auxiliary materialsfor welding of aluminium alloys are subject to classi-fication, designation and approval according to aquality grade corresponding to the code designationaccording to the standard, e.g. quality grade RAlMg4,5 Mn. For other aluminium alloys covered by therespective approval, see J., Table 5.26.

4.7 Welding consumables and auxiliary materialsfor welding of copper and copper alloys are subjectto classification, designation and approval accordingto a quality grade corresponding to the codedesignation for the welding consumable according tothe standard (DIN 1733), e.g. quality grade CuNi30Fe.For other base materials covered by the respectiveapproval, see K., Table 5.29.

4.8 Welding consumables and auxiliary materialsfor welding of nickel and nickel alloys are subject toclassification, designation and approval according to aquality grade corresponding to the code designationfor the welding consumable according to the standard(DIN 1736), e.g. quality grade NiCu30MnTi. Forother base materials covered by the respective approv-als, see L., Table 5.31.

4.9 The code numbers and letters indicated inTable 5.1 are used to identify the approved weldingpositions. In special cases, the approved welding posi-tions are specified individually; for example, an ap-proval applicable only to the vertical-down PG (v-d)position or individual welding positions are also speci-fied or excluded as applicable. For the limitationsrelating to the use of vertical-down welding, seeChapter 3, Section 1, H.6.

Chapter 1Page 5–6


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Table 5.1 Welding positions

Code No. Welding positions, code letters

1 All welding positions PA (d), PB (h), PC (h-v), PD (h-o), PE (o),PF (v-u), PG (v-d)

2 All except the vertical-down position PA (d), PB (h), PC (h-v), PD (h-o), PE (o),PF (v-u)

3 Butt welds in the down-hand position, fillet weldsin the down-hand and horizontal positions

PA (d), PB (h)

4 Butt welds in the down-hand position andfillet welds in the down-hand position

PA (d)

5 Vertical down-positions and those as forcode no. 3

PA (d), PB (h), PG (v-d)

4.10 The code letters indicated in Table 5.2 are tobe used to designate the type of current approved foruse with the relevant welding consumables and auxil-iary materials.

Table 5.2 Type of current and polarity

Code letterand symbol Type of current and polarity

DC + Direct current, + polarity

DC – Direct current, – polarity

DC ± Direct current, + and – polarity

AC Alternating current

5. Upgrading and downgrading

5.1 The upgrading of approved welding consum-ables and auxiliary materials into a higher qualitygrade shall be applied for by the manufacturer andmay suitably be effected on the occasion of the pre-scribed (annual) repeat tests. Upgrading requires thatin addition to the repeat tests, notched bar impact testspecimens shall be taken from all the butt-welded testpieces (welded joints) prescribed for the (original)approval test in the various positions and shall besubjected to test. Radiographic examination of thebutt-welded test pieces is recommended.

5.2 Downgrading into an appropriately lowerquality grade results when the outcome of the pre-scribed (annual) repeat tests fails to fulfil the require-ments, even if the retest specimens are included.Where the earlier test results and the evaluation of allthe new test findings point to the likelihood that thefailure of the specimens was due to defects in thematerial or the welding, the repeat test may be re-

peated at short notice. If the requirements are still notmet, the quality grade will be reduced. In such a case,a renewed upgrading may take place after threemonths at the earliest (i.e. after thorough revision andimprovement of the product) and only after testing asdescribed in 5.1.

5.3 The extension of an existing approval cover-ing the welding of normal-strength hull structuralsteels to the welding of higher-strength hull structuralsteels (e.g. from grade 2 to grade 2Y or from grade 3Yto grade 3Y40) requires the performance of a com-plete new approval test using higher-strength hullstructural steel in question as the base material. Thisrequirement applies in analogous manner to othermaterials as well.

5.4 Extension of an existing approval to includethe added symbol H15(H) or the modification of thesymbol H15(H) to H10(HH) or H5(HHH) is permissi-ble provided that the weld metal can be proved tocontain the stipulated lower quantity of hydrogen by atest in accordance with B.4. Corresponding tests per-formed elsewhere may be recognized as furnishing thenecessary proof, provided that they were carried outnot more than three years previously.

6. Physical characteristics, welding perform-ance and packaging

6.1 All welding consumables and auxiliary mate-rials must have physical characteristics compatiblewith the proposed application and conforming to therelevant standards and must display a satisfactorygeneral welding performance. The packaging must besuch as to prevent excessive moisture absorption anddamage to the contents provided that the materials areproperly handled and stored. Verification of thesecharacteristics and testing of the packaging form anintegral part of the approval tests and repeat tests.

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A

6.2 In the case of covered electrodes, the coatingmust encase the core rod concentrically and with uni-form thickness. When the electrodes are correctlyused, no projecting crater rim may be formed at oneside of the coating during welding. The coating shallnot display any marked irregularities or surface de-fects. It must adhere firmly to the core rod and becapable of storage within the specified limit condi-tions. Subject to proper handling and use, the coatingshall not rupture or break away from the core rod. Theclamping butt and the arcing end must be free fromcoating material.

6.3 Welding wires (wire electrodes and weldingrods) must have a smooth surface and must be freefrom surface defects, rust or other contaminationwhich might impair the satisfactory execution of thewelding operation (e.g. by impeding the current flow).Although welding wires may be provided with metalcoatings, these shall not adversely affect their weldingperformance or the properties of the weld. Coiledwelding wires must be free from buckling and mustunwind smoothly.

6.4 Welding fluxes and shielding gases mustpossess a degree of purity conforming to the relevantstandards together with the lowest possible moisturecontent. Welding fluxes should be granular in consis-tency and free-flowing to facilitate their smooth pas-sage through the flux supply system. The granulome-try of the flux should be uniform and constant fromone package to another. Regarding the identity testingof gases and the inspection of shielding gas mixingdevices on the user's premises, see C.1.5.

6.5 Other auxiliary materials such as nitrogen-hydrogen mixtures and powder or ceramic weld poolsupports (backings) should as far as possible be met-allurgically neutral and have no effect on the charac-teristics of the weld. Where such an effect cannot beruled out (e.g. with powder supports which deplete oradd to the alloying constituents), the materials shall beincluded in the scope of the relevant approval or re-peat tests, or shall be tested as part of the (preliminary)welding procedure tests; cf. Section 4, A.2. and B.3.2.

6.6 Welding consumables - where appropriate inconjunction with the corresponding auxiliary materialsmust in all positions and even at the limit values ofthe welding current display a satisfactory and constantwelding performance without excessive spatter. Thecoating of covered electrodes shall not flake off duringwelding, nor may coated wire electrodes burst open.Should the arc be accidentally interrupted duringwelding, the slag shall not impede the speedy restora-tion of the arc. Cooled slag shall be capable of beingremoved from the weld without undue difficulty. Theexternal characteristics of the weld and its internalfeatures (as revealed by radiography) must meet the

subsequent requirements of fabrication (cf. Chapter 2,Section 4, G.).

7. Performance of approval tests

7.1 Unless otherwise stated below, approval testsshall be conducted in accordance with Section 4. Theconditions under which the specimen welds are made(welding parameters, number of runs, weld build-up,etc.) must conform to the manufacturer's recommen-dations and to normal welding practice and be placedon record. Covered electrodes shall be consumeddown to a residual length of approx. 50 mm. The heatinput (energy input per unit length of weld E) appliedduring welding shall be determined by the followingformula and shall also be placed on record:

EU I

=⋅ ⋅ ⋅

⋅�

��

��volts amps welding time min

length of seam mm

kJ

mm

6

100

7.2 The base materials used for approval testsshall be of the chemical composition and strengthcategory for which the welding consumables andauxiliary materials are to be approved. For an approvalcovering only normal-strength hull structural steels(quality grades 1, 2 or 3), a normal-strength hullstructural steel or, failing this, a comparable structuralsteel possessing the same minimum tensile strength(400 N/mm2) shall be used. For approvals coveringhigher-strength hull structural steels (quality grades1Y, 2Y, 3Y or 4Y), a higher-strength hull structuralsteel or a comparable structural steel (e.g. S 355(St 52-3) having a tensile strength of at least490 N/mm2 shall be used.

For approvals covering the quality grades 2Y40, 3Y40or 4Y40, a hull structural steel or a comparable struc-tural steel with a tensile strength of at least 510 N/mm2

shall be used. For testing the pure weld metal, normal-strength hull structural steels or comparable structuralsteels may generally be used. For welding consum-ables with a very divergent chemical composition, theside walls of the test piece may, if necessary, be pro-vided with a buffer (e.g. in the case of stainless steels)and a backing strip of the same composition as theplate may be used. For the special features applicableto submerged-arc welding, see D.3.2 and D.3.5.

7.3 Where welding consumables and auxiliarymaterials are to be approved for welding with bothdirect and alternating current, this must be specifiedand the test shall be conducted with alternating cur-rent. In special cases, verification of the welding char-acteristics using direct current may be demanded as analternative or in addition (e.g. for covered electrodesused for gravity welding with direct and alternatingcurrent, and for certain welding processes).

Chapter 1Page 5–8


B

7.4 Post-weld heat treatment of the test pieces orspecimens is not allowed where products are to beapproved for the untreated condition alone; see alsothe preliminary remarks relating to B. Excepted fromthis rule is the heat treatment of tensile specimens toreduce their hydrogen content as described below inrelation to the various welding consumables and aux-iliary materials. Where welding consumables andauxiliary materials are also to be approved for theheat-treated condition, the prescribed additional testpieces must be prepared (cf. H.1.3) and heat-treatedaccordingly. Follow-up heat treatment of the speci-mens once they have been removed from the testpieces is not allowed.

7.5 In special cases, further tests (e.g. hardnessmeasurements, examination of macro- or mi-crographic specimens to check weld penetration andstructural characteristics, etc.) or the testing of notchedbar impact test specimens at temperatures lower thanthose specified may be stipulated in addition to the testpieces and specimens called for in the following para-graphs. In the case of welding consumables and aux-iliary materials for austenitic stainless steels, proof isrequired of resistance to intergranular corrosion andfor solid austenitic steels resistance to hot cracks mustalso be demonstrated.

7.6 Should individual test results fail to meet therequirements, a double quantity of test pieces andspecimens of the same kind shall be freshly preparedand subjected to testing. Base materials, welding con-sumables and auxiliary materials originating from thesame delivery as those used for the first test shall beused for this purpose. Should the specimens again fail,approval will not be granted until the reasons havebeen clarified and a complete new test has been con-ducted (cf. also 5.2). For the repetition of notched barimpact tests, see the following provisions relating tothe various welding consumables and auxiliary mate-rials.

B. Covered Electrodes for Manual Metal-ArcWelding of Hull Structural Steels


In normal shipbuilding practice, components are ingeneral not subjected to post-weld heat treatment (e.g.annealing to relieve stresses). Consequently, thewelding consumables and auxiliary materials to beused for ship constructions are generally tested andapproved for the untreated, i.e. as-welded, condition.

Should post-weld heat treatment nevertheless be in-tended or required in special cases, only weldingconsumables and auxiliary materials with propertiesand quality grades which have been proved to beadequate in the respective heat-treated condition shall

be used. The nature and scope of the necessary verifi-cations shall be determined on a case-by-case basis.

In the case of welding consumables for hull structuralsteels, the test temperature for the base material inquestion (see Chapter 3, Section 1, Table 1.1 as wellas the Rules for the Construction of Ocean-goingVessels, Chapter 1, Section 2) may be assumed to bethe minimum load temperature (design temperature).A temperature of 300 °C is generally considered to bethe maximum load temperature.

1. General

1.1 The following provisions apply to coveredelectrodes for manual metal-arc welding of hullstructural steels, including the corresponding grades ofsteel forgings and castings, and of comparable struc-tural steels. Covered electrodes for semi-mechanizedgravity welding and spring-loaded welding processesare treated in the same way as those for manual metal-arc welding.

1.2 Covered electrodes for normal-strength hullstructural steels are approved according to qualitygrades 1, 2 and 3 depending on the notch impact en-ergy values achieved during the approval tests. Cov-ered electrodes for higher-strength hull structuralsteels are approved according to quality grades 2Y, 3Yand 4Y or, where applicable, 2Y40, 3Y40 and 4Y40.In special cases, e.g. when the electrodes are also usedfor steels tough at subzero temperatures, approval maybe granted with a higher quality grade, as with weld-ing consumables and auxiliary materials for high-strength (quenched and tempered) structural steels (cf.F. and Table 5.14). Regarding added symbols, inclu-sions and exclusions, see A.4.1.

2. Testing the weld metal

2.1 For testing the deposited weld metal, two testpieces of the type shown in Fig. 5.1 are to be preparedin the downhand PA (d) welding position.

One of the test pieces is to be welded with 4 mm di-ameter covered electrodes, the other with coveredelectrodes of the maximum diameter produced, up to alimit of 8 mm. Where the electrodes produced are ofone diameter only or do not exceed 4 mm in diameter,one test piece is sufficient.

In accordance with the covered electrodes used andnormal welding practice, the weld metal shall be laiddown in layers comprising single or multiple runs. Thelayers shall be welded in alternate directions, and theindividual runs shall be 2 – 4 mm thick. Prior to thewelding of each new layer, the test piece shall becooled in still air to 250 °C or below, but on no ac-count to below 100 °C. The temperature shall bemeasured at the surface of the centre of the weld.

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B

2.2 The chemical composition of the depositedweld metal shall be determined by the manufacturerusing recognized methods of analysis and shall becertified by him. The analysis shall encompass all theimportant alloying constituents and impurities (e.g.phosphorus and sulphur). The results of the analysisshall not exceed the limits specified in the standards.In special cases, narrower tolerances for the constitu-ents may be stipulated.

2.3 Following the recommended radiographicexamination, one round tensile test specimen as shownin Fig. 5.2 and three ISO V-notch impact test speci-mens conforming to Fig. 5.3 shall be machined fromeach weld metal test piece. The longitudinal axis ofthe round tensile specimen shall be located in thecentre of the weld at the mid-point of the plate thick-ness. The upper lateral surface of the impact testspecimens shall lie 5 mm below the surface of theplate with the notch also located in the centre of theweld.

To remove the hydrogen from the weld metal, theround tensile specimens may be subjected to a tem-perature not exceeding 250 °C for not longer than16 hours prior to the tensile test.

In the notched bar impact test, the temperature of thespecimens for quality grades 2, 2Y, 2Y40, 3, 3Y,3Y40, 4Y and 4Y40 shall not deviate from the pre-scribed test temperature by more than 2 °C.

2.4 The mechanical properties of the weld metalmust meet the requirements stated in Table 5.3. If the

tensile strength exceeds the upper limit, approval ofthe electrode will be granted only after careful consid-eration of its other technological properties and thechemical analysis of the weld metal. The mean valuefor the notch impact energy must meet the require-ments of the following sections; an individual valuemay be below the required mean value but not lessthan 70% of this value.

2.5 For the carrying out of retests, see A.7.6; therequirements for the notch impact energy test are asfollows:

If the required notch impact energy values are notattained, but not more than two of the individual val-ues are below the required mean value and not morethan one of them is less than 70 % of the requiredvalue, three more impact test specimens may be takenfrom the same or an identical weld metal test pieceand tested. The results obtained are to be added to thefirst results and the resulting new mean value mustthen meet the requirements. In addition, no more thantwo of the six individual values in all may be belowthe required mean value and of these, not more thanone may be less than 70 % of the required value.

2.6 Further repeat tests require the consent of theSociety in each individual case; see also A.7.6. Suchtests, however, shall without exception comprise thewelding of a new test piece and the testing of all thespecimens originally required, even if some of themgave satisfactory results in the first test.

��

�

��

��

��

��

��

� ��

Fig. 5.1 Weld metal test piece

Chapter 1Page 5–10


B

3. Testing on welded joints

3.1 Tests on welded joints are generally per-formed on butt-welded test pieces in accordance withFig. 5.4 resp. Table 5.4. Where covered electrodes areto be approved only for fillet welding (e.g. for gravitywelding), fillet-welded test pieces as shown in Fig. 5.7instead of butt-welded test pieces shall be welded andsubjected to test. In special cases, the Society may callfor fillet-welded as well as butt-welded test pieces,e.g. for vertical-down welding.

10

R ≥ 5

• • ≥12

gauge length Lo50

parallel length60

Fig. 5.2 Round tensile test specimen

55 r = 0,25

45 °

10 8

10

Fig. 5.3 ISO V-notch impact test specimen

3.2 Butt-welded test pieces in accordance withFig. 5.4 shall be welded in the positions and with theelectrode diameters shown in Table 5.4 according tothe welding positions covered by the approval appli-cation (cf. A.4.9 and Table 5.1). For the base materialsto be used, see A.7.2; their chemical composition is tobe recorded.

The two parts of the test piece are to be juxtaposedwith sufficient allowance for angular shrinkage. Priorto the welding of each new pass, the test piece shall becooled in still air to 250 °C or below, but on no ac-count below 100 °C. The temperature is to be meas-ured at the surface of the centre of the weld. Beforethe backing pass is laid down, the root is to begrooved - wherever possible by machining - from therear.

Table 5.3 Required properties of the weld metal

Quality-grade 1

Minimumyield

strength

[N/mm2]

Tensilestrength

[N/mm2]

Minimumelongation(Lo = 5 do)

[%]

Minimum notchimpact energy 2

[J]

Testtemperature

[°C]

1 + 20

2 0

3

305 400 – 560 22 47 (33)

– 20

2Y 0

3Y – 20

4Y

375 490 – 660 22 47 (33)

– 40

2Y40 0

3Y40 – 20

4Y40

400 510 3 – 690 22 47 (33)

– 40

1 For possible higher quality grades, see 1.2.2 Mean value of three specimens; ( ) for minimum individual values; for this and retests, see 2.4 and 2.5.3 A tensile strength of 500 [N/mm2] is acceptable if adequate values are achieved in the welded joint.

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B

15-20

2-3

60°

≥100

BW

Z

K

BD

≥100

3030

≥35 Z

BD

BW

K

= Flat tensile test specimen

= Transverse bend test specimen, cover pass in tension

= Transverse bend test specimen, backing pass in tension

= ISO V-notch impact test specimen

Fig. 5.4 Butt-weld test piece

Table 5.4 Butt-weld test pieces, welding positions and electrode diameters

Butt-weld test pieces required . . .

. . . in position(s) . . . with electrode diameter(s) 1

Position(s) appliedfor approval

No. Position Root pass Fill and cover passes Back pass

111

PA (d)PF (v-u)PE (o)

43,253,25

5 to 8 2

4 or 54 or 5

444

All positionsincl. vertical-down

(1) 31 PG (v-d) acc. to manufacturer's instructions

All positions exceptvertical-down

(2) 3

111

PA (d)PF (v-u)PE (o)

43,253,25

5 to 8 2

4 or 54 or 5

444

Downhand positionsand vertical-up

(3) 3

1

1

PA (d)

PF (v-u)

4

3,25

5 to 8 2

4 or 5

4

4

Downhand positionsonly(4)

1

1

PA (d)

PA (d)

4

4

5 to 8 2

5 to 8 4

4

4

Horizontal-verticalPC (h-v) position

only1 PC (h-v) 4 or 5 5 4

Other individualpositions

(x)1 (x) as specified above

1 Electrode diameters in [mm].2 Filler passes with 5 or 6 mm size; last two runs including the cover pass with the largest diameter electrodes produced, up to a maximum

of 8 mm.3 Includes the horizontal-vertical PC (h-v) position.4 Second pass with 5 or 6 mm size; all other filler and cover passes to be made with the largest diameter electrodes produced, up to a

maximum of 8 mm..



B

R =

25

≥ 3525

weld width

parallel length

Fig. 5.5 Flat tensile test specimen

3.3 Following the recommended radiographicexamination, one flat tensile test specimen in accor-dance with Fig. 5.5, two 30 mm wide transverse bendtest specimens (one with the cover pass and one withthe backing pass in tension) and three notched barimpact bending test specimens (ISO V-notch speci-mens conforming to Fig. 5.3) are to be machined fromeach butt-welded test piece.

The parallel length of the flat tensile test specimensshall be equal three times the plate thickness or theweld width plus twice the plate thickness, whicheveris the greater. On the tension side, the edges of thetransverse bend test specimens may be rounded to aradius of not more than 2 mm. The position of theimpact test specimens shall conform to Fig. 5.6. Theweld reinforcement shall be machined flush with thesurface of the plate on both sides of all specimens.

1/2

1/2

15-2

0

Fig. 5.6 Position of impact test specimens

3.4 The mechanical properties of the weldedjoints must meet the requirements stated in Table 5.5.For the performance of the tests and the carrying outof retests, see paras. 2.4 and 2.5.

The position of the fracture shall be recorded. Bendtest specimens displaying incipient cracks shall bebroken open for assessment of the fracture. The Soci-ety may stipulate that the bend tests or supplementarybend tests be performed within a set time limit inorder to ascertain possible effects of hydrogen.

3.5 Fillet-weld test pieces as shown in Fig. 5.7shall, if necessary according to 3.1, be prepared ineach of the welding positions applied for approval (cf.3.2).

For the base materials to be used, see A.7.2. The firstfillet weld is to be made with the largest, the secondwith the smallest electrode diameter recommended bythe manufacturer for the particular welding positionand throat thickness concerned. Unless otherwisestipulated or agreed, each fillet weld shall be made ina single pass. Electrodes of the maximum length pro-duced are to be used. The amperages used shall berecorded.

The length "L" of the test piece shall be such as topermit the melt-off of at least one complete electrodelength - namely, the longest produced - with a throatthickness appropriate to the electrode diameter.

3.6 Following visual inspection and assessment,the fillet-weld test pieces shall be sectioned in themanner shown in Fig. 5.7, and the macrographicspecimens marked with "M" shall be prepared forevaluation of the weld penetration and measurementof the hardness in accordance with Fig. 5.8. Whereverpossible, Vickers hardness measurements (DIN 50133,HV 10) should be performed.

3.7 The hardness of the weld metal obtained withwelding consumables and auxiliary materials forhigher-strength hull structural steels with minimumyield strengths up to 355 N/mm2 (added symbol Y)shall not be less than 150 HV and the correspondinghardness for higher-strength hull structural steels witha minimum yield strength of 390 N/mm2 (added sym-bol Y40) shall not be less than 160 HV. The test reportshall also record the hardness values measured in theheat-affected zone and the base material. Equivalentvalues for other methods of measurement shall beagreed.

After machining off one of the fillet welds, the tworemaining pieces of each fillet-weld test piece shall bebroken open on alternate sides and the fracture shallbe assessed. The specimen must be free from anymajor defects such as large pores and slag lines in theroot, incomplete penetration, lack of fusion at the sidewalls, cracks, etc., cf. also Chapter 3, Sec-tion 1, G.10.3.4.

4. Hydrogen test

4.1 The hydrogen test to determine the diffusiblehydrogen content of the weld metal should, wherepossible, be conducted according to the mercurymethod prescribed in DIN 8572 Part 1 and ISO stan-dard 3690-1977 or, with the Society's consent, ac-cording to other comparable methods. For an interimperiod and with the Society's consent, the glycerinmethod described in para. 4.3 may continue to be usedas an alternative for the added symbols H15(H) andH10(HH). Depending on the added symbols H15(H),H10(HH) or H5(HHH) to be appended to the qualitygrade specified in the approval (cf. A.4.1), the hydro-gen content of the weld metal shall not exceed thelimits indicated in Table 5.6.

4.2 In the mercury method, the quantity of hy-drogen related to the fused weld metal VF shall bedetermined and recorded in addition to the quantity ofdiffusible hydrogen related to the deposited weldmetal VD (cf. DIN 8572/ISO 3690, Part 1).

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B

��

��

��

��

��

��

��

Fig. 5.7 Fillet-weld test piece

Table 5.5 Required properties of welded joints

Minimum notch impact energy[J] 2

PositionsQualitygrade 1

Tensilestrength[N/mm2]

PA, PC, PE

(d, h-v, o)PF. PG

(v-u, v-d)

Test temperature

[°C]

Minimum bendingangle, mandrel diame-

ter = 3 ×××× thicknessof specimen

1 + 20

2 0

3

≥ 400 47 (33) 34 (24)

– 20

2Y 0

3Y – 20

4Y

≥ 490 47 (33) 34 (24)

– 40

2Y40 0

3Y40 – 20

4Y40

≥ 510 47 (33) 41 (29)

– 40

120° before the first incipi-ent crack, minor pore expo-sures up to a maximumlength of 3 mm allowed.

1 For possible higher quality grades, see 1.2.2 Mean value of three specimens, ( ) minimum individual valves; for this and retests, see 2.4. and 2.5.



B

Table 5.6 Permissible hydrogen content of weldmetal

Permissible hydrogen content ofwelding material 1

Addedsymbol Mercury

methodGlycerinemethod

H15(H) 2 15 cm3/100 g 10 cm3/100 g

H10(HH) 2 10 cm3/100 g 5 cm3/100 g

H5(HHH) 2 5 cm3/100 g 3

1 Mean value of four specimens, related to the deposited weldmetal.

2 Previous added symbols H, HH and HHH should no longerbe used, wherever possible.

3 Not to be used.

base materialheat-affected

zone

weld metal

base material

Fig. 5.8 Hardness measurements

4.3 Where the glycerin method of testing forhydrogen is used, the following procedure shall beadopted:

4.3.1 Four sample bars of normalized steel 1

measuring 125 � 25 � 12 mm shall be thoroughlycleaned and weighed to the nearest 0,1 g. A singlebead of weld, approximately 100 mm long, is to belaid down on one of the 125 � 25 mm faces of eachsample bar, on each occasion using a new 4 mm di-ameter covered electrode. 120 to 150 mm of the elec-trode length shall be consumed in the process.

4.3.2 The welding operation shall be performedwith a current of approximately 150 A and the shortestpossible arc. Where the welding process is mecha-nized, the electrode diameter and the amperage shallbe so chosen that the thermal input corresponds to thatof manual arc welding. Prior to welding, the consum-

––––––––––––––1 Wherever possible, the steel should not contain more than the

following components: 0,15 % C, 0,10 % Si, 1,0 % Mn,0,03 % P, 0,03 % S.

ables may be baked in the normal manner prescribedby the manufacturer.

4.3.3 Not later than three seconds after the extinc-tion of the arc, the sample is to be quenched in icedwater (0 °C). During the cooling of the sample inwater, the slag and weld spatter are to be removedwith a steel brush within 30 seconds. Within the spaceof a further 30 seconds, the sample shall be removedfrom the water, cleaned and dried, and each sampleshall be placed separately into a test vessel (glassvolumetric flask) to catch the escaping hydrogen usingglycerin as the sealing liquid. After another 30 sec-onds the zero level adjustment of the gas collectingvessel must be completed and the measuring timemust begin.

4.3.4 During the test, the temperature of the glyc-erin is to be held at 45 °C. The sample bars are to beleft immersed in the glycerin for 48 hours, after whichthey are to be taken out and cleaned with water andalcohol. After drying, the sample bars shall again beweighed to the nearest 0,1 g to determine the quantityof deposited weld metal.

4.3.5 The volume of gas collected in the test vesselis to be measured to the nearest 0,05 cm3 and cor-rected for a temperature of 0 °C and a pressure of760 mm of mercury. The mean volume of the diffusi-ble hydrogen measured in relation to the depositedweld metal for the four sample bars may not exceedthe values indicated in Table 5.6.

5. Hot-cracking test

5.1 Where the Society requires that a hot-cracking test be performed, two plates shall for thatpurpose be welded together in the manner shown inFig. 5.9. The end face of the web plate must be cutstraight and at right angles and must fit snugly againstthe flat upper surface of the bottom plate. Any un-evenness is to be removed. The base plate shall bestiffened by three transverse web plates.

12 -

15

12 - 15120

80

80tack welds

transverseweb plates

Fig. 5.9 Test piece for hot cracking

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C

5.2 The first fillet weld is to be laid down in asingle pass in the downhand PA (d) position. Duringthis operation, the current must be at the upper limit ofthe range prescribed for the electrode. The secondfillet weld on the opposite side shall be laid downimmediately after the first, also in the downhand PA(d) position and starting at the end of the test piecewhere the first fillet weld terminated. Both fillet weldsare to be laid down at a uniform speed without weav-ing of the electrode.

5.3 For the welding of the complete length ofeach fillet weld (120 mm), the electrode lengths indi-cated in Table 5.7 are to be molten off.

Table 5.7 Molten-off lengths of electrodes

Molten-off lengthsElectrode corewire diameter

[mm]1st fillet weld

[mm]2 nd fillet weld

[mm]

4

5

6

200

150

100

150

100

75

After welding, the slag shall at once be removed fromthe fillet welds.

5.4 Half an hour after welding, at the earliest, i.e.when the test piece has cooled completely through itsentire thickness, the fillet welds are to be examined forcracks with a magnifying glass or by a crack-detectingtechnique.

The first fillet weld shall then be removed by ma-chining and the second fillet weld shall be fractured bycollapsing the plates (with the root in tension). Thefractured seam shall then be examined for hot cracks.When subjected to testing for hot cracks, the filletwelds may not reveal any superficial or internal cracksof any kind. Only end crater cracks may be tolerated.

6. Annual repeat tests

6.1 For covered electrodes for hull structuralsteels, the annual repeat test called for in A.3.1 re-quires the preparation of two weld metal test pieces inaccordance with 2.1. The test specimens prescribed in2.3 shall be taken from these. For the tests to be ap-plied and the required properties, see 2.4 and table 5.3.

6.2 In special cases the Society may stipulatemore extensive repeat tests (cf. A.3.2, A.7.4 andA.7.5).

C. (Flux-cored) Wire-Gas Combinations andFlux-Cored Wire Electrodes for Semi-Mechanized Welding of Hull StructuralSteels

1. General

1.1 The following provisions apply to (flux-cored) wire-gas combinations and flux-cored wireelectrodes for semi-mechanized welding of hullstructural steels, of corresponding grades of steelforgings and castings and of comparable structuralsteels. Wire-gas combinations for manual tungsten-inert-gas (TIG) welding shall be treated analogously tothose for semi-mechanized welding. For wire-gascombinations and flux-cored wire electrodes for fullymechanized welding and mesh-wound wire electrodes,see D.1.1.

1.2 (Flux-cored) wire-gas combinations andflux-cored wires for normal- strength hull structuralsteels are approved according to quality grades 1S, 2Sor 3S, depending on the notch impact energy valuesachieved during the approval tests. Quality grades2YS, 3YS and 4YS or, where applicable, 2Y40S,3Y40S and 4Y40S are awarded to wire-gas combina-tions and flux-cored wires for higher-strength struc-tural steels. For inclusions and exclusions, see A.4.

1.3 Approval is essentially linked to a specific(commercial) brand of wire - where appropriate, inconjunction with a shielding gas conforming to a stan-dard (e.g. to EN 439/ISO 14175) or defined in termsof its composition and purity. An approval relatesexclusively to the wire produced by a particular manu-facturer and used for the approval tests. The Society isto be notified of the manufacturer and the brand andstandard designations of the wire used for the approvaltest. The marketing of other wires (wires produced byother manufacturers) under the (commercial) brandname stated in the approval certificate is permittedonly after a renewed approval test using the otherwire.

1.4 Approval may be granted for a (commercial)brand of wire in conjunction with a specific (commer-cial) brand of shielding gas produced by a particularmanufacturer or in conjunction with a shielding gascovered by EN 439/ISO 14175 and defined by itsgroup and code number (e.g. M 21) in accordancewith Table 5.8.

1.5 Where a (commercial) brand of (flux-cored)wire is approved in conjunction with a standardizedshielding gas in accordance with 1.4, the wire in ques-tion may be used with other standardized gases of thesame type, provided that these gases are included inthe "List of Approved Welding Consumables " (cf.A.1.13) on the basis of an initial verification of iden-



C

tity performed on the manufacturer's premises fol-lowed by annual repeat tests of composition and pu-rity. Branch works, cylinder filling stations, etc. shallalso be covered by these tests. For gas mixing instal-lations (including those on the user's premises) ade-quate documentary proof shall be submitted to theSociety.

1.6 If in exceptional cases, e.g. where the gasproducer makes application for approval for a (flux-cored) wire-gas combination, approval is required tobe granted for a specific standard wire in conjunctionwith a (commercial) brand of gas produced by a par-ticular manufacturer, the brand of wire used in the testwill also be noted in the approval confirmation docu-ment. The use of other, equivalent (commercial)brands of (flux-cored) wire or standard wire as part ofsuch an approval is only permitted if the particularwire in question has already been tested and approvedelsewhere with a gas of the appropriate compositionand is included on the "List of approved welding con-sumables" (cf. A.1.13).


2.1 For testing the deposited weld metal, two testpieces are to be prepared in the downhand PA (d)welding position in accordance with B.2.1 andFig. 5.1. One of the test pieces is to be welded withwire of 1.2 mm diameter or the smallest diameterproduced for use in shipbuilding. The other is to bewelded with wire of 2.4 mm diameter or the largestdiameter produced. Where wire of only one diameteris produced, a single test piece is sufficient. The testpieces are to be welded in a manner analogous to thatprescribed in B.2.1 (cf. also EN/440/ISO 14341) insuch a way that the thickness of the individual passesis at least 2 mm but not more than 6 mm.

2.2 The chemical composition of the depositedweld metal shall be determined and certified in a man-ner analogous to that prescribed in B.2.2. The resultsof the analysis shall not exceed the limiting valuesspecified in the standards or by the manufacturer, thenarrower tolerances being applicable in each case.

Table 5.8 Classification of shielding gases according to EN 439/ISO 14175

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II - Part 3GL 2000


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2.3 The test specimens defined in B.2.3 andFigs. 5.2 and 5.3 shall be machined from the weldmetal test pieces and subjected to test.

2.4 The test results must meet the requirementsstated in B.2.4 and 2.5 resp. Table 5.3.


3.1 As in the case of covered electrodes for man-ual arc welding (cf. B.3.1), tests on the welded jointare generally carried out on butt-welded test pieces inaccordance with Fig. 5.4 and Table 5.4 and in certaincases on fillet-weld test pieces in accordance withB.3.5 and Fig. 5.7.

3.2 Depending on the welding positions appliedfor approval (cf. A.4.9), the butt-weld test pieces areto be welded in the positions indicated in Table 5.4,but with the wire diameters shown in Table 5.9. Forthe base materials to be used, see A.7.2. The testpieces shall be welded in a manner analogous to thatprescribed in B.3.2.

3.3 Following the recommended radiographicexamination, test specimens in accordance with B.3.3and Figs. 5.3 – 5.6 shall be machined from the butt-weld test pieces and subjected to test.

3.4 The test results must meet the requirementsstated in B.3.4 and Table 5.5.

3.5 If necessary according to B.3.1, fillet-weldtest pieces in accordance with Fig. 5.7 shall be weldedin each of the welding positions applied for approval(cf. A.4.9). For the base materials to be used, seeA.7.2. The test pieces shall be welded in a manneranalogous to that prescribed in B.3.5.

3.6 The fillet-weld test pieces are to be sectionedand tested in a manner analogous to that prescribed inB.3.6 and B.3.7.

4. Hydrogen test

4.1 (Flux-cored) wire-gas combinations andflux-cored wires whose composition (core material) orstructure (e.g. folded flux-cored wire) may result inmoisture uptake and consequently a higher concentra-tion of hydrogen in the weld metal shall be subjectedto a hydrogen test, unless otherwise agreed. In the caseof solid- wire-gas combinations, a hydrogen test isnormally unnecessary.

4.2 For the performance of the hydrogen test andthe requirements to be met, see B.4; unless otherwisestipulated in a particular case, a wire electrode 1.2 mmin diameter must be used for this purpose. The weld-

ing parameters shall comply with the manufacturer’srecommendations.

5. Hot cracking test

5.1 Where the Society calls for a hot cracking test(cf. B.5.1), a test piece conforming to Fig. 5.9 but250 mm in length shall be welded.

5.2 The wire diameters, weld thicknesses andweld lengths must conform to Table 5.10. In all otherrespects, the provisions of B.5.2 – B.5.4 shall be ap-plied in analogous manner.


6.1 For (flux-cored) wire-gas combinations andflux-cored wires for semi-mechanized welding, theannual repeat test in accordance with A.3.1 shall entailthe welding, with medium wire diameters (e.g. 1.2 and1.6 mm), of a weld metal test piece in accordance with2.1, from which shall be taken the test specimenscalled for in para. 2.3. For the tests to be applied andthe requirements to be met, see 2.4.

Table 5.9 Butt-weld test pieces, wire diameters

Weldingposition Root pass

Filler and coverpasses, back pass

DownhandpositionPA (d) 1

1,2 mm or smallestdiameter produced

2,4 mm or largestdiameter produced

Otherposition

1,2 mm or maximum diameter recom-mended by the manufacturer for theposition concerned

1 Where approval is required only for the PA (d) position, a sec-ond test piece shall be welded in this position with the variouswire diameters recommended by the manufacturer.

Table 5.10 Wire diameters and weld dimensions

1st fillet weld 2nd fillet weldWirediameter

[mm]

a-dimen-sion

[mm]

Weldlength[mm]

a-dimen-sion

[mm]

Weldlength[mm]

1,21,6

99

250 77

250

6.2 In special cases, the Society may require amore extensive repeat test (cf. A.3.2, A.7.4 and A.7.5).



D

D. Wire-Flux Combinations for Submerged-Arc Welding of Hull Structural Steels

1. General

1.1 The following provisions apply to wire-fluxcombinations for single-pass and multi-pass sub-merged-arc (SAW) welding of hull structural steels, ofthe corresponding grades of steel forgings and cast-ings, and of comparable structural steels. Approvalsgranted in accordance with these provisions are validfor standard single-wire welding. Approval also cov-ering tandem or multi-wire welding and single-sidewelding using (flux) backings necessitates the per-formance of a (preliminary) welding procedure test.(Flux-) wire-gas combinations and flux-cored wiresused only for fully mechanized welding and mesh-wound wire electrodes shall be analogously tested andapproved in accordance with these Rules.

1.2 Where there is a requirement to use multi-wire flux combinations of a certain, stipulated compo-sition and structure, the Society may require additionaltest pieces or tests to be performed over and above thestandard test described below. The test pieces submit-ted for these tests must be of this combination andstructure. The composition and structure will then beparticularly noted in the approval confirmation.

1.3 Wire-flux combinations for normal-strengthhull structural steels are approved according to qualitygrades 1, 2 or 3 depending on the notch impact energyvalues achieved during the approval tests. Qualitygrades 1Y, 2Y, 3Y and 4Y or, where applicable,2Y40, 3Y40 or 4Y40 are awarded to wire-flux combi-nations for higher-strength hull structural steels. Wire-flux combinations for welding in a single pass on eachside (two-run technique) are designated by the addedsymbol T. Those used for multi-run technique receivethe added symbol M, and those used for both weldingtechniques the added symbol TM. For inclusions andexclusions, see A.4.

1.4 Approval is essentially linked to a specific(commercial) brand of flux in conjunction with a(commercial) brand of wire produced by a particularmanufacturer, or in conjunction with a standardizedwire (e.g. to EN 756) or a wire otherwise identified byits chemical composition and other characteristics.The Society is to be notified of the manufacturer andthe brand or standard designation of the wire used forthe approval test.

1.5 Where approval is granted with a standard-ized wire, the type of flux concerned (the commercialbrand) may also be used with other standardized wiresof the same type (wires produced by other manufac-turers who have been checked by the Society in accor-dance with A.1.2), provided that these wires are in-

cluded in the "List of Approved Welding Consum-ables " (cf. A.1.13) on the basis of an initial verifica-tion of identity followed by annual repeat tests of thechemical composition and other qualitative character-istics. The marketing of wires produced by differentmanufacturers under a single brand designation ap-proved by the Society is not permitted.


2.1 Testing of the deposited weld metal is re-quired only in the case of an approval relating tomulti-run technique (added symbol M) or exclusivelyto the welding of (double) fillet welds. For this pur-pose, a weld metal test piece as shown in Fig. 5.10 isto be welded in the downhand PA (d) position usingwires at least 4 mm or the largest produced diameter.

The welding parameters should be as used for ordi-nary multi-run welding, and individual runs should belaid down in alternate directions. Before each new run,the test piece should be cooled in still air to 250 °C orbelow, but on no account below 100 °C. The tem-perature is to be measured at the surface of the centreof the weld. The thickness of the individual runsshould be at least equal to the diameter of the weldingwire used and shall not be less than 4 mm.

2.2 The chemical composition of the weld metalshall be determined and certified in a manner analo-gous to that prescribed in B.2.2. The results of theanalysis shall not exceed the limit values specified inthe standards or by the manufacturer, the narrowertolerances being applicable in each case.

2.3 Following the recommended radiographicexamination, two round tensile test specimens con-forming to Fig. 5.2 and three ISO V-notch impact testspecimens conforming to Fig. 5.3 shall be machinedfrom the weld metal test piece as shown in Fig. 5.10.For the preparation and heat treatment of the testspecimens, see B.2.3.

2.4 The mechanical properties of the weld metalmust meet the requirements indicated in Table 5.11.The provisions of B.2.4 and 2.5 apply in analogousmanner to the maintenance of the test temperature, theperformance of the notched bar impact tests and thecarrying out of retests.


3.1 Tests on the welded joint are generally per-formed on butt-weld test pieces as shown in Fig. 5.11for multi-run technique (added symbol M) and/orFig. 5.12 for the two-run technique (added symbol T).Where an application relates only to approval forwelding in a single run on each side (T), testing of the

II - Part 3GL 2000


D

deposited weld metal in accordance with 2. may bedispensed with.

Where approval is to cover wire-flux combinationsused exclusively for fillet welds, the butt-weld testpieces shall be replaced by a fillet-weld test pieceanalogous to Fig. 5.7 but with dimensions suitable forsubmerged-arc welding. After inspection for surfacecracks, this shall be sectioned and tested in a manneranalogous to that described in B.3.6 and B.3.7. TheSociety may also call for fillet-weld test pieces inaddition to butt-weld ones.

3.2 For multi-run technique (added symbol M), abutt-weld test piece conforming to Fig. 5.11 shall bewelded in the downhand PA (d) position. Where awire-flux combination is also to be approved for otherpositions (e.g. for welding in the horizontal-verticalposition), test pieces shall also be welded in thesepositions. For the base materials to be used, see A.7.2,although grade A hull structural steel shall as a rule beused for approvals with quality grades 1 and 2.

The two portions of the test piece shall be juxtaposedwith sufficient allowance for angular shrinkage. Theweld shall be executed by the multi-run techniqueusing wires of at least 4 mm diameter and the sameparameters and method as for the submerged-arc weldmetal test piece described in 2.1. Before the back passis laid down, the root is to be grooved at the back ofthe weld, if possible by machining.

3.3 Following the recommended radiographicexamination in accordance with Fig. 5.11, two flat

tensile test specimens in accordance with Fig. 5.5, fourtransverse bend test specimens (two with the coverpass, two with the back pass in tension) and three ISOV-notch impact test specimens shall be machined fromthe M butt-welded test piece (cf. B.3.3).

3.4 The mechanical properties must meet therequirements stated in Table 5.12.

The provisions of B.2.4 and 2.5 as well as B.3.4 applyin analogous manner to the performance of the tests,including in particular the maintenance of the testtemperatures for the notched bar impact tests and theinformation on retest specimens.

3.5 For welding one run on each side (two-runtechnique - added symbol T), two butt-weld test piecesas shown in Fig. 5.12 are to be welded in the down-hand PA (d) position using the base materials, platethicknesses, weld shapes and wire diameters shown inTable 5.13. The chemical composition of the basematerials used shall be stated in the test report.

The butt-weld test pieces shall be produced by layingdown one run on each side. The welding current pa-rameters and the feed rates must be those recom-mended by the manufacturer for application. Afterlaying down the first run, flux and slag are to be re-moved and the test piece allowed to cool down to100 °C in still air. The temperature is to be measuredat the surface of the centre of the weld. The rootshould be grooved prior to laying down the second runonly if this is expressly prescribed by the manufac-turer for the future application.

KK

K

R

Cut

10° 10°1/2

1/2 ≥30≥ 200

≥ 200

1650

20 - 2510

R

K = Notched bar impact test specimenR = Round tensile test specimen

Abb. 5.10 Weld metal test piece for submerged-arc welding



D

20-25

0,5

60°

≥150

K

≥1504

Z

BWBD

Z

BD

BW

30

30

≥35

3030

≥35

10

Z

BD

BW

K





Fig. 5.11 "M" submerged-arc butt-weld test piece for multi-run welding

Cut

≥150

BDZ

Z

KK

K

BW

t

7

≥150

30 R

10

30

30

≥35

≥35

Z

BD

BW

K

R





= Round tensile test specimen ( only required where approval relates exclusively to two-run T welding )

Fig. 5.12 "T" submerged-arc butt-weld test piece for one run on each side (two-run technique)

II - Part 3GL 2000


D

Table 5.11 Required properties of the weld metal in submerged-arc welding

Qualitygrade

Minimum yieldstrength[N/mm2]

Tensile strength

[N/mm2]

Minimumelongation

[%]


[J]

Testtemperature

[C°]

1 + 20

2 0

3

305 400 to 560 22 34 (24)

– 20

1Y + 20

2Y 0

3Y – 20

4Y

375 490 to 660 22 34 (24)

– 40

2Y40 0

3Y40 – 20

4Y40

400 510 2 to 690 22 41 (29)

– 40

1 Mean value of three specimens; ( ) minimum individual values; for this and retests, see B.2.4 and 2.5 and well as D.2.4.2 A tensile strength of 500 N/mm2 is acceptable of adequate values are achieved in the welded joint.

Table 5.12 Required properties of submerged-arc welded joints

Minimum notch impact energyQualitygrade

Tensile strength[N/mm2]

[J] 1 Test temperature [°C]

Minimum bending angle, mandreldiameter = 3 ×××× thickness of specimen

1 + 20

2 0

3

≥ 400 34 (24)

– 20

1Y + 20

2Y 0

3Y – 20

4Y

≥ 450 34 (24)

– 40

2Y40 0

3Y40 – 20

4Y40

≥ 510 41 (29)

– 40

120° before the first incipientcrack, minor pore exposures

up to a maximum lengthof 3 mm allowed.

1 Mean value of three specimen, ( ) minimum individual valves; for this and retests, see B.2.4, 2.5 as well as D.3.4 and 3.7.



D

Table 5.13 "T" submerged-arc butt-weld test pieces; base materials, plate thicknesses, weld shapes andwire diameters

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II - Part 3GL 2000


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3.6 Following the recommended radiographicinspection in accordance with Fig. 5.12, one roundtensile test specimen as shown in Fig. 5.2, two flattensile test specimens as shown in Fig. 5.5, twotransverse bend test specimens (one with the secondpass and one with the first pass in tension) and threeISO V-notch test specimens (located as shown inFig. 5.13) are to be machined from each "T" butt-welded test piece in accordance with Fig. 5.12 (cf.B.2.3 and B.3.3).

The round tensile test specimen can be dispensed withif the wire-flux combination is at the same time alsobeing tested for multi-run welding with an additionalweld metal test piece conforming to Fig. 5.10.

3.7 The mechanical properties must meet therequirements stated in Table 5.12. The provisions ofB.2.4 and 2.5 as well as B.3.4 apply in analogousmanner to the performance of the tests, including inparticular the maintenance of the test temperatures forthe notched bar impact tests and the information onretest specimens.

10

12-1

5xx

20-2

5

2

2nd run

30-3

5

2

2nd run

Fig. 5.13 "T" butt-weld test piece; location ofnotched bar impact test specimens

4. Hydrogen test

4.1 Where a hydrogen test is stipulated for awire-flux combination (or for the flux component),this shall be performed analogously to B.4, althoughwith the altered dimensions for the specimens and theclamping device according to DIN 8572/ISO 3690,Part 2.

4.2 Alternatively, the hydrogen test may, for aninterim period, continue to be conducted according tothe glycerin method described in B.4.3. Here too,however, the dimensions of the specimens and the

clamping device shall conform to DIN 8572/ISO3690, Part 2.


5.1 For multi-run technique (M), the annual re-peat test shall entail testing of the deposited weldmetal in accordance with 2. (submerged-arc weldmetal test piece as shown in Fig. 5.10). However, onlyone round tensile test specimen and three notched barimpact test specimens need to be tested on these occa-sions.

5.2 For two-run technique (T), a T butt-weld testpiece as prescribed in para. 3.5 (Fig. 5.12) shall beprepared and tested in accordance with 3.6 and 3.7.However, only one round tensile test specimen, oneflat tensile test specimen, two transverse bend testspecimens and three notched bar impact test speci-mens need to be tested on these occasions.

5.3 For two-run and multi-run technique (TM),the weld metal test piece prescribed in para. 5.1 andthe T butt-welded test piece in accordance with para.5.2 shall be welded and tested. The round tensile testspecimen called for in para. 5.2 may, however, bedispensed with.

5.4 Wire-flux combinations used exclusively forfillet welding (cf. 2.1 and 3.1) are to be repeat testedin accordance with 5.1.

5.5 For tandem and multi-wire technique and forsingle-side welding using (flux) backings, annualrepeat tests analogous to those provided for aboveshall be conducted with the welding method con-cerned (cf. 1.1 and A.3.7).

5.6 In special cases, the Society may requiremore extensive repeat tests (cf. A.3.2, A.7.4 andA.7.5).

E. Welding Consumables and Auxiliary Ma-terials for Electrogas and ElectroslagWelding of Hull Structural Steels

1. General

1.1 The following provisions apply to wire-gascombinations, flux-cored wires and wire-flux combi-nations for fully mechanized electrogas (EG) andelectroslag (ES) welding (in the vertical-up position)of hull structural steels, of corresponding grades ofsteel forgings and castings, and of comparable struc-tural steels. Where consumable nozzle electrodes areused, these are to be included in the test.



E

1.2 The welding consumables and auxiliary ma-terials referred to in para. 1.1 and used for normal-strength hull structural steels are approved accordingto quality grades 1V, 2V and 3V depending on thenotch impact energy values achieved during the ap-proval tests. Quality grades 1YV, 2YV, 3YV and 4YVor, where applicable, 2Y40V, 3Y40V and 4Y40V areawarded to such welding consumables and auxiliarymaterials used for higher-strength hull structuralsteels. For inclusions and exclusions, see A.4.


2.1 The testing of welding consumables andauxiliary materials covered by para. 1.1 and used forelectrogas and electroslag welding is performed exclu-sively on welded joints in a manner analogous to thatprescribed in D.3.5 – D.3.7 for wire-flux combina-tions, using butt-weld test pieces conforming toFig. 5.14.

2.2 Butt-welded test pieces conforming toFig. 5.14 are to be welded analogously to Table 5.13using base materials of known composition (to be

recorded) and two thicknesses of plate depending onthe quality grade applied for. The weld preparation,the wire diameter and the welding parameters mustconform to the manufacturer's recommendations forsubsequent practice and are to be recorded. The lengthof the test pieces shall be suited to the welding appli-ances used and, where appropriate, to the length of theconsumable nozzle electrodes.

2.3 Following the recommended radiographicexamination, the following shall be removed fromeach butt-welded test piece according to Fig. 5.14: twoflat tensile test specimens to Fig. 5.5, two side bendtest specimens (specimen width 10 mm), two roundtensile test specimens to Fig. 5.2, three notched barimpact test specimens (ISO V-notch impact testspecimens according to Fig. 5.3) each from the centreand side of the weld metal, and two macrographicspecimen. When the weld reinforcement has beenmachined off, the edges of the side bend test speci-mens may be rounded on the tension side to a radiusnot greater than 1 mm. The location of the notched barimpact test specimens shall conform to Fig. 5.15. Theprovisions of B.2.3 and B.3.3 apply in analogousmanner.

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II - Part 3GL 2000


F

2

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KS

2

2

Fig. 5.15 Location of notched bar impact testspecimens

2.4 The mechanical properties of the welded jointmust meet the requirements indicated in Table 5.12.The provisions of B.2.4 and 2.5 as well as B.3.4 applyin analogous manner to the performance of the tests,including in particular the maintenance of the testtemperature for the notched bar impact test and thecarrying out of retests.


3.1 For the annual repeat testing of welding con-sumables and auxiliary materials covered by 1.1, abutt-welded test piece as shown in Fig. 5.14 with amedium plate thickness (20 – 25 mm unless otherwisespecified) shall be welded in accordance with 2.2.

3.2 One round tensile test specimen, two sidebend test specimens and three notched bar impact testspecimens from the centre of the weld metal in accor-dance with para. 2.3 and Fig. 5.15 shall be taken fromthe test piece prescribed in 3.1.

3.3 For the performance of the tests and the re-quirements to be met, see 2.4, B.2.4., 2.5 and B.3.4.


F. Welding Consumables and Auxiliary Ma-terials for High-Strength (Quenched andTempered) Structural Steels

1. General

1.1 The following provisions apply to weldingconsumables and auxiliary materials for welding ofnormalized or quenched and tempered high-strength

fine-grained structural steels with minimum yieldstrengths of more than 390 N/mm2. For fine-grainedstructural steels with minimum yield strengths of up to390 N/mm2, the welding consumables and auxiliarymaterials for the corresponding hull structural steels(e.g. quality grade 3Y40 or 4Y40) may be used.

Note:

The chemical composition of the welding consumablesand auxiliary materials for high-strength (quenchedand tempered) fine-grained structural steels necessaryto obtaining weld metal with adequate mechanicalproperties often also results in good low-temperatureproperties. In view of this fact and also bearing inmind the increased resistance to brittle fracture whichis desirable when welding these steels, the weldingconsumables and auxiliary materials referred to in 1.1are generally approved only with a quality grade of 3or above. Such approval normally also constitutesproof of suitability for low-temperature applicationsdown to a minimum service temperature (design tem-perature) 5 °C above the respective test temperature.Cf. also G.

1.2 In a manner analogous to that applied to hullstructural steels, welding consumables and auxiliarymaterials covered by 1.1 are approved according toquality grades 3 – 9 with the added symbol Y and anappended code number designating the minimumyield strength of the weld metal. The respective basematerials will be classified in a manner analogous tothat applied to hull structural steels (cf. Chapter 3,Section 1, Table 1.1) depending upon the particularstrength and toughness properties in question. Forother added symbols, see A.4.1; for inclusions andexclusions, see A.4.2.

2. Testing of the weld metal

2.1 For testing the deposited weld metal, testpieces analogous to those called for in B.2.1, C.2.1 orD.2.1 shall be prepared, depending on the nature ofthe welding consumables and auxiliary materials (andaccording to the welding process). The base metalused shall be a fine-grained structural steel compatiblewith the properties of the weld metal, or the side wallsof the weld shall be buffered with a weld metal of thesame composition.

2.2 The chemical composition of the depositedweld metal shall be determined and certified in a man-ner analogous to that prescribed in B.2.2. The resultsof the analysis shall not exceed the limit values speci-fied in the standards or by the manufacturer, the nar-rower tolerances being applicable in each case.



F

2.3 Depending on the nature of the welding con-sumables and auxiliary materials (and according to thewelding process), the test specimens prescribed inB.2.3, C.2.3 or D.2.3 shall be taken from the weldmetal test pieces in a similar manner.

2.4 The mechanical properties must meet therequirements stated in Tables 5.14 and 5.15. The pro-visions of B.2.4, C.2.4 and D.2.4 apply in analogousmanner to the performance of the tests, including inparticular the maintenance of the test temperature inthe notched bar impact test and the carrying out ofretests.

Table 5.14 Required properties of the weldmetal, quality grades and test tem-perature

Qualitygrade

Test temperature[°C]

Minimumnotch impact

energy[J] 1

3 (3*) 2

45 (5*) 3

6789

10

– 20 (– 30) 2

– 40– 50 (– 60) 3

– 60– 70– 80– 90–100

≥ 47 (33)

1 Charpy-V-notch specimens in accordance with EN 10045-1/ISO 148, mean value of three specimens; ( ) minimum indi-vidual values; for this and retests, see B.2.4 and 2.5.

2 Corresponding to the test temperatures for the quality grades ofwelding consumables and auxiliary materials for the welding ofhull structural steels, but not conforming to the standards (e.g.EN 757/ISO 11837), in which a test temperature of – 30 °C isgiven for quality grade 3. If the test is performed at a tempera-ture of – 30 °C, an asterisk (*) will be added to the qualitygrade.

3 In line with the IACS "Unified Requirements", the Society maycall for a test to be performed at – 60 °C for quality grade 5, inwhich case an asterisk (*) will be added to the quality grade.


3.1 Depending on the nature of the welding con-sumables and auxiliary materials (and according to thewelding process), the testing on the welded joints shallbe performed on butt-weld test pieces in analogousmanner to B.3.1, C.3.1 or D.3.1.

Note:

In testing welded joints made with wire-flux combina-tions for submerged-arc welding, it should be assumedthat due to the limits on thermal input (heat input per

unit length of weld) which are generally necessary,multi-run welding is the only suitable method. Para.3.1 consequently refers only to the M type butt-weldedtest piece for multi-run welding in accordance withD.3.1. Where approval is also solicited in exceptionalcases for two-run welding (T, with one run on eachside), "T" type butt-weld test pieces shall be weldedfor this purpose in accordance with D.3.5 and testedin a manner similar to that prescribed in D.3.6 andD.3.7. For the same reasons, no reference is madebelow to the fillet-weld test pieces.

3.2 Depending on the nature of the welding con-sumables and auxiliary materials (and according to thewelding process), the butt-weld test pieces called forin para. 3.1 shall be welded in a manner analogous tothat prescribed in B.3.2, C.3.2 or D.3.2. The basemetal used shall be a high-strength fine-grainedstructural steel with an appropriate minimum yieldstrength and tensile strength and compatible with theadded symbol for which application is made (cf. Table5.15).

3.3 Depending on the nature of the welding con-sumables and auxiliary materials (and according to thewelding process), the test specimens described inB.3.3, C.3.3 and D.3.3 shall be taken from the butt-weld test pieces.

3.4 The mechanical properties must meet therequirements stated in Table 5.16. The provisions ofB.3.4, C.3.4 and D.3.4 apply in analogous manner tothe performance of the tests, including in particular themaintenance of the test temperatures in the notchedbar impact test and the requirements regarding theretest specimens.

4. Hydrogen test

4.1 Welding consumables and auxiliary materialsfor welding of high-strength (quenched and tempered)fine-grained structural steels with minimum yieldstrengths of > 390 N/mm2 shall - taking due accountof the provisions in C.4.1 - be subjected in every caseto a hydrogen test in accordance with the mercurymethod to DIN 8572/ISO 3690, Part 1 (for coveredelectrodes, wire-gas combinations and flux-coredwires) or Part 2 (for wire-flux combinations).

4.2 For quality grades or added symbols Y42 toY50, the diffusible hydrogen content of the weld metaldetermined in accordance with the provisions of B.4.2shall not exceed the figure of 10 cm3/100 g weld metal(related to the quantity of metal deposited) specified inTable 5.6 as the maximum for the added symbol H10(HH). For quality grades or added symbols Y55 toY69, the maximum figure of 5 cm3/100 g weld metalspecified for the added symbol H5 (HHH) shall not beexceeded.

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5.1 The annual repeat tests specified in A.3.1shall entail the preparation and testing of weld metaltest pieces as prescribed under 2. If the basis used forthese tests is a reduced tensile strength of the weldmetal as prescribed in footnote

1 to Table 5.15, or if

the specified tensile strength is not attained, two trans-

verse tensile specimens taken from the welded joint(in the down-hand position only) must also be testedand these must then meet the requirements stipulatedin Table 5.15.


Table 5.15 Required properties of the weld metal, added symbols, strength properties and minimum notchimpact energy

Symbols added toquality grade

Minimum yieldstrength or 0,2 %

proof stress[N/mm2]

Tensile strengthreference values 1

[N/mm2]

Minimumelongation

A5 [%]


[J]

Y42 420 530 (500 – 640) 2 20 47 (33)

Y46 460 570 (530 – 680) 2 20 47 (33)

Y50 500 610 (560 – 720) 2 18 50 (35)

Y55 550 670 (610 – 780) 2 18 55 (38)

Y62 620 720 (690 – 890) 2 18 62 (43)

Y69 690 770 (760 – 960) 2 17 69 (48)

1 The tensile strength of the weld metal may be up to 10 % below the minimum tensile strength of the base material corresponding to theadded symbol, provided that the results obtained with the transverse tensile specimens taken from the welded joints meet the minimumtensile strength requirements stated in Table 5.16. The elongation is to be stated in the test report.

Note:For welding very large plate thicknesses where the "supporting effect" of the base material on either side of the weld no longer applies andthe tensile strength of the weld metal also determines the tensile strength of the welded joint, it may be necessary, when applying footnote 1

of Table 5.15, to choose welding consumables and auxiliary materials of the next higher strength category (next higher added symbol).

2 The values in brackets denote the tensile strength requirements specified in the standards, for example EN 499 or EN 757/ISO 11837; inthe case of the lower values covered in footnote 1, but also where the tensile strength values are too high, these may also be used toevaluate the results.

3 Mean value of three specimens; for minimum individual values ( ) and retests, see B.2.4 and 2.5



G


Qualitygrade Added symbol

Tensile strength[N/mm2]

Minimum notchimpact energy,

test temperature

Minimumbending angle 1

Mandrel diameter(t = specimen

thickness)

3 to 9 inaccordance

withTable 5.14

Y42

Y46

Y50Y55

Y62

Y69

530 – 680

570 – 720

610 – 770670 – 830

720 – 890

770 – 940

Depending on thequality grade andadded symbol inaccordance with

Table 5.15

120° or providedthat the bending

elongation isattained 2

4 t

4 t

4 t5 t

5 t

5 t

1 Bending angle attained before the first incipient crack, minor pore exposures up to a maximum length of 3 mm allowed.2 If the specified bending angle of 120° is not attained, the requirements will still be regarded as having been met provided that the

bending elongation attained with a gauge length of L0 = Ls + t (Ls = width of weld, t = thickness of specimen, see sketch below) before

the first incipient crack complies with the elongation requirements given in Table 5.15.

�

� �

��

�

��

� . �� / � � . ��

��

��

G. Welding Consumables and Auxiliary Ma-terials for Steels Tough at Subzero Tem-peratures

1. General

1.1 The following provisions apply to weldingconsumables and auxiliary materials for welding ofsteels tough at subzero temperatures in accordancewith the GL Rules for Materials governing the fabri-cation of vessels, pipelines, etc. for liquefied gases.

Note:

According to the Society's Rules for Materials, thesteels tough at subzero temperatures used in ship-building fall into three categories: low-alloy carbon-manganese steels, nickel alloy steels and austeniticsteels. The following paragraphs are therefore con-cerned with welding consumables and auxiliary mate-rials for these three categories of materials. Othersuch products are to be treated in analogous manner;for aluminium alloys, see J.

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1.2 Depending on their nature and properties(type of alloy), welding consumables and auxiliarymaterials for welding of steels tough at subzero tem-peratures are classified and approved in the same wayas those for high-strength (quenched and tempered)structural steels in accordance with F. or those for(austenitic) stainless steels or, where applicable, nickelalloy steels tough at subzero temperatures in accor-dance with I. No special indication of suitability forlow-temperature service is given (except with thequality grade in accordance with F.); individual suit-ability for low-temperature service (test temperaturefor the notched bar impact test and proven notch im-pact energy) is indicated in the approval certificate. Ingeneral, the minimum service (design) temperature is5 °C above this test temperature.


2.1 Testing of the weld metal shall be carried outin accordance with the nature of the welding consum-ables and auxiliary materials, as described in F. and I.Unless otherwise stipulated in a particular case, thetest temperatures for the notched bar impact test statedin these provisions shall be replaced by the test tem-peratures shown in Table 5.17.

2.2 The requirements applicable to the strengthand elongation of the weld metal are determined bythose applying to the base material; cf. II - Rules forMaterials, Part 1, Chapter 2, Sections 1, F., 2, D.3, F.and 4, E. If particular base materials are welded withdissimilar welding consumables and auxiliary materi-als with strength values below those of the base mate-rial (e.g. in welding of 9 % nickel steel), the strengthvalues used in the design calculations for the compo-nents shall apply. Unless otherwise stipulated, theminimum notch impact energy values at the test tem-peratures shown in Table 5.17 shall be 47 J (meanvalue) and 39 J (lowest individual value).


The testing on the welded joints shall be performed inaccordance with the nature of the welding consum-ables and auxiliary materials as described in F. and I.In the case of welding consumables and auxiliarymaterials for nickel alloy steels, the welded joints shallbe made with the base material for which approval hasbeen solicited. In the case of such products for (low-alloy) carbon-manganese steels and austenitic steels, abase material of similar composition may be used. Inall other respects, 2.1 and 2.2 apply in analogousmanner.

4. Hydrogen test

4.1 If a hydrogen test is stipulated for the weldingconsumables and auxiliary materials in question (e.g.

according to F.4), it shall be performed in this casetoo. The requirements stipulated for each individualcase apply.


5.1 The annual repeat tests specified in A.3.1shall entail the preparation and testing of weld metaltest pieces as prescribed under 2. The Society mayrequire more extensive repeat tests (cf. A.3.2, A.7.4and A.7.5).

H. Welding Consumables and Auxiliary Ma-terials for High-Temperature Steels

1. General

1.1 The following provisions apply to weldingconsumables and auxiliary materials for welding ofhigh-temperature steels in accordance with the GLRules for Materials governing the fabrication of steamboilers, pressure vessels, pipelines, etc. with highservice temperatures.

Note:

Under the Society’s Rules for Materials, this essen-tially applies to the carbon-manganese steels P235GH(H I), P265GH (H II), P295GH (17Mn4), P355GH(19Mn6), the molybdenum alloy steel 16Mo3 (15Mo3)and the chromium-molybdenum alloy steels 13CrMo4-5 (13CrMo4-4), 10CrMo9-10 (10CrMoI-10 ) and11CrMo9-10 in accordance with EN 10028 Part 2.The following paragraphs are therefore concernedwith welding consumables and auxiliary materials forthese steels. Other such products are included if theycan be classed among the materials also covered bythe approval as shown in Table 5.18. Other weldingconsumables and auxiliary materials for other high-temperature steels are to be treated in analogousmanner.

1.2 Welding consumables and auxiliary materialsfor high-temperature steels are classified into thequality grades shown in Table 5.18 according to theirchemical composition (type of alloy) and mechanical(strength) characteristics and approved according tothese grades. The testing and approval of a steel in theleft-hand columns of Table 5.18 encompasses thesteel(s) in the right-hand columns. The different high-temperature strength properties are to be borne inmind. The table applies in analogous manner to thecorresponding grades of forgings and steel castings.



H

Table 5.17 Minimum design temperatures and test temperatures for the notched bar impact test

Welding consumablesand auxiliary materials

for:

References to Rules and Standardsrelating to Materials

Minimum designtemperature

[°C]

Test temperature for thenotched bar impact test

[°C]

Fine grain structural steelsfor ammonia liquefied

under pressure

in accordance with II – Rules forMaterials, Chapter 2, Section 1, F.,

Table 1.160 – 20

High-strength (QT) finegrain structural steels withnominal yield strengths of

420 to 690 N/mm2

in accordance with manufacturer'sspecification and II – Rules for

Materials, Chapter 2,Section 1, F., Table 1.17

0 – 20

Other fine grain structuralsteels with nominal yield

strengths of up to355 N/mm2

e.g. to EN 10028, Part 3 – 45 1

5°C below minimumdesign temperature, but

not above – 20°C

Nickel steels with:0,5 % nickel

1,5 % nickel

3,5 % nickel

5 % nickel

9 % nickel

steels conforming to EN 10028 Part 4:13MnNi6-3

15NiMn6

12Ni14

12Ni19

X8Ni9, X7Ni9

– 55

– 60 2

– 90 2

– 105 2, 3

– 165

– 60

– 65 2

– 95 2

– 110 2 (– 196) 3

– 196

Austenitic steels

e.g.. to EN ............(AISI)

X2CrNi19-11 / 1.4306 (304L)

X2CrNiMo17-13-2 / 1.4404 (316L)

X6CrNiTi18-10 / 1.4541 (321)

X6CrNiNb18-10 / 1.4550 (347)

– 165 – 196

1 The Society may approve lower design temperatures (down to a maximum – 55 °C) provided that corresponding properties aredemonstrated in the approval test.

2 A lower design temperature may be approved for QT steels with a 1,5 %, 3,5 % and 5 % nickel content; in these instances the Societywill specify the test temperatures.

3 Steel with a 5 % nickel content may be approved for a minimum design temperature of – 165 °C subject to the provisions stipulated inthe Rules for Materials, Chapter 2, Section 1, F., Table 1.15, footnote 1; the test temperature is then – 196 °C.

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Table 5.18 Welding consumables and auxiliary materials for high-temperature steels

Testing and approval relating to steel 1: Steels also covered by the approval 2:Quality grade

Designation Material No.: Designation 1 Material No.:

235GH P235GH 1.0345 –– ––

265GH P265GH 1.0425 P235GH 1.0345

295GH P295GH 1.0481 P235GHP265GH

1.03451.0425

355GH P355GH 1.0473P235GHP265GHP295GH

1.03451.04251.0481

16Mo3 16Mo3 1.5415

P235GHP265GHP295GHP355GH

1.03451.04251.04811.0473

13CrMo4-5 13CrMo4-5 1.7335 16Mo3 1.5415

10CrMo9-10 10CrMo9-10 1.7380 16Mo313CrMo4-5

1.54151.7335

11CrMo9-10 11CrMo9-10 1.738316Mo3

13CrMo4-510CrMo9-10

1.54151.73351.7380

1 Steel grades in accordance with the Society's Rules for Materials or conforming to EN 10028.2 Steel grades in accordance with the Society's Rules for Materials or conforming to EN 10028 as well as other grades of forgings and

steel castings.

Table 5.19 Required properties of the weld metal at room temperature (+ 20 °C)

Quality grade

Minimum yieldstrength or0,2 %-proof

stress 1

ReL or Rp0,2[N/mm2]

Minimum tensilestrength

Rm

[N/mm2]

Minimumelongation

A5

[%]


[J]

235GH265GH 285 480 22

295GH355GH 360 520 22

16Mo3 355 510 22

13CrMo4-5 355 510 20

10CrMo9-1011CrMo9-10 400 520 18

47 (33)

1 The lower yield strength (ReL) shall apply. Where the yield strength is not clearly defined, the 0,2 % proof stress (Rp0,2)must be used.

2 Mean value of three specimens; for minimum individual values ( ) and retests, see B.2.4 and 2.5 as well as H.2.4.



H

Table 5.20 Yield strength resp. 0,2 % proof stress at elevated temperatures

Minimum yield strength resp. 0,2 % proof stress 1 at a temperature of °C

50 100 150 200 250 300 350 400 450 500Quality grade

[N/mm2]

235GH 206 190 180 170 150 130 120 110 –– ––

265GH 234 215 205 195 175 155 140 130 –– ––

295GH 272 250 235 225 205 185 170 155 –– ––

355GH 318 290 270 255 235 215 200 180 –– ––

16Mo3 –– –– –– 215 200 170 160 150 145 140

13CrMo4-5 –– –– –– 230 220 205 190 180 170 165

10CrMo9-10 –– –– –– 215 200 170 160 150 145 140

11CrMo9-10 –– –– –– –– 255 235 225 215 205 195

1 The lower yield strength (ReL) shall apply. Where the yield strength is not clearly defined, the 0,2 % proof stress (Rp0,2) must be used.

1.3 Welding consumables and auxiliary materialsfor components which are to undergo post-weld heattreatment must be tested and approved separately forthe untreated condition and for each heat-treated con-dition. In general, the relevant conditions are:

– U = untreated (as-welded condition) and

– S = annealed to relieve stresses.

In special cases, normalizing (N) or quenching andtempering (V) may be necessary. The annealing tem-peratures and times shall be those applicable to thesubsequent heat treatment of the components accord-ing to the standards, material data sheets, etc. Unlessmore precise data are given in these documents, theannealing temperatures and times specified in Chapter2, Section 3, Table 3.2 may be used.


2.1 The testing of the weld metal shall be per-formed according to the nature of the welding con-sumable or auxiliary material (and, where applicable,according to the welding process) using test piecesand specimens in analogous manner to the provisionsof B.2, C.2 or D.2. In addition, for determining the0,2 % proof stress at the maximum application tem-perature and at intermediate stages according to 2.3two further round tensile specimens are to be takenfrom each test piece and tested. For this purpose, thetest pieces shall be made correspondingly larger.

2.2 The chemical composition of the depositedweld metal shall be determined and certified in a man-ner analogous to that prescribed in B.2.2. The resultsof the analysis shall not exceed the limit values speci-fied in the standards (e.g. DIN 1599, EN 12070 of EN12071) or by the manufacturer, the narrower toler-ances being applicable in each case.

2.3 As a minimum requirement, the test speci-mens prescribed in B.2.3, C.2.3 or D.2.3 shall be takenfrom the weld metal test pieces and tested at roomtemperature. In addition, to determine the yieldstrength or the 0,2 % proof stress at the highest appli-cation temperature and at a second test temperature100 °C lower, two further round tensile test specimensshall be taken from the test pieces and tested..

The Society may require further specimens to be takenand tests to be performed, e.g. determination of the1,0 % proof stress, creep tests, notched bar impacttests on specimens subjected to ageing treatment orembrittlement tests.

2.4 The mechanical properties at room tempera-ture must meet the requirements stated in Table 5.19while the yield strength or the 0,2 % proof stresses atelevated temperature must conform to Table 5.20. Iffurther tests are demanded by the Society, the re-quirements will be stipulated separately on a case-by-case basis. The provisions of A.7.6, B.2.4, C.2.4 andD.2.4 apply in analogous manner to the performanceof the tests and any retests which may be required.

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3.1 Depending on the nature of the welding con-sumables and auxiliary materials (and on the weldingprocess conerned), the testing on the welded jointsshall be performed on butt-weld test pieces in analo-gous manner to the provisions of B.3, C.3, D.3 or E.2.

3.2 The butt-weld test pieces shall be prepared inanalogous manner to the procedures described inB.3.2, C.3.2, D.3.2 or E.2.2, taking Table 5.19 intoaccount. Wherever possible, the base material shouldbe a high-temperature steel corresponding to the qual-ity grade in question.

3.3 Depending on the welding process, the testspecimens described in B.3.3, C.3.3, D.3.3 or E.2.3shall be taken from the butt-welded test pieces, unlessotherwise specified.

3.4 The mechanical characteristics of the weldedjoint must meet the requirements for the weld metalstated in Table 5.19; except in the case of the yieldstrength. The provisions of A.7.6, B.3.4, C.3.4, D.3.4and E.2.4 apply in analogous manner to the perform-ance of the tests and any retests which may be re-quired.

4. Hydrogen test

If a hydrogen test is required, it shall be performed inaccordance with B.4. The diffusible hydrogen contentshall not exceed 10 ml per 100 g of deposited weldmetal.

5. Testing for hot cracks

If testing for hot cracks is required, this shall be per-formed in accordance with B.5 or the relevant stan-dards (e.g. DIN 50129).


6.1 The annual repeat tests specified in A.3.1shall entail the preparation and testing of weld metaltest pieces as prescribed under 2. The Society mayrequire more extensive repeat tests (cf. A.3.2, A.7.4and A.7.5).

6.2 The annual repeat tests shall be performedaccording to the prescribed scope for both the un-treated condition and the various (approved) heat-treated conditions (cf. 1.3).

I. Austenitic and austenitic-ferritic weldingconsumables and auxiliary materials forstainless steels, non-magnetic steels andnickel alloy steels tough at subzero tem-peratures

1. General

1.1 The following provisions apply to weldingconsumables and auxiliary materials for welding ofstainless (austenitic) steels and steel castings, platesclad with these materials and joints of these materialswith unalloyed and low-alloy (hull) structural steels.They also apply to welding consumables and auxiliarymaterials for welding of non-magnetic steels, nickelalloy steels tough at subzero temperatures and other,similar steels. Austenitic welding consumables andauxiliary materials for clad welding and for joiningdifficult weldable (ferritic) materials are to be treatedin analogous manner.

Notes:

In (tanker) shipbuilding, the current practice is to use,in the main, the (austenitic or austenitic-ferritic) mo-lybdenum alloy stainless steels listed in the three left-hand columns of Table 5.21. For equipment compo-nents, use is also made of, among others, steels oftypes 5CrNi18-10 (mat. no. 1.4301, AISI 304) andX6CrNiTi18-10 (mat. no. 1.4541, AISI 321). The fol-lowing paragraphs therefore relate to welding con-sumables and auxiliary materials for these base mate-rials including their joints with hull structural steels.Furthermore, the welding consumables and auxiliarymaterials for which the Society had already grantedapproval have also been included. Welding consum-ables and auxiliary materials for other base materialsshould, where applicable, be allocated to the appro-priate categories and treated in analogous manner.

Inert gases with 1 to 3 % of oxygen added or thosewith a maximum of 2,5 % CO2 added can be used asshielding gases for welding austenitic welding con-sumables in the range of application specified in 1.1.Those inert gases with a high level of nitrogen addedcan be used for steels which contain nitrogen. Gasmixtures of the type M 21 (cf. Table 5.8) with a maxi-mum of 18 % of CO2 added may only be used withslag-forming flux-cored wire electrodes. Approvals for(flux-cored) wire-gas combinations are also grantedaccordingly.

1.2 Welding consumables and auxiliary materialsfor welded joints uniting (austenitic or austenitic-ferritic) stainless steels to one another are classifiedinto the quality grades shown in Table 5.21 accordingto the chemical composition (material no.) and me-chanical (strength) characteristics of the base materi-als to be welded. The testing and approval of a steel inthe left-hand column of the table encompasses the



I

steel(s) in the right-hand column, subject to separateconsideration of the corrosion conditions in each case.The table applies in analogous manner to the corre-sponding grades of forgings and steel castings.

1.3 Welding consumables and auxiliary materialsfor welding of non-magnetic stainless steels are ap-proved according to a quality grade corresponding tothe chemical composition (material no.) of the weldmetal. Table 5.22 contains a number of examples. Thetesting and approval of a steel in the left-hand columnencompasses the steel(s) in the right-hand column,subject to separate consideration of the corrosion con-ditions in each case. The table applies in analogousmanner to the corresponding grades of forgings andsteel castings.

1.4 Welding consumables and auxiliary materialsfor joining (austenitic or austenitic-ferritic) stainlesssteels to unalloyed or low-alloy steels, for intermedi-ate runs in welding of clad plates and for clad weldsare approved according to a quality grade corre-sponding to the chemical composition of the weldmetal. Table 5.23 gives a number of examples. Ap-proval is granted with due regard to the mechanicaland other properties in relation to the base materialsconcerned and/or for a particular type of applicationfor which suitability has been proved.

1.5 Austenitic welding consumables and auxil-iary materials, including those made of nickel basedalloys for welding of nickel steels tough at subzerotemperatures are classified into quality grades asshown in Table 5.24 according to the chemical com-position (material no.) and mechanical (strength andtoughness) characteristics of the base materials to bewelded. The testing and approval of a steel in the left-hand column encompasses the steel(s) in the right-hand column. The table applies in analogous mannerto the corresponding grades of forgings and steelcastings.


2.1 For testing the deposited weld metal, testpieces analogous to those called for in B.2.1 (only onetest piece welded in the down-hand position), C.2.1 orD.2.1 shall be prepared, depending on the nature ofthe welding consumables and auxiliary materials (and

according to the welding process). The base materialused shall be a stainless steel of the same composition,or the side walls of the weld shall be buffered with aweld metal of such composition.

2.2 The chemical composition of the depositedweld metal shall be determined and certified in a man-ner analogous to that prescribed in B.2.2. As an alter-native, the chemical composition may be determinedin a manner analogous to DIN 8556, Part 2 by analysisof a build-up weld. The results of the analysis shall notexceed the limits specified in the standards or by themanufacturer, the narrower tolerances being applica-ble in each case.

For the welding consumables and auxiliary materialsspecified in Tables 5.23 and 5.24, the pitting resis-tance equivalent (% Cr + 3,3 % Mo) shall be at least1 % higher than that of the base material on which thetest was carried out resp. on which approval wasbased. The analysis of the weld metal and an averagechemical composition determined from the data givenin the standards shall be the determining factors insuch a case.

2.3 Depending on the nature of the welding con-sumables and auxiliary materials (and according to thewelding process), the test specimens shall be takenfrom the weld metal test pieces in a manner analogousto the provisions of B.2.3, C.2.3 or D.2.3.

2.4 The mechanical properties must meet therequirements stated in Table 5.25. The provisions ofB.2.4, C.2.4 and D.2.4 apply in analogous manner tothe performance of the tests and the carrying out ofretests. For the welding consumables and auxiliarymaterials referred to in 1.4, the requirements dependon the particular application and are determined on acase-by- case basis. The notch impact energy valuesdemonstrated during the test and also the test tem-peratures are indicated in the approval certificate.Welding consumables and auxiliary materials forjoining stainless to normal-strength or higher-strengthhull structural steels must, as a minimum requirement,meet the requirements relating to those for the latter.For the welding consumables and auxiliary materialsreferred to in 1.5, G.2.2 and Table 5.17 should also benoted.

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Table 5.21 Austenitic welding consumables and auxiliary materials for welding of stainless steel

Testing and approval relating to steel Steels also covered by the approvalQualitygrade

Designation Mat. No./AISI Designation Mat. No./AISI

4301 X5CrNi18-10 1.4301/304 –– ––

4306 X2CrNi19-11 1.4306/304 LX5CrNi 18-10C2CrNi18-9

GX6CrNi18-9

1.4301/3041.4307/3047L

1.4308/–4307 X2CrNi18-9 1.4307/304L X5CrNi18-10 1.4301/304

4404 X2CrNiMo17-13-2 1.4404/316 L

X5CrNi18-10X2CrNi19-11GX6CrNi18-9

X5CrNiMo17-12-2GX6CrNiMo18-9

1.4301/3041.4306/304 L

1.4308/–1.4401/316

1.4408/–

4429 X2CrNiMoN17-13-3 1.4429/316 LN

X2CrNiN18-10X5CrNiMo17-12-2X2CrNiMo17-13-2

X2CrNiMoN17-12-2GX6CrNiMo18-9

X2CrNiMo18-14-3X5CrNiMo17-13-3

X6CrNiMoTi17-12-2X10CrNiMoTi18-12

X6CrNiNoNb17-12-2X10CrNiMoNb18-12

1.4311/303 LN1.4401/316

1.4404/316 L1.4406/316 LN

1.4408/–1.4435/316 L1.4436/316

1.4571/316 Ti1.4573/–

1.4580/316 Cb1.4583/318

4435 X2CrNiMo18-14-3 1.4435/316 L


X5CrNiMo17-12-2X2CrNiMo17-13-2GX6CrNiMo18-9

1.4301/3041.4306/304 L

1.4308/–1.4401/316

1.4404/316 L1.4408/–

4438 X2CrNiMo18-16-4 1.4438/317 L

X5CrNiMo17-12-2X2CrNiMo17-13-2X2CrNiMo18-14-3X5CrNiMo17-13-3

1.4401/3161.4404/316 L1.4435/316 L1.4436/316

4439 X3CrNiMoN17-13-5 1.4439/(317 LN)

X2CrNiMoN17-12-2X2CrNiMoN17-13-2X2CrNiMo18-16-4

GX2CrNiMoN17-13-4GX6CrNiMo17-13X5CrNiMo17-13

1.4406/316 LN1.4429/316 LN1.4438/317 L

1.4446/–1.4448/–

1.4449/317

4462 X2CrNiMoN22-5 1.4462/–X8CrNiMo27-5

X6CrNiMo24-8-2X4CrNiMoNb25-7

1.4460/3291.4463/–

1.4582/329

4550 X6CrNiNb18-10 1.4550/347


X6CrNiTi18-10GX7CrNiNb18-9

1.4301/3041.4306/304 L

1.4308/–1.4541/321

1.4552/–

4571 X6CrNiMoTi17-12-2 1.4571/316 Ti


X5CrNiMo7-12-2X2CrNiMo17-13-2GX6CrNiMo18-9

X2CrNiMo18-14-3X5CrNiMo17-13-3

X6CrNiTi18-10X6CrNiNb18-10GX7CrNiNb18-9

X10CrNiMoTi18-12X6CrNiMoNb17-12-2GX7CrNiMoNb18 -2X10CrNiMoNb18-12

1.4301/3041.4306/304 L

1.4308/–1.4401/3161.4404/316

1.4408/–1.4435/316 L1.4436/3161.4541/3211.4550/347

1.4552/–1.4573/–

1.4580/316 Cb1.4581/–

1.4583/318



I

Table 5.22 Austenitic welding consumables and auxiliary materials for welding of non-magnetic stainlesssteels

Testing and approval relating to steel 1 Steels also covered by the approval 1

Qualitygrade

Designation Mat. No. Designation Mat. No.

3954 X2CrNiMnMoNNb21-16-5-3 1.3964

X4CrNiMnMoN19-13-8X2CrNiMoN22-15

X2CrNiMoN18-14-3X2CrNiMo18-15

1.39481.39511.39521.3953

3984 X2CrNiMnMoNNb23-17-6-3 1.3974

X2CrNiMnMoNNb21-15-7-3X2CrNiMoN22-15

X2CrNiMoN18-14-3X2CrNiMnMoNNb21-6-5-3

1.39141.39511.39521.3964

1 Steels in accordance with the BWB Material Performance Sheets having the corresponding material number.

Table 5.23 Austenitic welding consumables and auxiliary materials for joining stainless steels to unalloyedor low-alloy steels, for intermediate runs and for clad welds (examples)

Welding consumable(weld metal)Quality

gradeDesignation 1 Mat. No./AWS

Usage(Instruction) 2

4332E 23 12 nC

X2CrNi24-12(1.4332) / E 309 L1.4332 / E 309 L

Intermediate runs for welded jointsbetween clad plates of similar com-position. Welded joints betweenheat resistant CrNi steels, jointsbetween stainless and unalloyed orlow-alloy steels. Clad welds.

4370E 18 8 Mn 6

X15CrNiMn18-8(1.4370) / (E 307)1.4370 / –

Joints between stainless and unal-loyed or low-allow steels.

4431E 20 10 3

X12CrNiMo19-101.4431 / –1.4431 / – as for 4370

4459E 23 12 2

X8CrNiMo23-31.4459 / E 309 Mo

(1.4459) / (E 309 Mo) as for 4332

1 First line (E....): Designation for covered electrode, second line: designation for (flux-cored) wire –gas and wire flux combinations2 The manufacturer's information given for the individual product are decisive abbr. information mentioned in the approval.

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I

Table 5.24 Austenitic welding consumables and auxiliary materials for welding of nickel steels tough atsubzero temperatures (examples)

Testing and approval relating to steel 1 Steels also covered by the approval 1Qualitygrade


5637 12Ni14 (3,5 % Ni) 1.5637 –– ––

5680 12Ni19 (5 % Ni) 1.5680 12Ni14 (3,5 % Ni) 1.5637

5662 X8Ni9 (9 % Ni) 1.5662 12Ni14 (3,5 % Ni)G9Ni14 (3,5 % Ni)12Ni19 ( 5 % Ni

1.56371.........1.5680

5663 X7Ni9 (9 % Ni) 1.5663 12Ni14 (3,5 % Ni)G9Ni14 (3,5 % Ni)12Ni19 ( 5 % Ni)X8Ni9 ( 9 % Ni)

1.56371.........1.56801.5662

1 Steels conforming to EN 10028-4.

Table 5.25 Required properties of the weld metal

Minimum 0,2 %proof stress

Tensilestrength

Minimumelongation

Minimum notchimpact energy

Test temperatureQuality grade

[N/mm2] [N/mm2] [%] [J] 1 [°C]

4306

4404

4429

4435

4438

4439

195

205

295

205

205

295

500 – 700

510 – 710

580 – 800

510 – 710

510 – 710

580 – 800

30

30

30

30

30

30

47 (33) + 20 2

4462 480 680 – 900 25 35 (24) – 30

4550

4571

205

225

510 – 740

500 – 740

30

30 47 (33) + 20 2

3954

3984

430

510

700 – 950

850 – 1050

3070 (49) + 20

5637

5680

5662

5663

355

390

490 5

585

490 – 640

530 – 840

640 5 – 840

680 – 820

22

20

18

18

47 (33)

– 95 3

– 196 3

– 110 (– 196) 3, 4

– 196 3

1 Means value of three specimens; for individual values ( ) and retests, see I.2.4.2 In the case of low-temperature applications, special requirements apply: cf. G. (Table 5.17 and G.2.2).3 Cf. G. (Table 5.17 and G.2.2).4 If quality grade 5680 (welding of 5 % nickel steel) is to be applied at a minimum design temperature of – 165 °C. The test temperature

shall be – 196 °C.5 If the "as dilivered" condition (of the base material) is HT 640, this welding consumable shall also be approved for the as-delivered

condition HT 680 of the base materials. In such a case the same minimum requriements as stated for quality grade 5663 shall apply.



J


3.1 Depending on their nature (and on the weld-ing process concerned), the testing on welded jointsmade with the welding consumables and auxiliarymaterials referred to in 1.2, 1.3 and 1.5 shall be per-formed on butt-weld test pieces analogous to thoseprescribed in B.3.1, C.3.1 or D.3.1. For the weldingconsumables and auxiliary materials covered by para.1.4, testing of welded joints is required only if theproducts are used wholly or chiefly for making weldedjoints or where, in welded joints, they constitute asubstantial proportion of the weld section (as in thecase of the intermediate runs of welds joining cladplates). However, the Society may call for specimenwelds to prove the satisfactory performance of theseproducts in the various positions for which approval issolicited (see also A.6.). For welding consumables andauxiliary materials covered by 1.3 which are usedexclusively for clad welding, the scope of the tests tobe applied shall be determined on a case-by-case ba-sis.

3.2 Depending on the nature of the welding con-sumables and auxiliary materials (and according to thewelding process), the butt-weld test pieces called forin para. 3.1 shall be welded in a manner analogous tothat prescribed in B.3.2, C.3.2 or D.3.2. The basematerial used shall be a steel of the same or similarcomposition in accordance with Tables 5.21, 5.22 and5.24 and shall possess at least the mechanical proper-ties indicated in Table 5.25. An analogous procedureshall be adopted in the case of the welding consum-ables and auxiliary materials covered by para. 1.4 andTable 5.25.

3.3 Depending on the nature of the welding con-sumables and auxiliary materials (and according to thewelding process), the test specimens prescribed inB.3.3, C.3.3 or D.3.3 shall be taken from the butt-welded test pieces.

3.4 The mechanical properties must meet therequirements stated in Table 5.25. The Society mayagree to the application in analogous manner of foot-note

1 in Table 5.15 also for the austenitic welding

consumables and auxiliary materials covered by thissection. The provisions of A.7.6, B.3.4, C.3.4 andD.3.4 apply in analogous manner to the performanceof the tests and the carrying out of retests.

4. Testing of resistance to intergranular cor-rosion

4.1 Testing of resistance to intergranular corro-sion (IC) shall be performed in accordance withDIN 50914 on test specimens with intersecting buttwelds using the copper sulphate - sulphuric acidmethod (Strauss test). No cracks may be detected andthe metallographically measured depth of penetration

of the attack at the grain boundaries shall not exceed0,05 mm.

4.2 In the case of special corrosion conditions orparticular materials, the Society may stipulate othercorrosion tests as an additional or alternative measure,e.g. testing of resistance to pitting under corrosiveattack by chlorides, e.g. by seawater.

5. Testing for hot cracks

5.1 Testing for hot cracks is to be performed inanalogous manner to the provisions of B.5. orDIN 50129 on the (shape 2) test piece prescribed foraustenitic welding consumables and auxiliary materi-als.

5.2 Other methods of testing for hot cracks maybe agreed with the Society.


6.1 The annual repeat tests specified in A.3.1shall entail the preparation and testing of weld metaltest pieces as prescribed under 2. (determination of themechanical properties and chemical composition ofthe weld metal). If the tensile strengths prescribed inTable 5.25 are not attained and footnote 1) in Table5.15 applies analogously, the repeat test, too, shallinclude the testing of flat tensile specimens taken fromthe welded joints.


J. Welding Consumables and Auxiliary Ma-terials for Aluminium Alloys

1. General

1.1 The following provisions apply to weldingconsumables and auxiliary materials for the weldingof aluminium alloys for structural components andequipment parts used in shipbuilding and mechanicalengineering. Welding consumables and auxiliary ma-terials for the welding of aluminium alloys for low-temperature applications are dealt with separately, therequirements being specified on a case-by-case basisin accordance with the application conditions. Cf. G.

Note:

In the present state of shipbuilding technology onlythe MIG and TIG inert gas welding methods usingargon or helium or their mixtures and plasma arcwelding are of practical significance. Because of theirsuitability for seawater applications, the wrought

II - Part 3GL 2000


J

alloys indicated in columns 2 and 3 of Table 5.26 aremainly used, cf. II - Rules for Materials, Part 1,Chapter 3, Section 1., A.4. Cast alloys are hardly everused for load-bearing structural components in ship-building. The following paragraphs therefore relatechiefly to wire-gas combinations for the aforemen-tioned wrought alloys. Other welding consumablesand auxiliary materials or those for other base mate-rials shall be treated in analogous manner. The re-quirements are determined by those applicable to thebase materials being welded together and are speci-fied on a case-by-case basis.

1.2 In accordance with European standards draftsexisting up to now, welding consumables and auxil-

iary materials (wire (electrode) or filler rod shieldinggas combinations) for the welding of aluminium alloysare classified into the quality grades shown in Table5.26 on the basis of their chemical composition andmechanical (strength) properties. Testing and approvalof the base material in the left-hand columns of thetable also encompasses the base material(s) shown inthe right-hand columns.

1.3 Approval is tied up with a specific shieldinggas as prescribed in Table 5.27 or with a "special gas"which is defined separately according to its composi-tion and purity. The composition of the shielding gasused in the test is to be recorded.

Table 5.26 Welding consumables for aluminium alloys

Testing and approval relatingto the base material 1

Base material alloys alsocovered by the approvalQuality grade

Alloy No. Mat. Designation Alloy No. Mat. Designation

RAIMg3 2 EN AW-5754 EN AW AlMg3 –– ––

RAlMg4 3 EN AW-5086 EN AW AlMg4 EN AW-5754 EN AW AlMg3

RAlMg4,5 4 EN AW-5083 EN AW AlMg4,5Mn0,7

EN AW-5754

EN AW-5086

EN AW 6005(A)

EN AW 6061

EN AW 6082

EN AW AlMg3

EN AW AlMg4

EM AW AlSiMg(A)

EN AW AlMgISiCu

EN AW AlSilMgMn

RAlSi5 5 EN AW-6082 EN AW AlSilMgMn

EN AW-5754 6

EN AW-5086 6

EN AW-5083 6

EN AW 6005(A) 6

EN AW 6061 6

EN AW 6082 6

EN AW AlMg3 6

EN AW AlMg4 6

EN AE AlMg4,5Mn0,7 6

EN AW AlSiMg(A) 6

EN AW AlMglSiCu 6

EN AW AlSiMgMn 6

RAlMg4,5mod. EN AW-5383 AlMg4,5Mn0,7 mod as for RAlMg4,5

RAlMg5,5 –– AlMg5,5Mn0,8ZnZr as for RAlMg4,5

1 In respect to the bend test (see Table 5.28) it is recommended to carry out the test with base material in soft conditions2 e. g. welding consumables RAlMg3Mn0,4 / R5018 conforming to EN ......... (at the moment draft European Standard without no.)3 e. g. welding consumables RAlMg5 / R5119 conforming to EN ......... (at the moment draft European Standard without no.)4 e. g. welding consumables RAlMg4,5Mn0,7(A) / R5183 or RAlMg4,5MnZr / R5087 conforming to EN ......... (at the moment draft

European Standard without no.)5 e. g. welding consumables RAlSi5(A) / R4043 conforming to EN ......... (at the moment draft European Standard without no.)6 In the case of less exacting strength requirements, the strength values established during the welding procedure tests shall apply for

dimensioning purposes. The values given in Table 5.28 provide an indication.



J

Table 5.27 Shielding gases for the welding ofaluminimum alloys

Composition of shielding gas(Vol. %) 1

GroupArgon Helium

I-1 100 ––

I-2 –– 100

I-3(1) Remainder > 0 to 33 2



S"Special gas", Composition

specified, cf. 1.3

1 The purity and other properties of the shielding gasesmust comply with EN 439/ISO 14175.

2 Where argon (up to a max. 95 %) is replaced by heliumand the helium content is marked by means of an addedsymbol, a gas with the following composition must beused for the test.:– for (1) = > 0 to 33 % He:

an argon-helium mixture containing approx. 15 %helium

– for (2) = > 33 to 66 % He:an argon-helium mixture containing approx. 50 %helium

– for (3) = > 66 to 95 % He:an argon-helium mixture containing approx. 75 %helium, Group I-2 is included in this case.


2.1 Unless otherwise specified (e.g. testing thestrength properties of the pure weld metal for thewelding together of large wall thicknesses), the testingof the weld metal shall consist of an analysis of thedeposited weld metal.

2.2 The chemical composition shall be deter-mined and certified in a manner analogous to thatprescribed in B.2.2 using a build-up weld in accor-dance with EN 26847/ISO6847. The results of theanalysis shall not exceed the limits specified in thestandards or by the manufacturer, the narrower toler-ances being applicable in each case.


3.1 The testing on welded joints shall be per-formed in a manner analogous to that prescribed inpara. B.3 resp. C.3, as applicable, on butt-weld testpieces conforming to Fig. 5.16. The base materialsindicated in Table 5.26 shall be used. The plate thick-nesses shall be 10 – 12 mm for MIG and plasma arcwelding and 4 – 6 mm for TIG welding.

3.2 Depending on the welding positions forwhich approval is solicited (cf. A.4.9), the butt-weldtest pieces shown in Fig. 5.16 shall be welded in thepositions indicated in Table 5.4, including as a mini-mum requirement the downhand PA (d) and vertical-up PF (v-u) positions.

The wire diameters shall conform to Table 5.9 and thewelding parameters to the manufacturer's or supplier'srecommendations. The composition of the shieldinggas used for the test shall be stated in the report. Forthe welding of the test pieces, see also DIN 1732, Part2. The root may be mechanically grooved and backwelded.

Post-weld heat treatment of the test piece (e.g. in thecase of age-hardenable alloys) is only allowed if suchheat treatment may and is to be carried out in the fu-ture production of welded components (cf. the pre-liminary remarks to Section 5). Where necessary, theheat treatment must be agreed prior to the test and is tobe recorded in the test report.

3.3 Following the recommended radiographicexamination, the following test specimens shall betaken from each butt-weld test piece in accordancewith Fig. 5.16: four flat tensile test specimens con-forming to EN 895/ISO 4136, four transverse bendtest specimens (two FBB and two RBB) conformingto EN 910/ISO 5173 and a macrographic specimen. Ofthe four flat tensile specimens, two shall be tested withthe weld reinforcement in place and two with the weldreinforcement machined off. Of the transverse bendtests (with the weld reinforcement machined off), twoare to be tested with the cover pass in tension and twowith the back pass in tension.

3.4 The mechanical characteristics must meet therequirements stated in Table 5.28. The provisions ofA.7.6, B.3.4 and C.3.4 apply in analogous manner tothe performance of the tests and the carrying out ofretests. The position of the fractures is to be stated inthe test report. With the transverse bend test speci-mens the bending elongation is to be determined. Themacrographic specimen shall be examined for defects(such as lack of fusion, cavities, inclusions, pores andcracks).

3.5 Fillet-weld test pieces analogous to thosecalled for in B.3.5 or C.3.5, as applicable, shall beprovided for those welding consumables and auxi-liary materials (wire-gas combinations) which are tobe approved or used exclusively for the execution offillet welds. In special cases, the Society may call forfillet-weld test pieces in addition to the butt-weld testpieces prescribed in para. 3.1.

II - Part 3GL 2000


K

(00

��!��#��

� ��

&

'

&

(00&

�00&

&

(00

�00

'

� (��

� 1��2�� 3 ��2��

� 1��2�� 3 ��4 ��

� '��

�00

Fig. 5.16 Butt-weld test piece


4.1 The annual repeat tests called for in A.3.1shall entail the preparation and testing of a butt-weldtest piece in accordance with 3. welded in the down-hand position with wire of 1,2 mm diameter. Half asmany specimens may be used in the repeat tests as inthe initial test (Fig. 5.16).

4.2 In special cases, the Society may requiremore extensive repeat tests (e.g. analysis of the weldmetal as an additional measure) (cf. A.3.2, A.7.4 andA.7.5).

K. Welding Consumables and Auxiliary Ma-terials for Copper and Copper Alloys

1. General

1.1 The following provisions apply to weldingconsumables and auxiliary materials for the weldingof copper and copper alloys conforming to the Soci-ety's Rules for Materials and used for structural com-ponents in shipbuilding (e.g. rudders) and especiallyfor pipelines conveying seawater.

Note:

According to the Society's Rules for Materials, besidescopper and high-strength brass, the copper-nickelalloys CuNi10Fe1Mn and CuNi30Mn1Fe as well ascertain cast copper alloys (used in the manufacture ofpropellers) are mainly used for welding purposes. Inaccordance with current approval practice, the fol-lowing paragraphs therefore relate to welding con-sumables and auxiliary materials for these base mate-rials; other such products for the welding of other castalloys are to be treated in analogous manner.

1.2 Welding consumables and auxiliary materialsfor welding of copper and copper alloys are classifiedinto the quality grades shown in Table 5.29 on thebasis of their chemical composition (type of alloy) andmechanical (strength) properties. Testing and approvalin respect of a base material in the left-hand column ofTable 5.29 also encompasses the base material(s)shown in the right-hand column.


2.1 Unless otherwise stipulated, the testing of theweld metal shall consist of a chemical analysis of thedeposited weld metal and a tensile test analogous tothat described in B.2 (only one test piece to be weldedin the down-hand position).



K

Table 5.28 Requirements applicable to welded joints

Quality gradeMinimum

tensilestrength 1

[N/mm2]

Diameter ofmandrel

(t = specimenthickness)

Minimum bending angle 2

Bendingelongation 3

[%]

RAlMg3 190 3 t 20

RAlMg4 240 17

RAlMg4,5 275

180°

17

RAlSi5 160 20° 8

RAlMg4,5Mnmod. 290 180° 17

RAlMg5,5 300

6 t

180°

orbending

elongationachieved 3

17

1 Using the base materials shown in Table 5.26, columns 2 and 3.2 Bending angle achieved before first incipient crack, minor pore exposures permitted up to a max. length of 3 mm.3 Where the bending angle is not achieved, the requirements shall still be regarded as having been met if the elongation achieved with a

gauge length L0 = Ls + t before the first incipient crack meets the requirements

– (Ls = width of seam, t = thickness of specimen, see sketch below)

Note:

Because of the different flow behaviour of the base material and the weld metal, incipient cracking of the specimens may occurprematurely - especially with too rapid deformation - when the “free” bending test according to DIN 50121, Part 1 is carried out. It isrecommended that a test rig of the type shown in the following sketch be used in which the bending test specimen, clamped at one end, is"rolled" around the mandrel

�

�3# � / �, / �35 �

�3�

�,

�

�

�

�

�

II - Part 3GL 2000


K

Table 5.29 Welding consumables and auxiliary materials for copper and copper alloys

Testing and approval related to Materials also covered by the approvalQuality grade


CuNi30Fe CuNi30Mn1Fe 2.0882

CuNi5Fe

CuNi10Fe1Mn

CuNi20Fe

2.0872

2.0878

CuNi30Mn CuNi30Mn1Fe 2.0822

CuNi5Fe

CuNi10Fe1Mn

CuNi20Fe

2.0872

2.0878

SCU1 1 CU1 5 ––– ––– –––

SCU2 2 CU2 5 ––– CU1 1 –––

SCU3 3 CU3 5 –––CU1 1

CU2 2

–––

–––

SCU4 4 CU4 5 –––

CU1 1

CU2 1

CU3 1

–––

–––

–––

1 e. g. Al-bronze or Mn-bronze2 e. g. Al-bronze or Ni-Mn-bronze3 e. g. Al-bronze, Ni-Al-bronze or Mn-Al-bronze4 e. g. Mn-Al-bronze5 Cast copper alloys (for propeller manufacture) in accordance with the Society's Rules for Materials or other comparable alloys with

the appropriate strength properties.

2.2 The chemical composition shall be deter-mined and certified in a manner analogous to thatprescribed in B.2.2. The results of the analysis shallnot exceed the limits specified in the standards (e.g.DIN 1733) or by the manufacturer, the narrower toler-ances being applicable in each case.


3.1 The testing on welded joints shall be per-formed in a manner analogous to that prescribed inJ.3. for welding consumables and auxiliary materialsfor aluminium alloys or, with the Society's consent, inaccordance with the standards (e.g. DIN 1733, Part 2).

3.2 The mechanical properties must conform tothe required properties of the base materials shown inTable 5.30. Different values for these properties areonly permissible with the Society's consent and are tobe taken into account where applicable when dimen-sioning the components.


4.1 The annual repeat tests called for in A.3.1shall entail the preparation and testing of a butt-weldtest piece in accordance with 3.1 welded in the down-hand position as in the case of aluminium alloys (cf.J.4.1).


Qualitygrade

Minimum0,2 %-proofstress

[N/mm2]

Tensilestrength

[N/mm2]

Minimumelongation

[%]

CuNi30Fe

CuNi30Mn

120

120

360 – 490

360 – 490

30

30

SCU1

SCU2SCU3

SCU4

175

195245

275

370 min.

410 min.500 min.

550 min.

20

1816

18



L

L. Welding Consumables and Auxiliary Ma-terials for Nickel and Nickel Alloys

1. General

1.1 The following provisions apply to weldingconsumables and auxiliary materials for welding ofnickel and nickel alloys.

Note:

According to current approval practice, the weldingconsumables and auxiliary materials shown in theleft-hand column of Table 5.31 are used. The follow-ing paragraphs therefore relate to welding consum-ables and auxiliary materials for these materials, butalso cover such products for joining of different mate-rials by welding (e.g. austenitic steels to ferritic/ per-litic steels) and especially for nickel steels tough atsubzero temperatures.

1.2 Welding consumables and auxiliary materialsfor welding of nickel and nickel alloys, for joining ofdifferent materials by welding and for welding ofnickel steels tough at subzero temperatures are classi-fied according to their chemical composition (type ofalloy) and mechanical properties (mechanical andtensile strength) into the quality grades shown in Ta-ble 5.31. The testing and approval of a base materialin the left-hand columns of Table 5.31 encompassesthe material(s) in the right-hand columns. Suitabilityfor welding of the nickel steels tough at subzero tem-peratures in low-temperature applications is indicatedseparately in the approval certificate; cf. G.


2.1 For testing the deposited weld metal, the testpieces described in the standards (e.g. DIN 1736, Part2 and DIN 32525) shall be prepared according to theprovisions of B.2., C.2., and D.2. The provisions ofthe standards with regard to the base materials to beused, including, where applicable, the buffering of theside walls of the weld, and to the welding parametersshall be complied with.

2.2 The chemical composition of the depositedweld metal shall be determined and certified in a man-ner analogous to the provisions of B.2.2, taking intoaccount the provisions of the standards. The results ofthe analysis shall not exceed the limits specified in thestandards or by the manufacturer, the narrower toler-ances being applicable in each case.

2.3 Depending on the nature of the welding con-sumables and auxiliary materials (and according to the

welding process), the test specimens shall be takenfrom the weld metal test pieces in accordance with thestandards and the provisions of B.2.3, C.2.3 and D.2.3.

2.4 The mechanical properties must meet therequirements stated in Table 5.32. For welding ofnickel steels tough at subzero temperatures, the notchimpact energy requirements stated in G.2.1 and G.2.2apply. The provisions of A.7.6, B.2.4, C.2.4 and D.2.4apply in analogous manner to the performance of thetests and any retests that may be necessary.

2.5 The Society may require other tests to beperformed or stipulate other values for the requiredproperties if they are more appropriate to the characterof the welding consumables and auxiliary materials orare necessitated by the intended use of the material.


3.1 Depending on the nature of the welding con-sumables and auxiliary materials (and on the weldingprocess concerned), the tests are to be performed onbutt-weld test pieces in a manner analogous to B.3.,C.3., or D.3

3.2 The butt-weld test pieces shall be welded inaccordance with B.3.2, C.3.2 or D.3.2, taking intoaccount the provisions of the above-mentioned stan-dards (cf. 2.1). Wherever possible, the base materialsshall be the materials to be welded in the future appli-cation; in any case, however, materials of adequatestrength must be used.

3.3 Unless otherwise stipulated, the test speci-mens prescribed in B.3.3, C.3.3 and D.3.3 for thevarious types of welding consumables and auxiliarymaterials (and, where applicable, the various weldingprocesses) shall be taken from the butt-weld testpieces.

3.4 The mechanical properties must meet therequirements stated in 2.4 and Table 5.32, with theexception of the proof stresses. The Society maystipulate other values for the required properties; cf.2.4.


4.1 The annual repeat test specified in A.3.1 shallentail the preparation and testing of a weld metal testpiece in accordance with 2. The Society may requiremore extensive repeat tests (cf. A.3.2, A.7.4 andA.7.5).

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Table 5.31 Welding consumables and auxiliary material for nickel and nickel alloys

Testing and approvalrelating to Materials also covered by the approval

Quality grade

Designation Mat. No. Designation Mat.-No.

Ni99,2

Ni99,6

LCNi99,6

LCNi99

2.4066

2.4056

2.4061

2.4068NiTi3

(2.4156)Ni 99,6 2.4060

and joints between different non-ferrousmetal alloys and with steels

NiTi4(2.4155) Ni 99,6 2.4060 as for NiTi3

NiCr15Fe

LC-NiCr15Fe

NiCr20Ti

NiCr20TiAl

NiCr23Fe

2.4816

2.4817

2.4951

2.4952

2.4851NiCr19Nb(2.4648)

NiCr15Fe 2.4816

and welded joints between different nickel alloys(except for NiCu) and with steels; welded joints in

nickel steels tough at subzero temperatures.

NiCr20Nb(2.4806) NiCr15Fe 2.4816 as for NiCr19Nb

NiCr16FeMn(2.4620) NiCr15Fe 2.4816 as for NiCr19Nb

NiCr21Mo

NiCr22Mo6Cu

NiCr22Mo7Cu

NiCr21Mo6Cu

2.4858

2.4618

2.4619

2.4641

NiCr20Mo9Nb(2.4621)

NiCr22Mo9Nb 2.4856

nickel steels tough at subzero temperatures

NiCr21Mo9Nb(2.4831) NiCr22Mo9Nb 2.4856 as for NiCr 20 Mo 9 Nb

NiCu30Mn(2.4366) NiCu30Fe 2.4360

NiCu30MnTi(2.4377) NiCu30Fe 2.4360

Joints with dissimilar materials, namely withunalloyed structural steels to EN 10025 and

boiler steels to DIN 17155



L

Table 5.32 Required properties of the weld metal 1

Proof stresses Tensile strength Elongation

Quality grade Rp 0,2[N/mm2]

min

Rp 1,0[N/mm2]

min

Rm[N/mm2]

min

A5[%]min

NiTi3NiTi4 200 220 410

NiCr19NbNiCr20Nb 360 380 600

NiCr16FeMn 360 380 600

NiCr20Mo9NbNiCr21Mo9Nb 420 440 700

NiCu30MnNiCu30MnTi 200 220 460

25

1 The notch impact energy stated in 2.4 and, where applicable, G.2.1 and G.2.2.

II - Part 3GL 2000

Section 6 Overweldable Shop Primers Chapter 1Page 6–1

B

Section 6

Overweldable Shop Primers

A. General

1. Overweldable shop primers applied to plates,sections, etc. before welding shall not significantlyimpair the quality of welded joints.

Note:

Research and practical experience hitherto indicatethat the characteristics of welded joints suffer practi-cally no deleterious effects apart from an increasedtendency towards porosity in fillet welds. Tests, ap-provals and supervisory measures are therefore exclu-sively concerned with this increased tendency towardsporosity.

2. Only those overweldable shop primers maybe used for which the Society has issued a confirma-tion of acceptability based on a porosity test relating tooverwelding.

3. The requirements relating to shop primers inrespect of corrosion protection are covered in theRules for Classification and Construction, I – ShipTechnology, Part 1, Chapter 1, Section 35.

4. Even where a confirmation of acceptabilityhas been issued, overweldable shop primers may onlybe approved for fully mechanized double fillet weldingafter a special welding procedure test in the user'sworks.

B. Testing and Approval of Shop Primers

1. Initial confirmation of acceptance

1.1 Application for a confirmation of acceptabil-ity shall be made, unaccompanied by any forms, to theSociety's head office together with the following in-formation and supporting documents:

– Manufacturer (and licensor, where applicable)

– Brand name (and licensor's brand name, whereapplicable) together with the original brandname in the case of commercial designationsused for marketing

– Code number / short name / symbol identifyingthe formulation or product

– Characteristic pigment base

– Characteristic binding agent base

– Data sheet with instructions for use (preparationof surface, methods of application, dry coatthickness, etc.)

– Documentation relating to previous tests, ap-provals, etc.

– Place and date of proposed tests.

1.2 The Society reserves the right to carry out aninspection of the manufacturer’s work. To this end,the Society’s Surveyor shall be granted access to allproduction and test departments and laboratories. Anexplanation of the production conditions is to be givento the Surveyor and particularly satisfactory qualityassurance measures demonstrated.

1.3 The porosity tests shall be performed byneutral, properly equipped testing authorities recog-nised by the Society for that purpose or by a suitabletest laboratory under the supervision of a Society Sur-veyor.

1.4 The test is to be performed in accordancewith the March 1976 edition of the German WeldingSociety guideline DVS 0501 "Porosity test relating tothe overwelding of shop primers on steel".

1.5 The identity of the coating material submittedfor testing shall be established and recorded in the testreport. This may be done by, for instance, stating thebatch/production number and date of manufacture. Incase of doubt, the Society may require a test (e.g. ofthe chemical composition) to verify the identity of thesample.

1.6 The mean total pore area to be determined inaccordance with regulation DVS 0501 shall not exceed150 mm².

Note:

The standardized testing of shop primers as pre-scribed in regulation DVS 0501 leads to heavy poros-ity not normal in ordinary practice. Together with thenumber of pores and the mean individual pore area,the mean total pore area has proved to be the mostserviceable criterion for the comparative assessmentof shop primers, although it does not permit any directinferences about the degree of porosity to be expectedunder the particular production conditions applicable.

Chapter 1Page 6–2

Section 6 Overweldable Shop Primers II - Part 3GL 2000

C

1.7 The Society’s Head Office issues a confirma-tion of acceptability based on the tests performed andthe records relating to these which must be submitted,and also based on the inspection of the manufacturer’swork where applicable and adopts the shop primer inthe list of approved welding consumables.

1.8 The confirmation of acceptability relates tothe particular product tested (brand name, formulation,identification number etc.) from a specific manufac-turer (production site). It does not relate to any otherproducts or to products from another production proc-ess. For information on transferring approval docu-ments, cf. 2.

1.9 With the issue by the Society of a confirma-tion of acceptability, the manufacturer (or, where ap-plicable, the marketing company) assumes responsi-bility for ensuring that the composition and character-istics of the shop primer remain constant (cf. Section1, F.1.). Any modifications shall automatically bedrawn to the Society's attention and shall normallynecessitate a new test in accordance with para. 1.4.

2. Transferring approval documents

2.1 In the case of products which have a differentbrand name but an identical formulation/identificationno. or another manufacturer’s products (a differentproduction site) with the same brand name, formula-tion/identification no. etc., the Society may agree totransfer the approval documents for products forwhich a confirmation of acceptability has already beenissued without necessitating a retest of the product asspecified in 1.3 and 1.4.

2.2 The information and documentation specifiedin 1.1 and also a statement of conformity from bothmanufacturers, together with documentary proof of theidentity of the product for which the first confirmationof acceptability was issued and that to which the ap-proval document is to be transferred, must be submit-ted to the Society with the simple application for thetransfer of approval documents.

2.3 Where an approval document is to be trans-ferred to a product from another manufacturer, theSociety may also carry out an inspection of the manu-facturer’s work at this other production site in accor-dance with B.1.2. The Society may also require pro-duction tests to be performed in accordance with C.

3. Validity, Extensions to Validity

3.1 Approvals (initial and transferred) are validfor 3 years. On application by the manufacturer theymay be extended by a further 3 years at a time. In theapplication, the manufacturer shall confirm in writingthat no changes have been made to the product sincethe initial approval was granted.

3.2 Proof that regular identity validation checkshave been made must be furnished by the manufac-turer. The requirement for product validation checksmay be satisfied by the submission of the manufac-turer’s quality inspection records and confirmation ofoutside supervision from a testing authority recognisedby the Society for that purpose.

3.3 The Society may demand a repeat test asspecified in 1.3 to 1.5 in doubtful cases or wherechanges have been made to the product or the manu-facturing conditions themselves have been altered.

C. Supervising the Use of Shop Primers, Pro-duction Tests

1. By suitable checks carried out in the course ofnormal production (e.g. measurements of coat thick-ness, production tests), workshops using shop primersshall ensure that the conditions of use on which theconfirmation of acceptability was based are adhered toand that, in fillet welding, no excessive pore formationoccurs which adversely affects the application.

Note:

The pores in fillet welds due to overweldable shopprimers occur mainly as strings of pores made up ofround or elongated individual pores. They originate atthe gap between the web plate and the plating orflange, to which they are usually joined, and seldomextend to the surface. They can therefore practicallyonly be detected by non-destructive or destructiveinspection methods.

2. Production tests are to be performed underthe Society's supervision on a random basis duringnormal fabrication, as a supplementary test when atransfer of approval is sought, when a shop primer ischanged or when the conditions of use are altered. TheSociety may demand production tests in doubtfulcases. The conditions in which the production testpieces are welded shall be the same as those prevailingin normal fabrication. Fabrication off-cuts may beused as production specimens.

3. T-joints as shown in Fig. 6.1 shall be pro-duced as part of the production test. To facilitate thebreaking open of the two welds (if possible, on thebisector of the angle made by the web plate and theplating or flange), the test piece shall be grooved in themanner shown in Fig. 6.1 and shall be divided into testsections each 100 mm long. Alternatively, fillet weld(cruciform) test pieces may be welded in accordancewith Chapter 3, Section 1, F.3.2 (Fig. 1.1) and testedin accordance with F.4.5.

II - Part 3GL 2000

Section 6 Overweldable Shop Primers Chapter 1Page 6–3

C

≈ 12

- 2

0

0 -

0,5

50≈ 100

≥ 6

≈60

≈40

100

100

≈ 300

test sections

2nd weld

1st weld

Fig. 6.1 Double fillet weld production test piece

4. The production test piece shall be brokenopen for assessment. The fracture surfaces of the weldrevealing the largest number of pores shall be as-sessed. The number of pores over a 100 mm weld

length shall be established and the individual poreareas shall be measured (e.g. as ellipses with the lengthand breadth of the pore providing the main axes).Pores whose largest main axis is less than 0.5 mm areignored.

5. The number of pores and individual poreareas are used to calculate the total pore area and thisis then related to the area of the weld fracture. Thepercentage pore area arrived at in this way shall bestated in the test report. The test report shall also statethe shop primer material, the coat thickness and thewelding parameters.

Note:

In DASt regulation 006 "Overwelding of shop primersin structural steelwork" issued by the DeutscherAusschuss für Stahlbau (German Committee forStructural Steelwork), the maximum permissible rela-tive pore areas are specified as 4 % for dynamicloading and 7 % for static loading. (Positive) Experi-ence to date shows that these figures are "on the safeside". In shipbuilding, somewhat higher figures maybe acceptable.

II - Part 3GL 2000

Annex A Application for Approval Chapter 1Page A–1

Annex A

Application for Approval

Application for Approval in accordance with the Rules for Welding

We,

COMPANY:

ADDRESS:

hereby make application for approval by Germanischer Lloyd

for the welding shop

for the welding consumables and auxiliary materials

for the welding shop named in the attached description or the products specified in the Annexes, asapplicable.

The applicant accepts the following conditions:

• The Rules for Classification and Construction (particularly, in this instance, the Rules for Welding)issued by Germanischer Lloyd (The Society) in the version applicable at the time application ismade.

• The applicant will ensure that all the information required for the approval, and specified in the rulesis provided and documents, test results etc. are submitted as applicable and that access to all therelevant workshops and production areas is at all times allowed to the Society's Surveyor to enablehim to carry out his inspection functions.

• In the absence of any written arrangements to the contrary, fees will be calculated based on the Soci-ety's rate of charges at the time approval is granted. Fees are payable even if approval fails to begranted due to unsatisfactory test results.

• Any withdrawal of this application for approval requires notice in writing and will be subject to acharge in line with the scope of services provided at the time of notification of withdrawal.

The documents marked with a cross the attached list (Annex to this Annex A of the Rules for Welding)are enclosed with the application for approval of the welding shop; the documents stipulated in theRules for Welding, Chapter 1, Section 5, A.1.6 are enclosed with the application for approval of thewelding consumables and auxiliary materials.

Place Date Applicant

Chapter 1Page A–2

Annex A Application for Approval II - Part 3GL 2000

Annex to the Application for Welding Approval

List of documents to be submitted or enclosed with the application for approval

Nature of the approval sought:

Approvalfor welding

shopExtension

Approvalfor weldingprocedure

Extension

1. Application from welding shop

2. Description of welding shop in accordance with Annex B,together with Annexes

1)

3. "Range of application" annex(es) to description ofwelding shop

1)

4. Proof of qualification for welding supervisor 1)

5. Proof of qualifications for deputy welding supervisor 1)

6. Welder qualification test certificates (or list of validwelder qualification tests verified by Surveyor)

7. Descriptions of welding procedures (WPS) 1) 1)

8. Standard submerged-arc welding procedure test record 1)

9. Records of welding procedure tests 1)

10. Records of production tests performed 2) 3) 2) 3) 2) 2)

11. Documents/information on inspection (supervisory)personnel

1)

12. Other available documentary proof, approvals etc. 1)

13. Other (e.g. proof of compliance with the qualityrequirements conforming to EN 729/ISO 3834)

1) ( ) ( )

For Society use only:

Surveyor's report following inspection of welding shop

Statement of fees

1) Only if changes have been made since the first approval. 2) If stipulated for certain ranges of application e.g. steam boiler and pressure vessel construction. 3) If tests which have already been performed elsewhere are to be used as a basis for approval.

II - Part 3GL 2000

Annex B Description of Welding Shop Chapter 1Page B–1

Annex B

Description of Welding Shop

Description of Welding Shop for Approval for Welding

Company:

Full address:

Work/work's division:

Full address:

Telephone no.: Fax-Nr.: Telex no.: E-mail address:

Manager (name) responsible for the works/work's division:

Work's authority (name) (for container repair works only):

Number of employees (total): of which welders/operators:

Approval sought for the range of application:

Welding of hull structures

Welding of steam boilers

Welding of pressure vessels

Welding of pipelines

Welding of machinery components

Welding of containers (including repairs)

Welding of .................................................

Past activities in the range of application for which application is made (welding production schedule;components, materials, welding process etc. Where applicable attach separate reference list):

1. Workshop facilities 1)

1.1 Assembly/welding shops and covered assembly bays (number and size):

1.2 Storage facilities for materials and welding consumables (description, e.g. open/covered/heated storage):

________________________ 1) Summary, for general information about the work's production capabilities. Alternative or additionally add brochure, leaflet etc.

Chapter 1Page B–2

Annex B Description of Welding Shop II - Part 3GL 2000

1.3 Lifting gear (lifting capacity, lifting height):

1.4 Machining equipment and tools:

1.5 Welding and cutting equipment, machines and plant:

1.6 Baking ovens and heatable containers for welding consumables (type, number, maximum temperature):

1.7 Welding jigs (e.g. turntables, manipulators):

1.8 Equipment for preheating, post-weld heat treatment and temperature measurement:

1.9 Available test equipment and test media (for destructive and non-destructive testing, container test bed etc.):

1.10 Other information (e.g. flame descaling/priming facilities):

II - Part 3GL 2000

Annex B Description of Welding Shop Chapter 1Page B–3

2. Scope of approval sought (classification of materials, welding processes [details in accordance withEN 24063/ISO 4063], welding consumables and auxiliary materials etc. If necessary continue on separatesheets):

Components:

Weld factor 1):

Material(s):

Plate/wall thicknesses;pipe diameters:

Types of weld, weld forms:

WPS No.:

Welding process:

Welding position(s):

Welding consumables andauxiliary materials:

Heat treatment 2):

Other:

1) Where applicable, e.g. for pressure vessels

2) Where applicable, e.g. stress-relief annealing

3. Welding Personnel

3.1 Welding Supervisor(s) (surname(s) and first name(s)):

Welding qualifications 1) given as:

Date: Place:

Area of responsibility:

Reporting to (relationship):

3.2 Deputy welding supervisor(s) (surname(s) and first name(s))):

Welding qualifications 1) given as:

Date: Place:

Area of responsibility:

Reporting to (relationship):

________________________ 1) Vocational training and employment are listed in tabular form and enclosed; copies of certificates are attached.

Chapter 1Page B–4

Annex B Description of Welding Shop II - Part 3GL 2000

3.3 Welders/operators (if necessary, continue on separate sheet):

Initial test Last repeat testSurname,first name No.:

Test basis(Rules, standard etc.)

Test designation(e.g. conforming toEN 287/ISO 9606)

date testingbody

date testingbody

3.4 In-house training for welders: yes no 3)

4. Inspection supervisors and inspection personnel 4):

5. Existing recognitions, verifications, confirmations, aptitude certificates, certificates, awards,approvals, etc.:

Welding supervisor(s)

Place Date Company stamp / signature

Annex(es):

________________________ 3) Tick as applicable 4) Proof of qualification attached

II - Part 3GL 2000

Annex C Assessment Form for Welder Qualification Test Certification Chapter 1Page C–1

Annex C

Assessment Form for Welder Qualification Test Certification

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II - Part 3GL 2000

Annex D Welding Procedure Chapter 1Page D–1

Annex D

Welding ProcedureI. Manufacturer's Welding Procedure Specification (WPS)

Company:

Full address:

Works/work's division:

Full address:

Telephone No.: Fax No.: Telex: E-mail address:

Responsible welding supervisor:

Welding Procedure Specification (WPS) No.: Parent material(s) specification:

Test report (WPAR) No.: Material thickness [mm]:

Welding Process: Outside diameter [mm]:

Joint type:

Welding position(s): Method of preparation and cleaning:

Joint preparation details (sketch):

Joint design Welding sequences

Welding details:

Run Process Size of fillermetal

Current[A]

Voltage[V]

Type ofcurrent/polarity

Wire feedspeed

Travel speed*

[cm/min]Heat input *

[J/cm]

Filler metal classification:– Brand name: Manufacturer:

– Any special baking or drying:

Gas / flux:– shielding: backing:

– Brand name: Manufacturer:

– flux: backing:

Gas flow rate– shielding: backing:

Tungsten electrode type/diameter:Gouging/backing:Preheating temperature:Interpass temperature:

Post-weld heat treatment and/or ageing *:– Time, temperature, method:

– Heating and cooling rate:

Other information *, e.g.:– Weaving (max. width of run):

– Oscillation: amplitude, frequency, dwell time:

– Pulse welding details:– Stand-off distance:

– Plasma welding details:

– Torch angle:

Welding over shop primer *:– Brand name:

Other:

Manufacturer's welding supervisor(Name, date signature)

* If required

Chapter 1Page D–2

Annex D Welding Procedure II - Part 3GL 2000

II. Welding procedure test / production test – details relating to specimen welds

Company: Test report (WPAR) Nr.:

Welding Procedure Specification (WPS) No.:

Location (of specimen welding), works/works division:

Welding supervisor:Welder's name: Parent material(s) specification:Date of test: Material thickness [mm]:Examiner or test body: Outside diameter [mm]:Welding Process: Joint type:Welding position(s): Method of preparation and cleaning:

Joint preparation details (sketch):

Joint design Welding sequences

Welding details:

Run ProcessSize of filler

metalCurrent

[A]Voltage

[V]

Type ofcurrent/polarity

Wire feedspeed

Travel speed*[cm/min]

Heat input *[J/cm]

Filler metal classification:– Brand name: Manufacturer:– Any special baking or drying:Gas / flux:– shielding: backing:– Brand name: Manufacturer:– flux: backing:Gas flow rate– shielding: backing:Tungsten electrode type/diameter:Gouging/backing:Preheating temperature:Interpass temperature:

Post-weld heat treatment and/or ageing*:– Time, temperature, method:– Heating and cooling rate:

Other information*, e.g.:– Weaving (max. width of run):– Oscillation: amplitude, frequency, dwell time:– Pulse welding details:– Stand-off distance:– Plasma welding details:– Torch angle:Shop primer*:Other:

We hereby confirm that the specimen welds have been prepared and performed satisfactorily using the data listedabove, in accordance with the Rules for Welding issued by Germanischer Lloyd.

Welding supervisor (Name, date signature)

Society's Surveyor(Name, date, signature)

* If required

II - Part 3GL 2000

Annex D Welding Procedure Chapter 1Page D–3

III. Welding procedure test / production test – test results

Company: Test report (WPAR) No.:Examiner or test body: Welding Procedure Specification (WPS) No.:

Non-destructive testing

Test method Results Test report no.

Visual inspection:

Radiographic test:

Ultrasonic test:

Magnetic particle test:

Dye penetrant test:

-test:

Tensile tests

SpecimenForm/No.:

Dimen-sions

Cross-section

Test loadFr

Yield or0,2 % proof

stress

BreakingloadFm

Tensilestrength

Rm

Elongation Reductionin area

Position offracture,Remarks

[mm] [mm2] [N] [N/mm2] [N] [N/mm2] [%] [%]

Require-ments

Bend tests

Specimen,From/No.

Dimension

[mm]

Bending mandreldiameter

[mm]

Bending angle

[degrees]

Elongation on bending(L0 = .......... mm)

[%]

Results, Remarks

Requirements

Notched bar impact test: Shape of specimens: Sizes:

Individual values[J]

Specimen, No.,Position of

notch:

Test temperature[°C]

1 2 3

Average value[J] Remarks:

Requirements min min

Chapter 1Page D–4

Annex D Welding Procedure II - Part 3GL 2000

Hardness tests Type, test load:

Position of measurement (sketch/diagram)

Basematerial

HAZ/Transition zone

Weldmetal

Transitionzone/HAZ

Basematerial

Fracture tests: butt weld fillet weld

Position of fracture:

Results:

Metallographic examinations:Results (if necessary attach photographs/explanations on a separate sheet):

Other tests:Type:

Results:

The trial welds were made and the tests performed in accordance with the requirements of the Rules for Weldingissued by Germanischer Lloyd and also the following Rules:

The results meet the requirements The results do not meet the requirements

Welding supervisor(Name, date signature)

Examiner or test body(Name, date, signature)

Society's Surveyor(Name, date, signature)

II - Part 3GL 2000

Annex E Welding Consumables and Auxiliary Materials Chapter 1Page E–1

Annex E



Information for approval purposes – Annex to the Application in accordance with Annex A

Electrode/Wire Manufacturer Supplier Distributor Licenses (where applicable):

Company name, full address:

Full address:

Telephone No.: Fax No.: E-mail address:

Address for approval certification:

Contact / Department:

Flux/shielding gas Manufacturer Supplier Distributor Licenses (where applicable):

Company name, full address:

Telephone No.: Fax No.: E-mail address:

Address for approval certification:

Contact / Department:

Details relating to consumable/auxiliary material: Type of consumable/auxiliary material:

Filler wire Solid wire-gas combination

Welding rod Flux-cored wire-gas combination

Covered electrode Solid-wire flux combination

Flux-cored wire Flux-cored wire-flux combination

Other (describe)

Brand designation of welding consumable ((flux-cored) wire, electrode, etc.):

Brand designation of auxiliary material (shielding gas, flux, etc.):

Classification to standards (DIN, EN, ISO etc.):

Intended scope of approval / range of application:

Quality grade for which application is made and added symbol:

Base materials to be joined by welding:

Welding positions for which approval is sought:

Dimensions for which approval is sought (diameters, lengths of products):

Welding current, polarity:

(Post-weld) heat treatment conditions:

Special application conditions (e.g. minimum or maximum application temperature):

Rules for Application (e.g. re-baking, post-weld heat treatment):

Marking, Packing:

Other information, attached documents.

Preconditions for awarting the "Ü"-symbol for the construction supervision fieldalso checked?

yes no

Verifications of identity ("Affidavits") for transfers of approval attached? yes no

Approval test programme attached? yes no

Approval test records attached? yes no


3 Welding

2 Design, Fabrication and Inspection of Welded Joints

Edition 2000





Phone: +49 40 36149-0 Fax: +49 40 36149-200

[email protected]

www.gl-group.com




Table of Contents

Section 1 General Design Principles

A. General ....................................................................................................................................... 1- 1

B. Information Contained in Manufacturing Documents ................................................................ 1- 1

C. Materials, Weldability ................................................................................................................ 1- 2

D. Design Details ............................................................................................................................ 1- 2

E. Dimensioning of Welded Joints ................................................................................................. 1- 4

Section 2 Execution of Welds

A. General ....................................................................................................................................... 2- 1

B. Weld Preparation, Assembly ...................................................................................................... 2- 2

C. Weather Protection, Preheating ................................................................................................. 2- 2

D. Welding Positions, Welding Sequence ....................................................................................... 2- 3

E. Performance of Welding ............................................................................................................ 2- 3

F. Straightening, Tolerances ........................................................................................................... 2- 3

G. Post-Weld-Treatment of Welds .................................................................................................. 2- 4

Section 3 Heat Treatment

A. Scope .......................................................................................................................................... 3- 1

B. Equipment and Appliances for Heat Treatment ......................................................................... 3- 1

C. Principles Relating to Heat Treatment ....................................................................................... 3- 1

D. Weather Protection, Preheating, Heat Input during Welding ..................................................... 3- 2

E. Post-Weld Heat Treatment ......................................................................................................... 3- 7

Section 4 Non-destructive Testing of Welds

A. General ....................................................................................................................................... 4- 1

B. Test Methods, Appliances and Test Media ................................................................................ 4- 1

C. Inspection Personnel, Supervisors .............................................................................................. 4- 2

D. Inspection Schedule, Inspection Reports .................................................................................... 4- 2

E. Timing of Inspection, Waiting Times ......................................................................................... 4- 3

F. Preparation and Performance of Tests ........................................................................................ 4- 3

G. Evaluation of Test Results .......................................................................................................... 4- 4

H. Extension of the Scope of Inspection ......................................................................................... 4- 4

I. Repairs, Re-inspection ............................................................................................................... 4- 4

J. Visual Inspection ........................................................................................................................ 4- 6

K. Radiographic Inspection ............................................................................................................. 4- 7

L. Ultrasonic Inspection .................................................................................................................. 4- 8

M. Magnetic Particle Inspection ...................................................................................................... 4- 13

N. Liquid Penetrant Inspection ........................................................................................................ 4- 14

II - Part 3 GL 2000


Section 5 Mechanical and Technological Tests

A. Scope .......................................................................................................................................... 5- 1

B. Preparation of Specimens and Testing ........................................................................................ 5- 1

C. Tensile Tests ............................................................................................................................... 5- 2

D. Bend Tests .................................................................................................................................. 5- 3

E. Notched Bar Impact Tests (EN 1d5/DIN 50115) ....................................................................... 5- 5

F. Hardness Testing of Welds (DIN 50163, Part 1) ........................................................................ 5- 6

G. Metallographic Inspections ......................................................................................................... 5- 6

H. Inspection reports ........................................................................................................................ 5- 7

Annex A Imperfections in Welded Joints in Steel

Annex B Imperfections in Welded Joints in Aluminium

Annex C Comparison of Equivalent, Internationally Recognized Film System Classes

Chapter 2 Page 4


II - Part 3GL 2000

Section 1 General Design Principles Chapter 2Page 1–1

B

Section 1

General Design Principles

A. General

1. Scope

These Rules contain universal principles applicable tothe designing and dimensioning of welded joints, andto the information contained in the manufacturingdocuments.

2. Supplementary Rules

The designing and dimensioning of welded joints inthe various ranges of application is additionally gov-erned by the component-specific requirements statedin the various sections of Chapter 3 and in the respec-tive Rules for Construction of Germanischer Lloyd.

B. Information Contained in ManufacturingDocuments

1. Joint/weld shapes, symbols

1.1 The depiction of welded joints and also theshapes of joints and welds shall conform to the stan-dards (e.g. EN 12345/ISO ….., EN 22553/ISO 2553or EN 29692/ISO 9692). They shall be identified inthe manufacturing documents (drawings, etc.) in anunambiguous manner, e.g. by means of the standardsymbols.

1.2 Non-standard weld shapes or symbols shallbe illustrated and, where applicable, explained in de-tail in the manufacturing documents (drawings, weld-ing schedules or specifications). They must be ap-proved by the Society (e.g. in conjunction with theinspection of drawings or a welding procedure test).

1.3 A weld shape appropriate to, and adequatelydimensioned or well designed for the nature (static ordynamic) and magnitude of the forces to be transmit-ted shall be chosen. Where necessary, documentaryproof of the design calculations shall be submitted (cf.the supplementary Rules mentioned in A.2.).

2. Information on fabrication

2.1 The manufacturing documents to be submit-ted for approval shall contain information on fabrica-tion insofar as is relevant to the quality of the welded

joints and necessary for inspection by the Society.Besides the materials and weld shapes, this comprisesthe following information:

– Method of weld preparation (mechanical, ther-mal, etc.)

– Welding process, welding positions

– Welding consumables and auxiliary materials

– Preheating and, where applicable, heat inputduring welding

– Weld build-up and number of passes

– Welding sequence (in special cases)

– Grooving of root (method)

– Post-weld (heat) treatments, if any

– Number and location of any production speci-mens to be welded at the same time (wherestipulated).

With regard to the information on the requirementsapplicable to the welded joints and their inspection,see 3.

2.2 If the preparation and execution of the welds(in conjunction with approved welding procedures,welding consumables and auxiliary materials) conformto normal welding and shipbuilding practice as well asto these Rules and the recognized standards, the Soci-ety may waive the requirement that they be speciallyillustrated or indicated in the manufacturing docu-ments.

3. Requirements for welded joints, inspec-tions

3.1 The manufacturing documents (e.g. drawings,welding or inspection schedules) to be submitted forapproval shall also indicate the quality requirementsfor the welded joints. Depending on the range of ap-plication, this may be done by means of the weld fac-tor (cf. Chapter 3, Section 2 and 3), or by means of theweld quality grade (cf. Chapter 3, Section 1, I., Table1.9) or the evaluation category according to EN25817/ISO 5817 or EN 30042/ISO 10042 (cf. An-nexes A and B). The tests (testing methods and scopeof testing) to be used to verify the stipulated weldquality shall also be indicated.

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3.2 The requirements to be stated also include theleak-tightness to gases and liquids or the corrosionresistance to particular media.

3.3 With regard to the welding procedure andproduction tests, cf. Chapter 1, Section 4 and the ap-plication-specific Section 1 – 5 of Chapter 3, withregard to non-destructive testing, cf. Section 4 and theapplication-specific sections of Chapter 3.

C. Materials, Weldability

1. Weldability, processing

Only materials of proven weldability may be used forwelded structures. Any conditions linked to the ap-proval of the materials or to the welding proceduretests which impose restrictions on processing and thematerial manufacturer's recommendations shall beallowed for when designing the welded joint. Withregard to the processing and use of TM steels, see thespecial GL Guidelines.

2. Material-related characteristics

Material-related characteristics, such as the (inferior)strength of rolled products in the thickness direction(cf. D.7.2), the softening of hardened aluminium alloyswhen welded, or the different degrees of thermal ex-pansion of the various materials, shall be allowed forwhen designing and dimensioning the components andwelded joints.

3. Clad plates

Clad plates where the efficiency of the bond betweenthe supporting and cladding material has been provedby materials testing (cf. Part 1, Chapter 2, Section 1)may generally be treated as solid plates (up to mediumplate thicknesses with mostly fillet welds).

4. Pairs of materials, corrosion

Where pairs of different materials are exposed to sea-water or other electrolytes, e.g. welded joints betweenunalloyed (hull) structural steels and stainless steels,attention shall be paid to the increased tendency to-wards corrosion due to the differences in electro-chemical potential. Where possible, these weldedjoints should be located at points where there is lessdanger of corrosion, or special corrosion protectionshould be provided (e.g. coating or cathodic protec-tion).

D. Design Details

1. Accessibility, workmanship and fitness forinspection

1.1 Welded joints shall be planned at the designstage to ensure that they are readily accessible duringfabrication and can be executed in the optimum weld-ing position and welding sequence.

1.2 Welded joints and welding sequences shall bedesigned to minimize residual weld stresses and avoidexcessive deformation. Welded joints should thereforenot be over-dimensioned.

1.3 Welded joints shall be designed to ensure thatthe proposed weld type and quality (e.g. complete rootfusion in the case of single- and double-bevel buttwelds) can be satisfactorily achieved under the givenfabricating conditions. Failing this, provision shall bemade for welds which are easy to execute and their(possibly inferior) load-bearing capacity shall be al-lowed for when dimensioning the welds.

1.4 Severely stressed welded joints, which aretherefore normally subject to compulsory inspection,shall be designed to facilitate application of the mostappropriate inspection technique (radiography, ultra-sonic or surface crack inspection, possibly in combi-nation) so that tests offering reliable results can becarried out.

2. Location and configuration of weldedjoints

2.1 In areas of high stress concentrations result-ing from the design - and especially in cases of dy-namic loading -, welded joints should be avoided asfar as possible or designed in such a way as to providea generally smooth stress profile without a significantadditional notch effect originating from the weldingoperation. Cf. GL Rules I, "Ship Technology", Part 1,Chaper 1, Section 20 "Fatigue Strength".

2.2 Intersecting butt welds in load-bearing wallsof steam boilers and pressure vessels shall be avoided.The longitudinal seams of pipes shall be offset relativeto one another at the pipe joints by at least 50 mm.Intersecting butt welds in hull structures are allowed; ifpossible, however, the first (e.g. longitudinal) weldedjoint shall be completed and cleanly finished at theends before the second (e.g. transverse) joint is made.

3. Local clustering of welds, minimum spacing

3.1 The local clustering of welds and insufficientdistances between welded joints are to be avoided (cf.also Chapter 3, Section 1, G.4). Welds shall not be

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over-dimensioned. The thickness of fillet welds shallnot exceed 0,7 times the thickness of the thinner of thetwo parts to be joined.

3.2 Adjacent butt welds should be separated fromeach other by a distance of at least 50 mm + 4 × platethickness. Fillet welds should be separated from eachother and from butt welds by a distance of at least30 mm + 3 × plate thickness. The width of inter-changeable sections (strips) of plate should, however,be at least 300 mm or ten times the plate thickness,whichever is the greater. Cf. also Chapter 3, Section 1,G.4.1.

4. Cut-outs, welding apertures

4.1 Adequately sized cut-outs (welding apertures)shall be provided when, for instance, stiffeners areapplied to platings before the butt joints in the platingare welded. Cf. also Chapter 3, Section 1, G.5. Thewelding apertures shall be rounded with a minimumradius of 25 mm or 2 × plate thickness, whichever isthe greater.

4.2 In special cases, e.g. when welding compo-nents subject to severe dynamic stresses, instead ofproviding welding apertures in the area of the buttwelds it may be advisable to make a double-bevelweld preparation on the component to be attached tothe plating, to weld up to this from both sides and tomachine out the resulting root defect in the butt weldfrom the opposite side (of the plating).

5. Local reinforcements, plate doubling

5.1 Where platings (including girder plates andtube or vessel walls) are subjected locally to increasedstresses, thicker plates should be used wherever possi-ble in preference to plate doublings. Bearing bushes,hubs, etc. shall invariably take the form of thickerplates, forgings or the like welded into the plating.

5.2 Where doubling plates cannot be avoided,their thickness should not exceed twice the platingthickness and their width should not exceed 30 timesthe doubling plate thickness. With regard to weldingof doubling plates and especially the ends of suchplates, cf. Chapter 3, Section 1, G.6. With regard tothe design and welding of doubling plates as cut-outreinforcements in pressure vessels, see the Rules forConstruction.

6. Stress flow, transitions

6.1 All welded joints on supporting membersshall be designed to provide as smooth a stress profileas possible with no major internal or external notches,

no discontinuities in rigidity and no obstructions toexpansion.

6.2 To this end, components with different di-mensions shall be adjusted to one another by means ofgradual transitions (e.g. by bevelling the edges of thethicker component). Steel castings and forgings musttherefore be provided with integrally cast or forgedwelding flanges. Cf. Chapter 3, Section 1, G.3. and theRules for Construction.

7. Double-T (cruciform) joints, stress in thethickness direction

7.1 Where, in the case of double-T (cruciform)joints, rolled products are stressed in the thicknessdirection due to the residual weld stresses or the ap-plied loads, suitable measures shall be taken in thedesign of the structures to prevent lamellar tearing(stratified fractures). Such measures include the use ofsuitable weld shapes with a minimum weld volumeand a welding sequence designed to reduce the shrink-age stresses in the thickness direction.

7.2 Where there are very severe stresses in thethickness direction (e.g. due to bulky single- or dou-ble-bevel butt welds), materials with enhanced char-acteristics in the direction at right angles to the surfaceof the product are to be used (cf. Part 1, Chapter 2,Section 1).

8. Welding of cold-formed sections

Welding of cold-formed sections of (hull) structuralsteels is permissible provided that the conditions statedin Chapter 3, Section 1, G.8. are complied with. Inspecial cases, post-weld heat treatment may be neces-sary or documentary proof of adequate toughness afterwelding may be demanded.

9. Other design measures

9.1 Welds should not be located in channels ofsections owing to the danger of the presence of segre-gations and the residual stresses in these areas arisingfrom the rolling process.

9.2 Welded joints (fillet weld joints) in areaswhere the risk of corrosion cannot be excluded shallbe continuously executed around components, cut-outs, etc. to provide a seal.

9.3 If heat treatment is carried out on componentswith sealed-off hollow spaces necessitated by the de-sign, such as occur in the case of cut-out reinforce-ments (doublings), mounted loose flanges or suspenderrings, a means of venting, e.g. a drilled hole, shall beprovided.

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E. Dimensioning of Welded Joints

1. Dimensioning, design calculations

1.1 Dimensioning shall be carried out in accor-dance with the Rules for Construction with referenceto the shape and quality of the weld in question and thetype (static or dynamic) and level of stress. The di-mensions of the weld (if required) must be apparentfrom the manufacturing documents to be submitted forapproval. In the case of fillet welds, an indicationshall also be given as to whether the dimensional datarefer to the throat thickness of the weld "a" or to theleg length "z".

1.2 Where required by the Society (e.g. in theRules for Construction or as part of the examination ofthe drawings), mathematical proof (a general stressanalysis and/or proof of fatigue strength) shall befurnished that the weld is adequately dimensioned.

2. Minimum thicknesses of fillet welds

Fillet weld throat thicknesses shall conform to the GLRules or the results of design calculations. Throatthicknesses not established according to the Rules ordesign calculations shall be executed, as a minimumrequirement, with a throat thickness of

a = 0,5 × plate thickness,

the smaller plate thickness being the ruling dimension.Unless otherwise agreed (e.g. for the fully-mechanisedwelding of smaller plate thicknesses in appropriateclamping jigs), the minimum fillet weld throat thick-ness shall be

[ ]at t

mmmin = +1 2

3, but not less than 3 mm

t1 = smaller (e.g. the web) plate thickness in [mm]

t2 = larger (e.g. the flange) plate thickness in

[mm]

A smaller minimum fillet weld throat thickness (e.g.2,5 mm) may be agreed to if its faultless execution isdemonstrated by means of a welding procedure test.

3. Machining allowance

Adequate machining allowances (thicker welds) shallbe provided for the subsequent machining of welds toensure that the prescribed minimum weld thicknessesare achieved on completion of the work. This particu-larly applies to welds with only partial penetration, asoccasionally occur for instance in machinery compo-nents, in which case provision shall be made for ma-chining correspondingly deeper joints from the outset.In the case of the notch-free grinding of the welds,which is employed in the case of particular weld qual-ity requirements, correspondingly thicker welds shallbe deposited.

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Section 2

Execution of Welds

A. General

1. Scope, supplementary provisions

1.1 This section contains universal rules applica-ble to the performance of welding work, extendingfrom the weld preparation to the completion of thewelded joints including any finishing operations. Forheat treatment see Section 3; for testing of the weldedjoints, Sections 4 and 5.

1.2 The performance of the welding work is ad-ditionally governed by the application- specific re-quirements stated in the various sections of Chapter 3.The relevant provisions of the respective Rules forConstruction shall also be complied with.

2. Welding shop requirements

2.1 All workshops wishing to carry out weldingwork shall comply with the welding shop requirementsstipulated in Sections 2 (Approval), 3 (Welder's Quali-fication Tests) and 4 (Welding Procedure Tests) ofChapter 1 and, where necessary, Section 4 of Chapter2 (Non-destructive Testing of Welds).

2.2 Workshops shall maintain up-to-date recordsof this compliance and shall submit them to the Sur-veyor at his request. If necessary (e.g. in the case of aprolonged interruption to the work, cf. Chapter 1,Section 2, A.4.2 and Section 3, E.), the Society mayreinspect the workshop.

3. Materials, marking

3.1 Welding may only be performed on materialswhose identity and weldability under the given fabri-cating conditions can be unequivocally established byreference to markings, certificates, etc.

3.2 In case of doubt, the identity and weldabilityof the materials shall be verified before welding com-mences.

4. Welding consumables and auxiliary mate-rials

4.1 Only welding consumables and auxiliarymaterials tested in accordance with Chapter 1, Section5, approved by the Society and of a quality grade

appropriate to the base material to be welded may beused. The various quality grades corresponding to thedifferent hull structural steels shall be as shown inTable 1.1 in Chapter 3, Section 1.

4.2 Welding consumables and auxiliary materialsfor particular materials or those intended for specialwelding processes which have been approved on thebasis of a (preliminary) welding procedure test may beused only for the range of application specified in therelevant approval certificate. Any special conditions orrules associated with such applications shall be com-plied with.

4.3 Welding consumables and auxiliary materialsmay only be used with the electrode diameters coveredby the tests and for the approved welding positions.The manufacturer's instructions and recommendationsfor use (e.g. the type of current and polarity used) shallbe complied with.

4.4 If necessary, welding consumables and aux-iliary materials are to be baked, prior to use, in accor-dance with the manufacturer's instructions (keeping tothe specified maximum baking time) and are to be keptdry at the place of work (in heated containers or simi-lar).

5. Overweldable shop primers

5.1 Overweldable shop primers which are appliedto plates, sections, etc. prior to welding and are notremoved must be tested and approved in accordancewith Chapter 1, Section 6.

5.2 Welding shops shall ensure by suitablechecks (especially on the thickness of the coating) andproduction tests carried out at random during thecourse of normal fabrication that the quality of thewelded joints is not impaired to an unacceptable de-gree.

6. Manufacturing documents, company stan-dards

6.1 Welds shall be executed in accordance withapproved drawings, welding schedules or companystandards recognized by the Society. Exceptions to thisrule are subject to the Society's consent in each indi-vidual case.

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6.2 Compliance with the manufacturing docu-ments is the responsibility of the welding shop.

B. Weld Preparation, Assembly

1. Weld preparation

1.1 Weld preparation may be carried out bythermal cutting or machining. Seam edges (groovefaces) prepared by thermal cutting shall be finished bymachining (e.g. grinding) if a detrimental effect on thewelded joint as a result of the cutting operation cannotbe ruled out. Welding edges of steel castings andforgings shall always be ground as a minimum re-quirement; roll scale or casting skin is to be removed.

1.2 Groove faces must be free from impuritiesand defects liable to impair the quality of the weldedjoint, e.g. laps, coarse grooves made by the cuttingtorch and slag. Prior to welding, the welding edgesshall be inspected for defects, e.g. cracks, inclusions,blowholes or pores, using non-destructive testingmethods if necessary.

2. Weld shapes, root openings (air gaps)

2.1 When preparing and assembling components,care shall be taken to ensure compliance with the weldshapes and root openings (air gaps) specified in themanufacturing documents. With single- and double-bevel butt welds in particular, care shall be taken tomake an adequate root opening to achieve sufficientroot penetration.

2.2 The root opening shall not exceed twice thespecified gap. If the size of the gap permitted by thisrule is exceeded locally over a limited area, the gapmay be reduced by build-up welding of the side walls,subject to the consent of the Surveyor. With filletwelds, the "a" dimension shall be increased accord-ingly, or a single- or double-bevel weld shall be madeif the air gap is large. Inserts and wires may not beused as fillers.

3. Alignment of components

3.1 Components which are to be united by buttwelding are to be aligned as accurately as possible.Sections welded to plating shall be left unwelded at theends for this purpose. Special attention shall be paid tothe alignment of (abutting) girders which are inter-rupted by transverse members. If necessary, suchalignment shall be facilitated by drilling check holes inthe transverse member which are subsequently closedby welding.

3.2 The permissible edge alignment error de-pends on the nature, importance and loading of thecomponent concerned and is dealt with in the varioussections of Chapter 3. Where special loading condi-tions or other requirements relevant to the applicationnecessitate a limitation of the edge alignment error, theallowable error shall be stated in the manufacturingdocuments.

4. Tack welds and preparations for welding

4.1 Tack welds should be used as sparingly aspossible and should be made by trained personnel.Where their quality does not meet the requirementsapplicable to the welded joint, they are to be carefullyremoved before the permanent weld is made.

4.2 Clamping plates, temporary ties and aligningpins shall be made from the same material as the basematerial or from a material of similar composition andshould not be used more than necessary. Any damagecaused during their removal shall be competentlyrepaired.

4.3 With mechanized welding processes or whenarc striking and end crater defects in butt welds haveto be avoided, run-in and run-off plates shall be pro-vided in continuation of the line of the weld.

4.4 Components must be clean and dry in the areaof the welds. Any scale, rust, cutting slag, grease, paint(except for approved overweldable shop primers),moisture or dirt shall be carefully removed beforewelding.

C. Weather Protection, Preheating

1. The areas to be welded shall be adequatelyprotected against climatic influences such as wind,damp and cold and shall be preheated where neces-sary.

2. The need for and degree of preheating isdetermined by various factors, such as chemical com-position, plate thickness, two- or three-dimensionalheat dissipation, ambient and workpiece temperatures,or heat input during welding (energy applied per unitlength of weld). Details are given in Section 3 andvarious sections of Chapter 3.

3. Preheating shall be applied uniformlythroughout the thickness of the plate or componentover a width of four times the plate thickness, but notless than 100 mm. Preheating may be as necessary fortack and auxiliary welds as for fabricating welds.

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Section 2 Execution of Welds Chapter 2Page 2–3

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D. Welding Positions, Welding Sequence

1. Welding should be performed in the optimumwelding position; positional welding is to be limited tothe indispensable minimum. The welders employed onpositional welding must be qualified for the weldingpositions concerned. With regard to welding in thevertical-down position, see Chapter 3, Section 1, H.6.

2. The welding sequence shall be chosen toallow shrinkage to take place as freely as possible.Butt joints in areas of plating shall invariably be fullywelded prior to attaching girders and stiffeners. TheSociety may require an assembly procedure or weldingsequence schedule to be drawn up in special cases.

E. Performance of Welding

1. The welding shop shall ensure that the speci-fied welding parameters are adhered to and that thewelding work is expertly performed.

2. Components shall not be subjected to anyappreciable movements or vibration during welding.Parts to be assembled while suspended from cranes orfloating shall be clamped prior to tack-welding of thejoints in such a way that no relative movement of theparts is possible. Components which have not beenfully welded and which are to be handled or turnedmust have welded joints of adequate strength.

3. Cracked tack welds may not be welded over,but are to be machined out. In multi-pass welding, theslag of the previous run shall be completely removedbefore the next pass is laid down. Pores, visible slaginclusions and other welding defects and cracks maynot be welded over, but are to be machined out andrepaired.

4. Welds must have sufficient penetration andmust display a clean, regular surface with "gentle"transitions to the base material. Excessive weld rein-forcements and undercuts or notches affecting theedges of plates and cutouts are to be avoided.

5. Butt-welded joints must display full fusionover the entire cross-section, unless otherwise speci-fied in a particular case. For this purpose, the rootshall normally be grooved and capped. Following asuccessful welding procedure test confirmed by theSociety, single-side welds, e.g. using ceramic back-ings, may be regarded as equivalent to butt weldsexecuted from both sides. Other joints welded on oneside only, e.g. using permanent backings, are subjectto the Society's approval when scrutinizing the rele-vant drawings.

6. Single- and double-bevel butt welds may bemade according to the design specification either withgrooved roots as full penetration welded joints or witha permitted incomplete penetration at the root or de-fined, unwelded root face subject to the appropriatereduction factors (cf. Chapter 3, Section 1, G.10.2.).The type of weld is to be specified in the drawings ineach case and must have received the Society's ap-proval when scrutinizing the drawings.

7. With fillet welds, particular attention shall bepaid to good root penetration. The penetration mustextend to at least the immediate vicinity of the theo-retical root point. The ideal fillet weld section is thatof an equal-sided flat-faced weld with smooth transi-tions to the base material. At the ends of web plates, atcutouts and at welding apertures, the fillet welds shallbe formed round the web to form a seal.

8. Major cases of faulty workmanship or defectsin the material may only be repaired with the Sur-veyor's agreement. Minor surface defects shall beremoved by shallow grinding. Defects which penetratemore deeply into the material (e.g. cracks, or damagecaused by the removal of auxiliary erection equip-ment) shall be cleanly machined out and where neces-sary repair-welded with an adequate heat input.

9. Repair (so-called production welds) on steelcastings and forgings shall only be made with theconsent of the Surveyor. If their volume is consider-able, sketches and descriptions of the repair work shallbe submitted to the Society's head office for approval,together with details of the analysis of the base mate-rial, the welding process and the welding consumablesand auxiliary materials. The Society may require stressrelief heat treatment or, in special cases, further heattreatment of the components after welding.

10. When working and welding higher-strengthhull structural steels, high-strength (quenched andtempered) fine-grained structural steels, austeniticstainless steels and aluminium alloys, attention shouldbe paid to the relevant information and instructions inthe various sections of Chapter 3. For this work, theSociety may require an appropriate welding specifica-tion to be submitted.

F. Straightening, Tolerances

1. Straightening operations (whether thermal ormechanical) shall not impair the quality of the materi-als and welded joints. The Society may require verifi-cation of the suitability of the straightening method(e.g. by means of a welding procedure test). This espe-

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cially applies to high-strength (quenched and tem-pered) fine grain structural steels.

2. Unless specific tolerances are stated in thevarious sections of Chapter 3 or in the manufacturingdocuments, the dimensional tolerances for weldedstructures shall be as specified in the standards, e.g.EN ISO 13920, or in the Manufacturing Standard ofthe German Shipbuilding Industry; for welded jointsconforming to EN 25817/ISO 5817 or EN 30042/ISO10042, (see Annexes A and B). The degree of finenessand the evaluation category shall be stipulated in themanufacturing documents. The Society may specifyother (tighter) tolerances where this is necessary forreasons of strength and/or operational safety.

G. Post-Weld-Treatment of Welds

1. If it is intended to carry out post-weld-treatment of the welds, e.g. to improve the surfacefinish in the case of dynamic loading, such treatmentshall not impair the characteristics (mechanical prop-erties) of the welded joints. The Society may demanddocumentary proof thereof.

2. For post-weld heat treatment, see Section 3;for the post-treatment of surfaces for non-destructivetesting, see Section 4, F.1.

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Section 3 Heat Treatment Chapter 2Page 3–1

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Section 3

Heat Treatment

A. Scope

1. These Rules apply to preheating for, andheat input during welding and to post-weld heattreatment of welded components where required. Forpreheating of hull structural steels, see also Chapter 3,Section 1, H.4. and H.5.

2. Requirements relating to the heat treatmentof hot or cold formed welded components (e.g.spherical or dished ends, T-pieces and elbows) arestipulated in the Society’s Rules for Materials.

B. Equipment and Appliances for HeatTreatment

1. Equipment and appliances for preheating

Preheating may be carried out either in heat treatmentequipment or by means of mobile heating appliances,e.g. gas burners or electrical induction or resistanceheating appliances as applicable (resistance mats). Acondition of their use is that the prescribed preheatingand interpass temperatures must be capable of beingkept constant and monitored throughout the weldingoperation.

The temperature may be monitored by means of suit-able appliances or aids, e.g. contact thermometers,temperature sensors or temperature-sensitive crayons.

2. Fixed heat-treatment equipment (heat-treatment furnaces)

2.1 The fixed heat-treatment facilities (heat-treatment furnaces) must be of suitable size for theparticular components and structures in question andbe fitted with an appropriate temperature controlfacility. The furnaces must ensure that the particularheat treatment temperatures stipulated can be guar-anteed and that the temperature is evenly and accu-rately controlled (DIN 17052, quality grade C).

2.2 An adequate number of temperature record-ers shall be provided, subject to a minimum of 2 toeach furnace. The temperature variation over theperiod shall be established and recorded. The tem-perature control device and the temperature and timerecording instruments used shall be checked at regu-

lar intervals (at least once a year) and documentaryproof of the inspection results submitted to the Soci-ety on request.

3. Other heat-treatment equipment

The primary requirements are given in B.1., but de-pend upon the particular requirements relating to thecomponent or structure. The type and method of theheat treatment in question is subject to the Society’sconsent.

If no heat treatment furnace of sufficient size areavailable for the heat treatment of components, heattreatment may be carried out in mobile facilities(transportable furnaces) or in equipment which hasbeen specially designed for the purpose, subject to theSociety’s consent. Such equipment shall comply withthe requirements stated in 2.1 and 2.2 with regard tofunction, temperature control and temperature re-cording and shall be presented to the Society forinspection before being used. Care shall be taken toensure that there is adequate insulation of the compo-nents or welds needing heat treatment. Unacceptabletemperature gradients in the component shall beavoided.

C. Principles Relating to Heat Treatment

1. Heat treatment, temperature measurementsand recording shall be performed by competent per-sonnel. For this and the performance of heat treatmentoperations, cf European draft Standard (DocumentN 225) "Welding, quality requirements relating toheat treatment in conjunction with welding andforming".

2. The type, temperature and duration of theheat treatment process, in addition to the rates ofheating and cooling are determined by the material,the thickness of the material, the production processand the nature of the component or structure. Cf alsothe provisions of EN 1011 Parts 1 to 4 and in theregulations given in Chapter 3. The information andrecommendations provided by the manufacturer ofthe materials and welding consumables shall be ob-served.

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3. Details of the pre- and post-weld heat treat-ment of a component or structure shall be included inthe production documents submitted for inspection bythe Society. Where the manufacturer’s welding pro-cedure specifications (WPS) are used, these shallcontain the necessary information relating to pre-heating, heat input during welding and post-weld heattreatment.

4. The whole of the component is normallysubject to post-weld heat treatment. The heat treat-ment of part or sections of welds or the heat treatmentof partial areas, especially pressurized components,require the Society’s consent in each individual case.A specification relating to this shall be submitted tothe Society for examination.

5. Where welded joints are to be producedbetween different materials, in the case of complexwelded components (e.g. LNG/LPG process pressurevessels and gas tanks), components which have highlevels of cold forming (more than 3 %)or extensivestructural and repair welds to castings, the need for,type and extent of any heat treatment shall be agreedwith the Society.

6. Parts shall be proberly prepared for heattreatment in due order. Flange facings and sealingsmust be adequately protected against scaling. Precau-tions shall be taken to protect against componentdistortions; components and structures shall be posi-tioned accordingly. Unacceptable temperature gradi-ents during the heat treatment process and duringheating and cooling shall be avoided.

D. Weather Protection, Preheating, HeatInput during Welding

1. Weather protection, welding at low tem-peratures

1.1 The area in which welding work is per-formed is to be sheltered from wind, damp and cold,particularly if out of doors. Where gas-shielded arcwelding is carried out, special attention is to be paidto ensuring adequate protection against draughts.When working in the open under unfavourableweather conditions it is advisable to dry weldingedges by heating.

1.2 At ambient temperatures below + 5 °C, ad-ditional measures shall be taken, such as shielding ofcomponents, extensive preliminary heating and pre-heating, especially when welding with a relatively lowheat input (energy input per unit length of weld), e.g.when laying down thin fillet welds or in the case of

rapid heat dissipation, e.g. when welding thick-walledcomponents. Wherever possible, no welding shouldbe performed at ambient temperatures below – 10 °C.

2. Preheating for the welding of ferriticsteels

2.1 The need for preheating of ferritic steels andthe preheating temperature depend on a number offactors. Chief among these are:

– the chemical composition of the base material(carbon equivalent) and the weld metal,

– the thickness of the workpiece and the type ofweld joint (two or three dimensional heat flow),

– the welding process and the welding parameters(energy input per unit length of weld),

– the shrinkage and transformation stresses,

– the temperature dependence of the mechanicalproperties of the weld metal and the heat-affected zone,

– the diffusible hydrogen content of the weldmetal.

2.2 The operating temperature to be maintained(minimum preheating temperature and maximuminterpass temperature) for (hull) structural steels maybe determined in accordance with EN 1011-2. Guidevalues for the preheating temperature are contained inFigures 3.1 and 3.2 shown below for two differentenergy inputs per unit length of weld 1 and hydrogencontents HD 2 of the weld metal, together with thevarious carbon equivalents CET 3.

––––––––––––––1 Energy input per unit length of weld:

EU I welding time

mm

kJ

mm

volts amps=

⋅ ⋅ ⋅

⋅�

��

��min 6

100length of weld

2 HD 5 = max. 5 ml diffusible hydrogen per 100 g of weldmetal

HD 15 = max. 15 ml diffusible hydrogen per 100 g of weldmetal

3 Carbon equivalent:

CET CMn Mo Cr Cu Ni

in weight= ++

++

+10 20 40

%

The above formula for calculating the carbon equivalent CETin accordance with EN 1011-2 can be applied to steels whichhave yield strengths ranging from 300 to 1000 MPa and tothe following chemical composition: 0.05 – 0,32 % C,max. 0,8 % Si, 0,5 – 1,9 % Mn, max. 0,75 % Mo, max.1,5 % Cr, max. 0,7 % Cu, max. 2,5 % Ni, max. 0,12 % Ti,max. 0,18 % V, max. 0,005 % B, max. 0,06 % Nb.

II - Part 3GL 2000


D

��

��

��

��

��

��

��

��

�

�

��

��

��

��

��

��

��

��

�� !"�#

$�%%��&'�� !��#

��

Fig. 3.1 Minimum preheating temperatures (operating temperatures) applicable to welding processes witha relatively low heat input (energy input per unit length 1 E ≈≈≈≈ 0,5 kJ/mm) as a function of the car-bon equivalent CET 3 of the base material and the hydrogen content of the weld metal

��

��

��

��

��

��

��

��

�

��

��

��

��

��

��

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�� !"�#

$�%%��&'�� !��#

Fig. 3.2 Minimum preheating temperatures (operating temperatures) applicable to welding processes witha relatively high heat input (energy input per unit length 1 E ≈≈≈≈ 3,5 kJ/mm) as a function of thecarbon equivalent CET 3 of the base material and the hydrogen content of the weld metal

Chapter 2Page 3–4


D

Note:

Table 3.1 below gives guide values for the carbonequivalents CET 3 of some of the standard grades ofsteel. Basis were the information of the steel manu-facturers. In case of doubt CET has to calculate bythe actual analysis.

Table 3.1 Guide values for the carbon equiva-lent CET

CET [% in weight]

Steel gradesAveragevalue 1

Maximumvalue 1

GL–A

GL–E

GL–D36

GL–E36TM

GL–D40

GL–E40TM

0,27

0,26

0,33

0,27

0,27

0,24

0,28

0,27

0,34

0,28

0,28

0,25

S275NL

S460NL

S460ML (TM)

S690QL

S890QL

0,25

0,34

0,27

0,26

0,38

0,27

0,36

0,28

0,38

0,41

2C22

34CrMo4

GS20Mn5

0,26

0,49

0,34

0,29

0,55

0,411 For product thicknesses up to 50 mm.

2.3 Table 3.2 contains guide values for preheat-ing high temperature Mo or CrMo alloy steels (usedfor steam boiler) in accordance with the Society’sRules for Materials; cf EN 1011-2.

2.4 Table 3.3 contains guide values for preheat-ing nickel steels tough at sub-zero temperatures inaccordance with the Society’s Rules for Materials.For details of this and also particulars relating to theuse of austenitic or nickel-based welding consum-ables, cf. EN 1011-2.

2.5 Depending on the complexity of the compo-nent, the welding process applied, the level of theresidual stresses in the component and the (low) am-bient temperature, the preheating temperatures shallbe increased or the boundary wall thicknesses re-duced as appropriate. For the effect of the variousfactors on the preheating temperature level, see Table3.4

2.6 If the temperature of the workpiece is lowerthan the minimum operating temperature calculatedon the basis of the above data, preheating is calledfor. Various methods are available:

– continuous heating prior to and during welding,

– alternate heating and welding,

– heating only prior to the start of welding, if theheat input during welding is sufficient to main-tain the minimum operating temperature.

The heating method may be chosen at will, providedthat it does not harm the material by localized over-heating or cause a nuisance by making the weldingarea contaminated.

Table 3.2 Guide values for preheating high-temperature steels (used for steam boiler)

Minimum preheating temperature [°C]given an H2 content of the weld metal of

Category in

accordance

with

DIN V 1738

(CR 12187)

Steel

grade

Thickness

[mm]

≤≤≤≤ 5 ml/100 g > 5 – ≤≤≤≤ 10 ml/100 g > 15 ml/100 g

1.2 16Mo3≤ 15

> 15 – ≤ 30> 30

202075

2075

100

100100

not permitted

5.1 13CrMo4-5≤ 15> 15

20100

100150

150not permitted

5.210CrMo9-1011CrMo9-10

≤ 15> 15

75100

150200

200not permitted

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D

Table 3.3 Guide values for preheating nickel steels tough at sub-zero temperatures

Minimum preheating temperature [°C]given an H2 content of the weld metal of

Category inaccordance with

DIN V 1738(CR 12187)

Steel grade Thickness[mm]

≤≤≤≤ 5 ml/100 g > 5 – ≤≤≤≤ 10 ml/100 g

7.2 12Ni14 (3,5 % Ni) > 10 100 150

12Ni19 (5 % Ni) > 10 100 not permitted

X8Ni9 (9 % Ni) > 10 100 not permitted7.3

X7Ni9 (9 % Ni) > 10 100 not permitted

Table 3.4 Effect of the various factors on the level of preheating

Shift in the preheatingtemperature to lower

valuesFactors influencing preheating

Shift in the preheatingtemperature to higher values

low alloyingelement content

chemical composition of the base material(hardenability), e.g. expressed by thecarbon equivalent

higher alloyingelement content

thinthickness of the workpiece or component(heat dissipation, rigidity, residual stresscondition)

thick

butt joints (2 planes),thick (multiple run) welds

type of joint, weld shape and dimensions,heat input, heat dissipation

T-joints (3 planes) thin(single-run) welds

high ambient or workpiece temperature (heatdissipation)

low

high heat input (energy input per unit length ofweld) during welding

low

lowhydrogen content of the weld metal (typeand rebaking of the welding consumablesand auxiliary materials)

high

2.7 Preheating is always necessary for tack andauxiliary welds whenever preheating is needed for therest of the welding. Possible exceptions to this ruleare tack and auxiliary welds where it can be guaran-teed that subsequent welds are remelted the heat af-fected zone, for instance tacks for submerged arcwelds.

2.8 Irrespective of the information given above,preheating is always necessary when making majorauxiliary erection welds, e.g. when welding on han-dling lugs and when welding very large wall thick-nesses and also thick-walled castings and forgings.

2.9 Preheating shall be applied uniformlythroughout the thickness of the plate or component

over a distance of four times the plate thickness,minimum of 100 mm, on both sides of the weld. Lo-calized overheating is to be avoided. Preheating withgas burners should be performed with a gentle,though not sooty, flame in order to prevent dirt beingdeposited in the area of the weld. For details on therecording of the preheating temperature, cf. EN IS013916.

2.10 To prevent cold cracks in higher-strengthand high-strength (quenched and tempered) steels,thick-walled components or components of complexdesign, it is advisable to use measures which give thehydrogen introduced into the weld metal duringwelding sufficient time to escape. The followingmethods are well established:

Chapter 2Page 3–6


D

– Maintenance of a specific minimum preheatingand interpass temperature throughout thewelding operation,

– Delayed cooling after welding,

– Holding at approx. 250 °C prior to cooling(hydrogen-reducing heat treatment) or

– Heat treatment immediately after welding(without cooling in between)

2.11 Where hull structural steels or fine-grainedstructural steels have undergone thermo-mechanicalprocessing (TM steels), the need for and degree ofpreheating shall be decided on separately on the basisof the carbon equivalent and the results of the ap-proval or welding procedure tests as applicable. Dry-ing of the areas to be welded by heating may be suffi-cient.

3. Monitoring interpass temperatures

The guide values contained in Table 3.5 for the inter-pass temperatures relating to the various steels shallnot be significantly exceeded.

4. Welding with controlled heat input perunit length of weld

In addition to controlling the preheating and interpasstemperature, the heat input per unit length of weldshall be controlled during welding, especially in thecase of weldable, high-strength (quenched and tem-pered) fine-grained structural steels. The heat input

per unit length of weld shall not fall below or exceedthe values indicated by the steel manufacturer orthose used in the welding procedure tests and speci-fied in the welding procedure specifications (WPS)by any significant amount.

5. Preheating and heat input during thewelding of other steels or metallic materi-als

5.1 Preheating is not normally required for aus-tenitic materials. Preheating may be necessary foraustenitic-ferritic materials. A maximum permittedinterpass temperature which is normally between150 °C and 180 °C shall be complied with in order toprevent hot cracks.

5.2 Ferritic and stainless martensitic steels shallbe adequately preheated and welded using controlledheat input per unit length of weld. Guide values forthe preheating and interpass temperatures are pre-scribed in EN 1011-3.

5.3 Preheating is not normally required forwelding aluminium alloys, but should not exceed50 °C. A maximum permitted interpass temperatureof 100 °C to 120 °C shall be complied with in orderto prevent undesirable phase dispersion. EN 1011-4contains guide values for the preheating temperatureto be applied and the interpass temperature.

Table 3.5 Guide values for the maximum interpass temperature during welding

Category inaccordance with

DIN V 1738(CR 12187)

Steel gradesMaximuminterpass

temperature[°C]

1.1 Normal-strength hull structural steels and comparable structural steels 250

1.2 Higher-strength structural steels and comparable structural steels 250

1.2 High-temperature, low Mo alloy steels 250

2Normalised or thermo-mechanically processed fine-grained steels withyield strengths of > 360 N/mm2 250

3Quenched and tempered or precipitation-hardened (excludingstainless) steels with yield strengths of > 360 N/mm2 250

5 Steels with a max. Cr content of 10 % and a max. Mo content of1,2 %

350

7 Nickel alloy steels with a max. Ni content of 10 % 250

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E

E. Post-Weld Heat Treatment

1. Welded components shall be subjected topost-weld heat treatment where this is prescribed inSections 1 to 5 of Chapter 3. Post-weld heat treatmentis generally used for ferritic steels, in which casestress relief heat treatment or tempering is normallysufficient. Where consideration also has to be paid toother codes of practice in the manufacture of certaincomponents or structures (e.g. TRD 201 relating tothe construction of steam boilers, cf. Chapter 3, Sec-tion 2, A.2.2), the provisions relating to post-weldheat treatment contained in these codes of practiceshall also be complied with.

Note:

The need for and type of post-weld heat treatment isdetermined by various factors, the most important ofwhich are given below:

– material characteristics and dimensions (wallthicknesses)

– minimum anticipated operating temperature(design temperature)

– type of operating and background environment(e.g. risk of corrosion)

– build-up of welds to inhibit elongation andshrinkage

– risk of distortion during subsequent machining

2. If stress relief heat treatment after welding isinsufficient and more extensive heat treatment isrequired (e.g. normalising or quenching and temper-

ing), the method of heat treatment shall be speciallyestablished in accordance with the material specifica-tion and the conditions of use and subject to agree-ment by the Society. This shall also apply in analo-gous manner to materials and material combinationsother than those dealt with here and also to othermethods of stress-relief.

3. The stress relief heat treatment shall be car-ried out by means of slow, even heating of the com-ponents to the prescribed temperature ranges (Table3.6 contains guide values), holding in these ranges fortwo minutes per mm of wall thickness (but not lessthan 30 minutes), slow cooling to 400 °C in the fur-nace or heat treatment appliance, and then completecooling in still air. For thick-walled components, theholding time need not be more than 150 minutes.

4. If there is a risk of the components beingdistorted during cooling, the heat treatment may,within certain limits, be carried out at a lower tem-perature with an increased holding time. The requiredtemperatures and holding times shall be agreed withthe Society.

5. Joints between ferritic and austenitic steels(weld metal) must not, as a general rule, be subjectedto heat treatment due to the risk of carbon diffusion,except where the welds are made using nickel-basefillermaterials.

Chapter 2Page 3–8


E

Table 3.6 Heat treatment temperatures for stress-relief heat treatment of welded joints using similar fillermetals

Category inaccordance

withDIN V 1738(CR 12187)

Steel grades

Examples of appropriatesteels in accordance

with the Society's Rules orthe standards 1

Heat treatmenttemperature

[°C]

1.1Normal-strength hull structural steelsand comparable structural steels, gradeof steel forgings and castings

GL Grade A – E 550 – 600

1.2Higher-strength hull structural steelsand comparable structural steels,grades of steel forgings and castings

GL Grade A 36 - E 36 530 – 580

1.2 High-temperature, low Mo alloy steels 16Mo3 550 – 620

2Normalised or thermo-mechanicallyprocessed fine-grained steels with yieldstrengths > 360 N/mm2

GL Grade A 39 – E 39S 460 TM 530 – 600

3Quenched and tempered fine-grainedstructural steels with yield strengths> 360 N/mm2

S 690 QL 530 – 580

55.15.2

Steels with a max. Cr content of 10 %,max Mo content of 1,2 %

13CrMo4-510CrMo9-10, 11CrMo9-10,

630 – 680670 – 720

77.17.27.37.37.3

Nickel steels with a maximum Nicontent of 10 %

13MnNi6-3 (0,5 % Ni)12Ni14 (3,5 % Ni)12Ni19 (5 % Ni)X8Ni9 (9 % Ni)X7Ni9 (9 % Ni)

530 – 560530 – 560530 – 560

2

2

1 Steel grades not listed here are to be classed together with comparable grades.2 Heat treatment should be avoided.

II - Part 3GL 2000

Section 4 Non-destructive Testing of Welds Chapter 2Page 4–1

B

Section 4

Non-destructive Testing of Welds

A. General

1. Scope

1.1 These Rules apply to the performance of thenon-destructive tests of welded joints according to themethods and scopes prescribed in the individual sec-tions of Chapter 3 for the various fields of application.Cf. also Chapter 1, Section 1, A.1. and A.2.

1.2 They also apply to the performance of allnon-destructive weld tests which are stipulated in otherregulations, rules or technical instructions issued bythe Society and for which no specific details are giventherein.

2. Standards and other codes of practice

2.1 The standards, etc. mentioned in the follow-ing paragraphs are an integral part of these Rules andshall also be complied with when performing the non-destructive weld tests. Where the standards contradictthese Rules, the latter shall take precedence.

2.2 The performance of tests according to other,comparable codes of practice requires the prior con-sent of the Society. For this purpose, the relevantcodes of practice shall be submitted to the Societytogether with the other inspection documents (cf.D.1.1) for examination and approval.

3. Requirements applicable to the inspectiondepartment

3.1 The works' inspection department shall be asindependent and free from the influence of the fabri-cation department as it is necessary to ensure that theinspection and the evaluation of the inspection resultsare carried out objectively. This applies in analogousmanner to outside inspection bodies.

B. Test Methods, Appliances and Test Media

1. Test methods

1.1 The choice of the test method to be used ineach case is determined among other things by thecomponent or weld shape, the material and the defects

to be demonstrated (type and position). Cf. the indi-vidual application-specific sections of Chapter 3.

1.2 Unless otherwise stated in the individualapplication-specific sections of Chapter 3, the follow-ing basic requirements apply:

– Up to a wall or weld thickness of approx.30 mm, radiographic inspection is the preferredmethod; for larger thicknesses, ultrasonic in-spection is to be used as the primary testmethod.

– For wall or weld thicknesses of approx. 10 mmand above, either radiographic or ultrasonic in-spections may be performed, in consultationwith the Society.

– For radiographic inspection, X-ray sources shallbe used wherever possible. Gamma ray sourcesmay only be used with the Society's consent onthe basis of an examination and recognition ofthe test method; cf. K.1.

– For magnetic materials, testing for surfacecracks shall wherever possible be carried out bymagnetic particle inspection; the use of liquidpenetrant inspections for magnetic materials re-quires the Society's consent in each individualcase.

1.3 The test method must be capable of reliablydetecting the external and/or internal defects whichmay be present. Where necessary, this shall beachieved by using two or more test methods in combi-nation. The particular test method(s) to be used shallbe stated in the inspection schedule (cf. D.1.1).

2. Test appliances and media

2.1 The test appliances and media used mustconform to the state of the art and the relevant stan-dards and must be in perfect, serviceable condition.The Society may require an inspection of the test ap-pliances and/or media used.

2.2 When making use of test equipment, testappliances, etc. owned by other, outside testing bodies,the works shall ensure that the conditions stated in 2.1are satisfied.

Chapter 2Page 4–2

Section 4 Non-destructive Testing of Welds II - Part 3GL 2000

D

C. Inspection Personnel, Supervisors

1. Inspection personnel (inspectors)

1.1 The non-destructive weld tests may only beperformed by persons trained in the use of the testmethod concerned and possessing adequate practicalexperience. The Society shall be supplied with appro-priate documentary proof of such training and experi-ence, e.g. conforming to EN 473/ISO 9712.

1.2 Inspection of welds by ultrasonic means shallonly be performed by inspectors holding a DGZfP 1

certificate U.2.1 (or equivalent, e.g. ASNT 2

Level II) and having at least 2 years of proven practi-cal testing experience who are recognized by the Soci-ety.

1.3 For such recognition, the Society may requireverification of the suitability of the ultrasonic inspec-tion personnel and of the test appliances and the testmethod under practical conditions in the works. Inexceptional cases and where necessary for a restrictedfield of use, the Society may, following successfulverification, also recognize inspectors who do not holdthe certificates specified in 1.2.

1.4 Application for such verification shall bemade to the Society's head office, accompanied by thefollowing information and documents:

– Documentary proof of the professional trainingof the inspection personnel and, where applica-ble, the inspection supervisors

– A description of the test equipment (appliances,probes, etc.)

– A description of the test method (instrumentsetting, angles and scanning directions, instru-ment sensitivity, etc.)

– Method of determining the size of defects

– Form of the inspection report.

After successful verification, recognition may belinked to authorization of the inspector for the inde-pendent performance of certain tests and inspections(materials, weld shapes) under his personal responsi-bility. The decision lies with the Society.

Note:

The recognition and authorization of an inspectornormally covers the inspection of normal butt andcorner joints (e.g. the joints uniting deck stringers andsheer strakes) or approximately right-angled T-joints

––––––––––––––1 Deutsche Gesellschaft für Zerstörungsfreie Prüfung (German

Association for Non-destructive Testing).2 American Society for Non-destructive Testing.

in hull structural steels and/or other comparablestructural steels. For the performance of further (moredifficult) tests (e.g. on other materials and/or onacute-angled tube connections and weld shapes ofcomparable complexity), the authorization shall besubject to special review and supplementation.

2. Inspection supervisors

2.1 An appropriately qualified works inspectionsupervisor shall be available for scheduling andmonitoring the performance of the non-destructiveweld tests and evaluating the results. The name of theinspection supervisor shall be given to the Society;proof of his qualifications (e.g. DGZfP 1 Stage 3,ASNT 2 Level III or, for welding supervisors, toEN 719/ISO 14731 standard with additional NDTtraining) shall be submitted to the Society.

2.2 The inspection supervisor is responsible forensuring that the non-destructive weld tests are com-petently and conscientiously carried out and recordedby suitable inspectors in accordance with these Rules,the relevant standards and the approved inspectionschedule.

2.3 When using the services of outside inspectionbodies, the works shall ensure that the above condi-tions are satisfied and shall inform the Society ac-cordingly.

D. Inspection Schedule, Inspection Reports

1. Inspection schedule

1.1 Unless already stated in the other manufac-turing documents (drawings, parts lists, etc.) to besubmitted for approval, an inspection schedule for thenon-destructive weld tests shall be drawn up, whichmust contain the following information:

– Components and welded joints to be tested

– Scope and method of testing, areas to be tested,location of testing positions (cf. the application-specific sections of Chapter 3)

– Requirements applicable to the welded joints(for evaluation criteria, cf. the application-specific sections of Chapter 3)

– Testing standards and/or specifications, if it isintended to use standards or specifications dif-ferent from those mentioned in these rules.

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F

1.2 The location of testing positions shall besubject to agreement between the welding shop andthe Society’s Surveyor, whereupon the inspectionschedule shall be submitted to the Society’s HeadOffice for approval. The Society reserves the right tomake changes to this inspection schedule even afterapproval has been given and especially to change thelocation of the individual testing positions or to extendthe scope of testing (cf. H.) if the production processand/or test results suggest this to be necessary.

2. Inspection reports

2.1 Reports shall be prepared on all (initial andrepeat) tests, and these shall be submitted to the Sur-veyor together with the other documentation (e.g.radiographs). The inspection reports must contain allthe necessary details according to Sections K. to N.relating to the particular test method used, the positionat which the test was performed and the results ob-tained.

Note:

Where the test results are to be recognized in place ofthe prescribed welder's repeat tests in accordancewith Chapter 1, Section 3, E.3., the inspection reportsshall also state the names or identification numbers ofthe welders.

2.2 Repeat tests (following repairs) and theirresults shall be specially identified in the inspectionreports; cf. I.2.2. The results and documents relating tothe initial test shall be submitted to the Society’s Sur-veyor along with the results and documents relating tothe repeat tests and also specifically if the repair wasarranged for in-house.

2.3 Inspection reports shall be signed by theinspector and the test supervisor. Reports and docu-mentation shall be kept for six years.

E. Timing of Inspection, Waiting Times

1. Non-destructive testing of welds shall as ageneral rule not be carried out until all the weldingoperations on the component concerned have beencompleted. In special cases, e.g. in the case of thick-walled components at risk of cracking, it may be ad-visable to carry out non-destructive tests, e.g. for sur-face crack examinations, as an interim measure (in thecourse of the welding work).

2. Before using the test methods described in K.to N., a visual inspection of the welded joints shall beperformed. Surface defects which restrict the ability ofthe tests to produce meaningful results or which may

lead to misinterpretation of the results shall be reme-died before any further tests are performed. Cf. alsoJ.3.

3. Components which are subjected to post-weldheat treatment (e.g. stress relief heat treatment) shall asa general rule be inspected after heat treatment. In-spection of the welds for welding defects before heattreatment as well is recommended. The Society maytake previous inspections into account when estab-lishing the final scope of inspection. Details shall beagreed with the Society on a case-by-case basis.

4. In the case of higher-strength and especiallyhigh-strength (e.g. quenched and tempered) structuralsteels where the possibility of delayed cracking (e.g.due to the presence of hydrogen in the weld metal)cannot be ruled out, the tests shall not be carried outearlier than 48 hours after completion of the weldingwork. The Society may demand longer waiting times(e.g. 72 hours up to a maximum of 7 days) or repeti-tion of the tests (at least on a random sampling basis)after an appropriate waiting time.

5. Repetition of non-destructive tests shall beallowed for or may be demanded if the components orwelded joints have been subjected to abnormal stresses(e.g. while in transit or during trial loading or pressuretesting) before being stressed in normal service. Thetype and scope of these tests shall be agreed with theSociety on a case-by-case basis.

F. Preparation and Performance of Tests

1. Preparation of areas to be tested

1.1 The areas to be tested (surfaces of welds andof adjacent parts of the workpiece) must be suffi-ciently clean and smooth for the respective testmethod. Irregularities in the welded joint (cf. E.2.),remains of auxiliary welds, welding spatter, fragmentsof slag, etc. and any protective coatings or preserva-tives must be removed before the tests if they are li-able to prevent them from being performed properly.

Note:

Cf. information sheet DVS 0709 "Requirements appli-cable to the surface condition of welded joints in steelfor the use of non-destructive test methods". Theoverweldable shop primers normally used in ship-building have been found not to affect the tests andtherefore can generally be left in place. With "re-primed" welds, however, the coating should not besignificantly thicker than the normal coating thick-ness.

Chapter 2Page 4–4


I

1.2 In special cases, e.g. ultrasonic testing fortransverse defects (cf. L.4.3), grinding of the seam andthe surface of the workpiece may be necessary.


2.1 Non-destructive testing of welds shall becarried out in the manner described in Sections K. toN. The place and date of the tests shall be notified tothe Society's Surveyor in good time. The Surveyorshall be given the opportunity to participate in or su-pervise the tests if he so wishes.

2.2 The individual positions (sections) to betested shall be durably marked on the component orthe welded joint in such a way that the test findings(e.g. weld defects requiring repair) can be unequivo-cally localized at any time up to the completion of alltests and, where applicable, repairs. If the dimensionsare appropriately indicated (or a similar measure isused) in the drawings, inspection schedules and in-spection reports, marking of the component may bedispensed with.

G. Evaluation of Test Results

1. Identification of test findings

1.1 In the case of radiographic testing and, whereapplicable, the methods of surface testing, the refer-ence numbers and/or symbols conforming to EN26520/ISO 6520 or, as applicable, in Table 4.1 (ex-tract from the standard) may be used to identify (de-scribe) test findings (e.g. welding defects). With re-gard to the description of defects in ultrasonic testing,cf. L.5.

2. Evaluation criteria

2.1 Unless otherwise specified for the respectivecomponents or welded joints in the application-specific sections of Chapter 3, the evaluation catego-ries according to EN 25817/ISO 5817 (Annex A) maybe used as evaluation criteria for steel and those ac-cording to EN 30042/ISO 10042 (Annex B) for alu-minium alloys.

2.2 In the inspection schedules, testing instruc-tions, etc. to be drawn up by the welding shop (cf.D.1.), the evaluation categories to be determined ac-cording to the type and level of stress or, where neces-sary, other individual evaluation characteristics shallbe assigned to the individual components and weldedjoints. With regard to the evaluation of results of ultra-sonic testing in conjunction with the stipulations in theabove-mentioned standards (evaluation categories),see L.5.

2.3 The Society may consent to the use of differ-ent evaluation criteria or criteria conforming to otherstandards, etc. if they are approximately comparable tothose mentioned in 2.1 and are suited to the particulartest method used. Details shall be agreed with theSociety on a case-by-case basis.

3. Evaluation, rating

3.1 The inspection results shall be evaluated bythe testing department or body and/or the weldingsupervisory staff. The ultimate evaluation and thedecision whether to leave defects in materials andwelds as they are or to repair them is reserved for theSociety's Surveyor.

3.2 The results may be rated according to Table4.2 (in the case of radiographic inspection) or, in thecase of ultrasonic testing or if a broader statisticalevaluation is not required, by "leave as is" or "satis-fied" or, as the case may be, "to be repaired" or "notsatisfied".

H. Extension of the Scope of Inspection

1. If it is not certain that a defect to be repairedends within the tested section of the weld, the adjacentsections of the weld shall also be inspected.

2. If major defects are found during inspectionsat random, the scope of inspection shall be extended.Unless otherwise agreed, for each section of weld tobe repaired two more of the same length shall be in-spected.

3. In the case of ultrasonic testing, the Societyreserves the right to carry out control tests at randomon the basis of the inspection reports compiled by thefirm's inspector or to require control tests to be per-formed by a second, independent testing authority. Ifmajor differences from the results of the initial testsperformed in the firm are found, the scope of the con-trol tests may be extended.

I. Repairs, Re-inspection

1. Repairs

1.1 Defects requiring repair on the basis of theevaluation shall be carefully grooved over a sufficientlength (especially in the case of intersecting welds)and/or re-welded. Where a number of defects needingrepair are located close together in a single section ofweld, the entire section shall be machined out and re-welded.

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Table 4.1 Symbols denoting defects (taken from EN 26520/ISO 6520)

Reference No. / symbol conformingto the IIW X-ray manual Description 1

100 E Crack

101 Ea Longitudinal crack

102 Eb Transverse crack

104 Ec End crater crack

2011 Aa Pore

2015 Ab Elongated cavity (Gas pocket)

2016 Ab Worm hole

2024 K Crater pipe (End crater cavity)

301 Ba Slag inclusion

304 H Metallic inclusion

4011 –– Lack of side-wall fusion

4012 –– Lack of inter-run fusion

4013 D Lack of root fusion

402 D Lack of penetration (Incomplete penetration)

5011 F Undercut, continuous

5012 F Undercut, intermittent

5013 –– Shrinkage groove, groove in the root (cf. 515)

502 –– Excessive weld reinforcement (butt weld)

503 –– Excessive convexity (fillet weld)

504 –– Excessive root reinforcement

507 –– Misalignment of edges

510 –– Burn-through

511 –– Incompletely filled groove

515 –– Root concavity (cf. 5013)

517 –– Poor restart

1 For explanations and illustrations, cf. EN 26520/ISO 6520.

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Table 4.2 Evaluation ratings (for a more comprehensive statistical interpretation)

Findings Rating Remarks

Weld free from detectable defects 1 = good ––

Minor defects such as isolated poresand small slag inclusions which do notreduce the strength or tightness of thewelded joint

2 = serviceable ––

Avoidable defects such as small rowsor clusters of pores, small slag lines,short root defects and minor lack of fu-sion

3 = leave as is

Repair not recommended for componentssubject to normal stresses. Short root de-fects and minor lack of fusion may be leftonly at non-critical points

Defects which must be avoided, e.g.coarse slag inclusions, accumulationsof pores, generally all root defects andlack of fusion, and small isolatedcracks

4 = to be repaired

Repair of defects required. Exceptions onlyfor components without particular require-ments on strength and tightness, but not atcracks.

Extensive major defects and cracks 5 = to be replacedReplacement of the section of weld or ofthe entire welded joint required

1.2 Undercuts in need of repair, poor transitionsto the surrounding material or other surface defectsshall, where possible, be remedied by grinding outwith smooth transitions to the surrounding material or,if they are too deep for this, they shall, with the Sur-veyor's consent, be ground out and repair- welded.

2. Re-inspection

2.1 Repaired welds shall be re-inspected. Wherewelds have been completely remade, retesting at leastequal in scope to the initial inspection shall be per-formed at random in accordance with the Surveyor'sinstructions.

2.2 Re-inspections shall be specially indicated inthe inspection reports and on the radiographs, e.g. bymeans of an "R" (= repair) next to the title of the film(cf. D.2.2).

J. Visual Inspection

1. The surfaces and back sides of the welds shallundergo a complete visual inspection, with the aid ofoptical (magnifying) appliances where necessary, tocheck their external characteristics. The followingcharacteristics shall be checked:

– Completeness

– Dimensional accuracy

– Compliance with the specified weld shape

– Absence from inadmissible external defects.

2. The dimensional accuracy shall be checkedwith suitable measuring instruments on a random sam-pling basis. When measuring fillet weld throat thick-nesses, measuring gauges which measure with suffi-cient accuracy in throats which are not an exact rightangle shall be used where necessary.

3. When checking for the correct shape of weldand external defects, attention shall be paid to thefollowing:

– Weld reinforcement or top bead depression

– Weld edge angles (transitions to surroundingmaterial)

– Misalignment of edges

– Undercuts

– Visible pores and slag inclusions

– Fused weld spatter

– Arc strikes on the surface of the base material

– Concave root surface and incomplete root fusion

– Cracks

– Unequal side lengths (in the case of fillet welds).

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With regard to the limits of acceptability, see G.2. andthe application-specific sections of Chapter 3. Repair-ing of visible cracks is mandatory.

K. Radiographic Inspection

1. Radiation sources, appliances

1.1 Wherever possible, X-ray units shall be usedas radiation sources for radiographic inspections. Theradiation energy (tube voltage) shall lie within theenergy limits specified in EN 1435/ISO 1106. Allow-ing for the differences in thickness of the component,the radiation energy (tube voltage) should be kept aslow as possible within the permissible working rangeso as to obtain a high-contrast image.

1.2 Where justified in exceptional cases (e.g. bylack of accessibility), gamma ray sources - preferablyIr 192 or Se 75 - may be used as radiation sources,subject to the Society's consent in each instance; cf.4.4.

2. Films, intensifying screens

2.1 Class C5 films conforming to EN 584-1 or GIII conforming to ISO 5579 may normally be used inshipbuilding for X-raying steel. Class C3 or C4 and GIor GII films, as applicable, are to be used for the ra-diographic inspection of aluminium alloys and whenusing gamma rays to inspect steel. The use of class C3or C4 and GI or GII films, as applicable, is obligatoryin steam boiler, pressure vessel and pipeline manu-facture (pipe class I and II).

Note:

Annex C provides a summary of the classification ofthe most popular X-ray films currently on the market.This summary does not claim to be exhaustive andmanufacturers of other X-ray films are invited to makethe classification of their products by independentinspection institutes public and make the appropriatedocuments available to the Society so that they cansupplement the list.

2.2 Front and rear 0,02 mm lead screens shallnormally be used when radiographing steel. Duringradiography, the film and the screens must be kept inintimate contact in suitable cassettes, packs, etc. Ra-diographs may be made of aluminium alloys up toabout 65 mm thick without the use of intensifyingscreens.

2.3 The use of salt intensifying screens and fluo-rometal screens is not allowed.

3. Radiographic parameters

3.1 As a general rule, the radiographic parametersprescribed in EN 1435/ISO 1106 for test category A(general inspection procedure) shall be applied inshipbuilding and those for test category B (higher-sensitivity inspection procedure) shall be applied insteam boiler, pressure vessel and pipeline manufacture(pipe class I and II). In special cases the Society maystipulate application of test category B in shipbuildingas well. For radiographic inspection using X-rays anda film length of 480 mm, the distance between the filmand the focal point shall normally be 700 mm, and inany case not less than the length of the film.

3.2 If several films are used to inspect a seam(e.g. for circumferential radiographs), they shall over-lap at the ends in such a way that the full pattern of theweld can be traced without interruption.

3.3 When inspecting pipes with an outside di-ameter ≤ 90 mm, elliptical radiographs may be made.Depending on the diameter and wall thickness of thepipe, two or more elliptical radiographs are to be madeso that the full length of the weld (the entire circum-ference of the pipe) is shown in the area of the radio-graphs capable of evaluation.

3.4 For larger-diameter pipes, either double-wallradiographs or, if the pipe diameter permits, central orsingle-wall radiographs shall be made. Care shall betaken to ensure that the film is capable of evaluation atboth its ends. The area capable of evaluation shall onlybe the section of the weld in which the rays delimitingthe beam do not cover more than 1.1 times the weldthickness that is radiographed with vertical irradiation.The number of radiographs shall be determined ac-cordingly.

3.5 In order to determine the image quality to EN462-3 standard, at least one image quality indicator toEN 462-1 (wire indicator) shall, for each radiograph,be laid on the side of the weld away from the film andfacing the radiation source and shall be radiographedtogether with the weld. Should this be impossible, theimage quality indicator may, with the Society's consentand after the preparation of comparative radiographsdesigned to determine the changed index of imagequality, be fixed to the workpiece on the side close tothe film (i.e. between the film and the weld). The filmimage must be marked with a corresponding identifi-cation ("N") to indicate that this arrangement wasused, and appropriate mention must be made in theinspection report.

3.6 Each film image must be clearly and unmis-takably identified by lead figures or letters simultane-ously irradiated and depicted on the film. This identi-fication must be the same as that given in the inspec-

Chapter 2Page 4–8


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tion schedule and must enable any defects found to bereadily located. The marking is to be located outsidethe weld area to be evaluated (the weld width plus atleast 10 mm on each side).

4. Film processing, density, image quality

4.1 The films must be processed in properlyequipped darkrooms in such a way as to avoid anyblemishes which interfere with their evaluation (e.g.fogging, scratches, dark crescent-shaped marks due tokinks in the film, etc.). The instructions and recom-mendations issued by the film and chemical manufac-turers are to be followed. Premature interruption of thedeveloping process and reduction with chemicals ofover-exposed films is not allowed.

4.2 The radiographic images must have a densityD of at least 2,0 over the entire area for evaluation.The upper limit value depends on the brightness of thefilm viewers available for the evaluation, but shouldnot exceed 2,5 to max. 3,0. Wide differences in den-sity within a single radiograph are to be avoided.

4.3 The image quality shall be determined withan image quality indicator of the type prescribed inpara. 3.5 and in accordance with EN 462-1. For cate-gory A inspection (cf. 3.1), image quality B is desir-able for steel, with image quality A as the minimumrequirement. In the case of aluminium alloys and testcategory B, image quality B must be attained. Thecriterion in each case is the smallest wire of the imagequality indicator which is still visible in the area to beevaluated, the density being uniform.

4.4 The works or the inspection department/ bodymust demonstrate on request by means of specimenradiographs that the required radiographic parametersand image quality can be attained.

5. Viewing conditions, evaluation, inspectionreport

5.1 Viewers with a luminous density toEN 25580/ISO 5580 sufficient for the required filmdensity shall be used for the examination and evalua-tion of radiographs. Stops must be fitted to enable thefield of view to be adapted to the film size for, orcapable of, evaluation. The brightness must be adjust-able.

5.2 The viewing and evaluation of radiographsshall take place in a dimly lit though not completelydarkened room. Evaluation should only be performedafter a sufficient period has been allowed for adapta-tion. Bright, dazzling areas within the field of view areto be screened. The use of magnifying glasses for thedetection of fine details may be beneficial.

5.3 The following information is to be given inthe inspection report, together with explanatorysketches where necessary:

– Works number, component, inspection schedulenumber, inspection position(s)

– Material, welding process

– Thickness of workpiece or weld, as appropriate

– Date and time of test (cf. E.3. and elsewhere)

– Radiation source and size of tube focus or emitter

– Tube voltage or activity at time of inspection

– Radiographic arrangement to EN 1435/ISO1106, position of wire indicator

– Type of film, nature and thickness of intensify-ing screens

– Test category, image quality index and imagequality class

– Symbols denoting defects and assessment inaccordance with G.

The inspection report must also indicate whether theinformation relates to an initial radiograph or to afollow-up inspection after repair work has been carriedout (cf. D.2.1 and I.2.2).

5.4 The initial evaluation shall be carried out bythe welding supervisory staff and/or the works inspec-tion department. Then the films (initial and follow-upradiographs, cf. D.2.1 and I.2.) shall be submitted tothe Society's Surveyor for evaluation together with theinspection reports (cf. G.3.1).

L. Ultrasonic Inspection

1. Test appliances and accessories

1.1 The test appliances, probes and other acces-sories (calibration and reference blocks for adjustingthe sensitivity, reference scales, etc.) shall conform tothe state of the art and the relevant standards (e.g.DIN 54120, EN 27963/ISO 2400, EN 1714 or DIN54126).

1.2 All possible echo heights within the range ofinstrument sensitivity used must be capable of beingdetermined with the aid of an amplification controlcalibrated in dB and a suitable scale marking on thedisplay. The interval between the switching stagesshall not exceed 2 dB. Instruments not equipped with acalibrated amplification control may not be used.

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1.3 Stepless controls must enable the ranges ofadjustment available on the instrument to follow onfrom one another, as far as possible without any inter-vening gap. Within each individual range the timesweep must be continuously adjustable.

1.4 With regard to the geometrical characteristicsof the sound field, especially the incidence and squintangles, the testing frequency and the resolution, theprobes must lie within the tolerances specified in thestandards mentioned above. The incidence and squintangles shall not in either case deviate by more than 2°from the nominal value or from the centre line of theprobe. The angle of incidence and the probe index (ofangle beam probes) shall be verified.

2. Calibration, sensitivity setting

2.1 The distance signal (time sweep) may becalibrated in projection distances "PA", shortenedprojection distances "VPA'" or sonic distances "s" asdesired or, if necessary, depth positions "b". Unlessotherwise agreed, calibration in shortened projectiondistances "VPA'" is preferred for weld inspections, orin sonic distances "s" for parts of complex shape.

2.2 For calibration in accordance with 2.1 a cali-bration block to DIN 54120 or EN 27963/ISO 2400shall be used when testing (hull) structural steels.Appropriate calibration or reference blocks shall beused for materials having other sound velocities (e.g.high-alloy steels and non-ferrous metals). Bore holesused for calibration shall not be larger than 2 mm andshall lie parallel to the testing surface. Where possible,calibration should not be performed at edges.

2.3 Depending on the intended method of echoheight definition, the sensitivity setting shall be per-formed using calibration reflectors of known shape,position and size (e.g. large flat reflectors, side-drilledholes) in accordance with the provisions ofDIN 54 127, Part 1. Unless otherwise agreed, the DGSmethod of inspection shall be used. With the DGSmethod, the sensitivity setting is to be carried out inaccordance with the instrument manufacturer's in-structions using calibration blocks to DIN 54 120 andEN 27963/ISO 2400. Flat-bottom holes and groovesshould not be used as calibration reflectors.

2.4 If necessary (e.g. for defects close to thesurface), the sensitivity setting is to be corrected inaccordance with DIN 54 127, Part 1. When testingunalloyed and low-alloy (hull) structural steels andwhere the sonic distances are not too far (cf.DIN 54 127, Part 1), the sound attenuation may nor-mally be disregarded. A transfer correction to deter-mine the coupling differences between the surface ofthe reference block and that of the test piece shall,however, be performed in every case. The value of the

transfer correction shall be stated in the inspectionreport.

2.5 For more efficient detection of defects it isrecommended that testing be performed with a testsensitivity (search sensitivity) increased by approxi-mately 6 dB over the chosen registration level (seepara. 5.1). However, the registration level setting isgenerally to be used when evaluating defect indica-tions. All echo indications to be registered must attainat least 20 % of the display height even at the maxi-mum sonic distance (cf. DIN 54 127, Part 1). In thecase of electrogaswelded seams, the inspection shallnormally be performed with a sensitivity increased by12 dB, and this fact shall be expressly stated in theinspection report with a reference to the welding proc-ess (e.g. EG + 12 dB).

3. Surface preparation, coupling

3.1 On both sides of the welded seam (cf. 4.1) thetesting surfaces must be smooth and free from impuri-ties liable to interfere with coupling. Rust, scale andweld spatter are to be removed so that the probes liesnugly against the surfaces, which should if necessarybe ground. Firmly adhering paint need not be removedprovided that it does not interfere with the inspectionand quantitative allowance can be made for the re-sulting loss of sensitivity when evaluating the echoheights.

3.2 Where angle beam probes have to be appliedto the surface of the weld for the inspection of trans-verse defects (see 4.3), this shall also be prepared as atesting surface in the manner described above.Notches, grooves and the like lying across the beamaxis which produce false indications and may impairthe test are to be removed.

3.3 Coupling to the testing surfaces prepared inaccordance with 3.1 should be as uniform as possibleand should not vary by more than ± 4 dB. If greatervariations are found, the condition of the surface shallbe improved. Where greater variations cannot beavoided, this fact must be stated in the inspectionreport. Running water, cellulose glue, oils, grease orglycerine may be used as coupling media.

4. Scanning directions, angle of incidence

4.1 Unless otherwise agreed or stipulated, testingfor longitudinal defects shall be performed from onesurface and from both sides of the weld, as shown inFig. 4.1. The testing area must embrace the weld metalitself and an area on both sides of the seam equal toabout 1/3 of the wall thickness, subject to a minimumof 10 mm and a maximum of 20 mm. The testing sur-face must encompass a width at least equal to the fullskip distance plus twice the length of the probe.



L

testingsurface

testingarea

Fig. 4.1 Testing for longitudinal defects

4.2 Depending on the weld geometry and thepossible orientation of defects, it may be expedient toperform the test from both surfaces or (e.g. in the caseof bevels) from only one side of the seam. With cornerand T-joints, the testing shall normally be performedboth from the side of the web and from that of thecontinuous (flange) plate using a standard probe, asshown in Fig. 4.2. Such probe arrangements differingfrom 4.1 shall be specially noted in the inspectionreport. The same applies in analogous manner tocurved surfaces.

Fig. 4.2 Testing for longitudinal defects in cornerand T-joints

4.3 Testing for transverse defects shall be per-formed from both sides of the weld in two directionsalong the seam as shown in Fig. 4.3 or - where the test

requirements are more stringent - on the face of theweld which has been machined flush with the surface.The Society may require that testing for transversedefects be performed with two probes connected inparallel. Where welds are made with a large weld pool(as in electroslag welding), testing for oblique defectsshall also be performed at an angle of approximately45° (cf. EN 1714).

4.4 With plate thicknesses (weld thicknesses) ofless than 30 mm, testing may be performed with anangle of incidence of 70°. With thicknesses of 30 mmand over, two angles of incidence (70° and 45° or 60°)shall be used. Where the surface is curved, the neces-sary angle of incidence shall be determined in accor-dance with DIN 54127, Part 1. With very large wallthicknesses (above about 100 mm), the inspectionmust be performed using a tandem technique (withfixed, mechanical coupling of two similar probes) fordifferent depth zones.

- 20 °

Fig. 4.3 Testing for transverse defects

5. Registration level, evaluation of echo indi-cations

Note:

Recommendations on the evaluation of the findings ofultrasonic inspections of fusion-welded joints (in steel)according to EN 25817/ISO 5817 are also given inInformation Sheet DVS 0704 of the Deutscher Ver-band für Schweisstechnik e.V. (German Associationfor Welding Technology). The information sheet alsocontains information on the usefulness and perform-ance of ultrasonic inspections and the evaluation ofform-related indications.

5.1 For tests carried out by the DGS method, theregistration level (reference reflector size) for longitu-dinal and transverse defects is given by the diametersof the disc-shaped reflectors specified in Table 4.3 inrelation to the wall thickness (weld thickness).

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Table 4.3 Registration levels

Diameter ofdisc-shaped reflectorWall thickness

(weld thickness)

4 MHz 2 MHz

from 10 – 15 mm

over 15 – 20 mm

over 20 – 40 mmover 40 – 60 mm

1,0 mm

1,5 mm

2,0 mm3,0 mm

1,5 mm

2,0 mm

3,0 mm4,0 mm

Where the thickness is greater than 60 mm, the regis-tration level will be determined on a case-by-casebasis. For tandem testing, the registration level shall bedetermined by a 6 mm diameter disc-shaped reflector.For other methods of echo height definition (e.g. thereference block method), the registration level shall bedetermined in accordance with DIN 54127, Part 1.

5.2 The registration of non-form-related echoindications which are observed when inspectingwelded joints and whose echo heights attain or exceedthe registration level (reference reflector size) speci-fied in para. 5.1 is required only when expresslystipulated by the Society or where subsequent repeattests have to be performed. Otherwise only those echoindications shall be registered which exceed the repairlimit value specified in para. 5.4.

5.3 One characteristic which is to be stated forthe classification of echo indications is by how manydB the maximum echo height of the reflections founddiffers from the registration level defined in 5.1. In thecase of the DGS method, the size of the (substitute)disc-shaped reflector may also be stated. Further char-acteristics to be stated are the registration lengths andhalf-value depths in accordance with EN 1714. Thelocation of reflections shall be defined by coordinatesindicating the "longitudinal and transverse distancesfrom a reference point" and the "depth position".

5.4 Unless otherwise stated in the application-specific sections of Chapter 3, echo indications pro-duced by longitudinal defects which exceed the repairlimit values shown in Table 4.4 (excess of registrationlengths and/or echo heights above the registrationlevel shown in Table 4.3) shall be regarded as welddefects which must be repaired.

5.5 Continuous echo indications which point tosystematic weld defects (such as root defects due toincomplete penetration or rows of pores) call for re-pairs even if the repair limit values are not attained.Echo indications which point to the presence of cracksnecessitate repairs in every case.

5.6 Echo indications produced by transversedefects shall in every case count as weld defects re-

quiring repair unless they can be unequivocally associ-ated with the indications produced by longitudinaldefects and remain below the repair limit valuesstipulated in Table 4.4.

5.7 Where the evaluation of echo indicationsgives rise to doubt regarding the need for repair, re-course may be had to radiographic inspection to helpin the assessment (cf. B.1.3). However, echo indica-tions obtained with welded seams 30 mm or more inthickness which exceed the repair limit values invaria-bly necessitate repair even if radiographic inspectionfails to reveal any defects or fails to reveal themclearly.

6. Inspection reports

6.1 Complete inspection reports as prescribed inEN 1714 and containing the information listed belowshall be prepared for all ultrasonic inspections in ac-cordance with the inspection schedule; cf. D.1. Theinspection reports must enable the inspections to berepeated identically. They must be signed by the per-son performing the inspection and the supervisor.

6.2 Inspection reports must contain the followinggeneral information:

– Clear identification of the component, the mate-rial, the welded joint inspected together with itsdimensions and location (sketch to be providedfor complex weld shapes and testing arrange-ments) and the welding process.

– Indication of any other rules (e.g. specifications,standards or special agreements) applied to theinspection.

– Place and time of the inspection, testing bodyand identification of the person performing thetest.

6.3 Inspection reports must contain at least thefollowing specific details relating to the inspection:

– Make and type of test equipment

– Make, type, nominal frequency and angle ofincidence of probes

– Distance calibration (testing range)

– Sensitivity setting (calibration reflector used,instrument sensitivity, registration level)

– Correction values (for defects close to surface,transfer correction)

– Test sensitivity

– Surface preparation, coupling media

– Testing surfaces, testing directions, angles ofincidence



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Table 4.4 Repair limit values

Longitudinal defects Transverse defectsWallthickness

(weldthickness)

Number ofdefects per mof weld seam

Registrationlength

Max. per-missible excess

echo height

Number ofdefects per mof weld seam

Registrationlength

Max. per-missible excess

echo height

Evaluationcategory

accordingto G.2.1

[mm] [mm] [dB] [mm] [dB]

10...15

10 and

3 and

1

10

20

10

6

6

12

3 10 6

> 15...20

10 and

3 and

1

10

20

19

6

6

12

3 10 6

> 20...40

10 and

3 and

1

10

25

10

6

6

12

3 10 6

B

> 40

10 and

3 and

1

10

30

10

6

6

12

3 10 6

10...20

10 and

3 and

1

15

30

10

6

6

12

3 10 6

> 20...40

10 and

3 and

1

15

30

10

6

6

12

3 10 6C

> 40

10 and

3 and

1

15

50

10

6

6

12

3 10 6

10...20

10 and

3 and

1

15

50

10

6

6

12

5 10 6

> 20...40

10 and

3 and

1

15

50

10

6

6

12

5 10 6D

> 40

10 and

3 and

1

20

50

10

6

6

12

5 10 6

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6.4 The test results (where these are to be statedin the inspection report; cf. 5.2) shall, wherever possi-ble, be tabulated or shown on sketches with the fol-lowing details:

– Coordinates of defects with indication of refer-ence point

– Maximum excess echo height (+ ... dB) com-pared with the given registration level (referencereflector size) or, where applicable, the diameterof the corresponding (substitute) disc-shaped re-flector

– Defect characteristics (registration length, half-value depth).

Where echo indications below the repair limit valuesshown in Table 4.4 are also registered, each defectthus identified is to be allocated an assessment (e.g.leave as is or repair, a = acceptable or na = not accept-able).

M. Magnetic Particle Inspection

1. Test appliances and media

1.1 The test appliances and media used mustconform to the state of the art and the relevant stan-dards (e.g. DIN 54130, 54131, 54132, 54152). Themagnetizing equipment must be provided with mark-ings or measuring devices which indicate the magnet-izing current strength at any time. The Society maystipulate that measurements be performed to verifythese data. Proof of the suitability of the test mediashall be furnished on request.

1.2 Magnetic particles suspended in suitable,readily volatile vehicle liquids shall be used as testmedia for revealing the leakage flux due to disconti-nuities in the material. These magnetic particles maybe black or fluorescent. Where black magnetic parti-cles are used, the surface to be tested shall be coatedwith a permanent white paint, applied as thinly aspossible, to provide a contrast.

1.3 The proportion of magnetic particles in thevehicle liquid must conform to the manufacturer'sinstructions and shall be verified (e.g. by means of atest indicator or by a separation test using a glass cen-trifuge vessel to ASTM D 96-73, Fig. 6). Dry testmedia may only be used for tests at elevated tempera-tures (e.g. on root passes).

2. Magnetization method and field strength

2.1 The choice of the method of magnetizationdepends on the geometry of the component and is tobe agreed with the Society. If possible, magnetization

shall be effected by passing a current through theworkpiece or, in the case of minor localized inspec-tions, by yoke magnetization using electromagnets or,if no other possibilities are given, permanent magnets.

2.2 In special cases (e.g. where burn marks haveto be avoided at all costs or for circumferential welds),it may be expedient to effect magnetization with a liveconductor (a cable or coil). A combination of differentmethods of magnetization for the detection of vari-ously orientated defects is allowed.

2.3 Where a current is passed through the work-piece, alternating, direct, impulse or surge current maybe used. AC or DC magnets may be used for yokemagnetization. Where the magnetizing current ispassed through the workpiece, fusible supply elec-trodes should be used to prevent burn marks. WhereAC is used, fusible electrodes are obligatory.

2.4 The magnetizing field strength (effectivetangential field strength) must be at least 20 A/cm(25 Oe) but shall not exceed 50 A/cm (62,5 Oe). Theadequacy of the magnetization shall be checked at thetime of the test by suitable means (e.g. test indicator)or with a tangential field strength meter.

3. Preparation of testing surfaces, directionand duration of magnetization

3.1 The testing surfaces must be free from loosescale, rust, weld spatter and other impurities. Notches,grooves, scratches, edges, etc. which may producefalse indications are to be removed prior to inspection.Thin, dry layers of paint (e.g. shop primer, up to a coatthickness of 20 µm) may be left in place as long asthey do not hinder the inspection.

3.2 Magnetization must be effected, as shown inFig. 4.4, in two different directions including an angleof not less than 60° and not more than 90° so as toenable variously orientated defects to be located.

60 - 90°

Fig. 4.4 Directions in which magnetization is tobe effected



N

3.3 Magnetization must be continued as long asthe testing surface is sprayed with magnetic particlesuspension and for as long thereafter as any movementof the magnetic particle suspension can be detected,subject to a minimum of 5 seconds. Testing underconditions of remanent magnetization is not permitted.

4. Evaluation, inspection reports

4.1 Every accumulation of magnetic particles notdue to a false indication indicates a discontinuity orcrack in the material which is to be registered in theinspection report and repaired. In the case of smallcracks (e.g. end crater cracks) this may be done bygrinding. Larger cracks are to be machined out andrepair-welded; cf. I.1.2.

4.2 Inspection reports relating to magnetic parti-cle inspections must include the following details:

– Details of the component and weld concerned

– Details of magnetization, with amperage whereappropriate

– Test arrangement (directions of magnetization,distance between electrodes or poles)

– Test media

– Test results


N. Liquid Penetrant Inspection

1. Test media

1.1 Coloured or fluorescent penetrants shall beused as penetrant media. Penetrant removers and de-velopers must be compatible with the penetrant used.Proof of the suitability of the inspection system (pene-trant, penetrant remover, developer) shall be furnishedto the Society on request.

2. Preparation of testing surfaces, perform-ance of inspection

2.1 To allow the penetrant to enter any defectspresent, the testing surfaces must be completely freefrom scale, rust, greases, oils, paints or electrodepositsbefore the penetrant is applied. During this operationcare should be taken to ensure that defects are notmechanically sealed by preliminary cleaning. Thetesting surfaces must be dry. The temperature of theworkpiece shall be between 5 °C and 50 °C.

2.2 Any method of applying the penetrant may beused. Care shall be taken to ensure that the testingsurface is completely wetted throughout the entirepenetration time. The penetration time shall be chosenin accordance with the manufacturer's instructions, butshall not be less than 15 minutes for workpiece tem-peratures of 15 °C and over or less than 30 minuteswhere the temperature is below 15 °C. The penetrantshall not become dry during the penetration period.

2.3 Following penetration, the surplus penetrantshall be completely removed from the testing surfacein such a way as to leave behind the penetrant lodgedin any defects present. It is advisable first to wipe offthe surplus penetrant with a cloth and quickly to re-move only the remains with sparing use of the pene-trant remover. The testing surface should then be driedas quickly as possible (max. 50 °C).

2.4 The developer is to be applied evenly and asthinly as possible immediately after removal of thesurplus penetrant and drying. The testing surfaceshould be just covered. The developing time should beabout the same as the time allowed for penetration.Visual inspection for defects shall begin as the devel-oper is applied, but the final inspection can only takeplace after the expiry of the developing time. M.4.1applies in analogous manner to the evaluation.

3. Evaluation, inspection reports

3.1 Should an unequivocal evaluation of theindications be impossible, the entire inspection proce-dure, starting with preliminary cleaning, must be re-peated. Where necessary, the surface quality shall alsobe improved. The repeat inspection must be performedwith the same test system as on the first occasion. Theconditions specified in standard EN 571-1 are alsoapplicable.

3.2 Inspection reports relating to penetrant me-dium inspections must include the following details:

– Details of the component and weld concerned

– Test media (type, brand name)

– Description of the test procedure (temperature ofthe workpiece, penetrant acting time, etc.)

– Test results


Inspection reports shall conform to the form providedin Annex A to EN 571-1.

II - Part 3GL 2000


B

Section 5

Mechanical and Technological Tests


This section has, for the time being, still been retainedin its earlier form despite the fact that more up-to-dateEN and ISO standards have since been either issuedor are available in draft form relating to the key de-structive tests carried out on welded joints in metallicmaterials. The intention is to delete this section alto-gether at a later date and instead to make referenceonly to the new standards in Chapter 1, Section 4,"Welding Procedure Tests" (where the informationrelating to the mechanical and technological tests ischiefly needed). These standards include:

– EN 895/ISO 4136Transverse tensile test (replacement for DIN50120-1 and 50120-2)

– EN 876/ISO 5178Longitudinal tensile testing of the weld metal infusion welded joints

– EN 910/(ISO 5173)Bend tests (replacement for DIN 50121-1 and50121-2)

– EN 875/ISO 9016Notched bar impact test (replacmenet forDIN 50122)

– EN 1043/ISO 9015Hardness test, miscellaneous parts(Replacement for DIN 50163)

– EN 1320/ISO 9017Fracture tests (replacement for DIN 50127)

– EN 1321Macroscopic and microscopic examinations

– EN ISO 8249Determination of ferrite number

The mechanical and technological tests shall, whereverpossible, be performed in accordance with the newstandards. For an interim period, or where the newstandards are not yet available, the mechanical andtechnological tests may continue to be performed inaccordance with the following provisions, but also incompliance with the information given in Chapter 3.The test records shall state which rules were used as abasis for the test. Where the provisions given in thevarious rules differ widely, the procedure shall beagreed with the Society.

A. Scope

1. These Rules relate to the normal methods andforms of test specimens to be used in the mechanicaland technological testing of welds, e.g. of test piecesfor the welding procedure and workmanship tests, aswell as to the metallographic inspections necessary forthis purpose.

2. Special methods and forms of test specimens(e.g. for testing the manual skill of welders or testingof welding consumables, auxiliary materials and over-weldable shop primers) are specified in the relevantsections.

3. The test methods and forms of specimensindicated in the standards mentioned in the followingparagraphs shall be used wherever possible. Methodsand forms of specimens conforming to other standardsmay be used by agreement with the Surveyor, pro-vided that the same results can be achieved.

B. Preparation of Specimens and Testing

1. All tests are to be performed by trained per-sonnel using calibrated testing machines. The testingmachines must be kept in good working order by theirowners and are to be calibrated at regular intervals byan independent inspecting authority.

2. Before being cut out of the test piece, speci-mens are to be marked by the Surveyor. They shallthen be cut out, wherever possible by a mechanicalprocess, and machined to the required dimensions.Where specimens are cut from the test piece by athermal process, they must be wide enough to ensurethat the heat-affected zone can be completely ma-chined off.

3. All mechanical and technological tests are tobe performed in the presence of the Surveyor, unlessotherwise stipulated or agreed. The photographs ofmetallographic specimens are to be submitted to himfor evaluation.

Chapter 2Page 5–2


C

C. Tensile Tests

1. Tensile tests on flat tensile specimens(DIN 50120, Part 1)

1.1 This test is carried out to determine the ten-sile strength, position, type of fracture and, whereappropriate, the elongation of specimens located atright angles to the seam. The flat tensile specimenshown in Fig. 5.1 should be used wherever possible.

1.2 The thickness 'a' of the specimen is normallythe wall thickness. If this is greater than 30 mm butless than 50 mm, the specimens may be machineddown on one side to a thickness of 30 mm. Withthicknesses of 50 mm and over, two or more speci-mens regularly spaced over the section are to be pre-pared.

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1.3 Welded joints in aluminium alloys shall betested using a tensile specimen conforming toDIN 50123.

2. Tensile test on round tensile specimens(EN 10002/DIN 50125)

2.1 This test is carried out to determine the ten-sile strength, yield strength or 0,2 % proof stress, re-duction in area and elongation of the weld metal.Where necessary in the case of high-temperature

steels, the 0,2 % proof stress at elevated temperaturesshall also be established. Wherever possible, the testshould be performed on a 10 mm diameter round ten-sile specimen of the type depicted in Fig. 5.2, which isto be cut out of the weld metal with its longitudinalaxis in the direction of the seam.

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Fig. 5.3 Location of specimens in weld metal

2.2 If, in exceptional cases, the weld dimensionsdo not permit the preparation of a 10 mm diametertensile specimen, specimens with a smaller diametermay be used, provided that the gauge length is 5 timesand the parallel length at least 6 times the diameter ofthe specimen.

3. Tensile tests on cruciform tensile speci-mens

3.1 This test is carried out to determine the ten-sile shear strength ZS of the weld metal. Three speci-

mens with the dimensions shown in Fig. 5.4 shall betested in each test.

II - Part 3GL 2000


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D. Bend Tests

1. Transverse bend test (DIN 50121, Part 1)

1.1 This test is carried out to determine the duc-tility of the welded joint across the seam. For thispurpose the specimen is bent over a mandrel or pre-scribed diameter and the angle achieved and, if speci-fied, the bending elongation on the tension side of thespecimen are measured. Specimens to Fig. 5.6 are tobe prepared for the test.

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Chapter 2Page 5–4


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1.2 The thickness of the specimen is normallythe wall thickness. If this is greater than 30 mm, thespecimens may be machined down on one side to athickness of 30 mm. On the side of the specimenwhich is in tension during the test, the edges may berounded to the specified radius r.

1.3 Depending on the test specification, thespecimens are to be mounted in the testing device insuch a way that either the upper or the lower side ofthe weld is in tension during the test. The test rig is tobe set up as shown in Fig. 5.7.

1.4 If the bending elongation is to be deter-mined, the deformation zone on the tension side ofthe specimen shall be provided prior to the test withgauge marks set 5 mm apart and these shall be used tomeasure the elongation when the prescribed bendingangle has been reached.

The gauge length L0 is the weld width plus the wall

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1.5 If the elongation behaviour of the base mate-rial and the weld metal differ greatly, e.g. in the caseof welded aluminium test pieces, the test rig shown inFig. 5.8 may be used in order to prevent prematureincipient cracking of the specimen.

Fig. 5.8 Special test rig

2. Side bend test (DIN 50121, Part 1)

2.1 This test is carried out to determine the duc-tility of the welded joint in the cross-sectional plane.For this purpose the specimen is bent over a mandrelof specified diameter and the bending angle attained

is measured. Specimens to Fig. 5.9 are to be preparedfor the test.

2.2 The specimens are to be mounted in thetesting device shown in Fig. 5.7 in such a way that thetesting load acts in the direction of the original lon-gitudinal axis of the seam. On the side in tensionduring the test, the long edges of the specimen may berounded to the specified radius r.

2.3 If welded clad plates are to undergo sidebend tests, the form of specimen shown in Fig. 5.10 isto be used. The dimensions are as stated in the tablein Fig. 5.9.

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II - Part 3GL 2000


E

3. Bend test specimens from pipe joints

3.1 If bend test specimens are to be taken fromcircumferential pipe welds, the side faces must beparallel. If necessary, the side of the specimen whichis in compression shall be machined in accordancewith Fig. 5.11.

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E. Notched Bar Impact Tests(EN 10045/DIN 50115)

1. The purpose of this test is to determine theimpact energy in joules (J). ISO V-notch specimensshall be used; their location in the test piece shall besuch that the longitudinal axis of the specimen isperpendicular to the direction of the seam while thenotch axis is at right angles to the surface of the prod-uct (cf. Fig. 5.12). In addition, determination of thecrystalline portion of the fracture surface and/or ofthe lateral expansion of the specimen may be agreed.

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2. Depending on the test specification, thenotch shall be located either at the centre of the weldmetal, on the fusion line or in the heat-affected zoneof the base metal at a specified distance from thefusion line (cf. Fig. 5.12).

3. The test is to be carried out at the specifiedtest temperature. Where the product thickness is< 10 mm, specimens measuring 7,5 × 10 mm, 5 × 10mm and 2,5 × 10 mm should be used wherever possi-ble. For these specimens the required impact energy E(J) in relation to the standard 10 × 10 mm test speci-men shall be as indicated in the table below.

4. Where specimens are taken from only oneside of a double-V weld, they shall be taken from theside of the seam which was welded last.

5. The specimens shall be machined down tothe dimensions shown in Fig. 5.13 and compliancewith the stipulated tolerances shall be verified.

6. If in technically justified exceptional casesspecimens with forms or locations different fromthose described in paras. 1 to 5 are to be used, the testrequirements shall be specially agreed with the Soci-ety.

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F. Hardness Testing of Welds(DIN 50163, Part 1)

1. The hardness of welded joints shall be meas-ured by Vickers hardness tester using a load of 49 or98 N (HV 5 or HV 10) on polished and etchedspecimens whose test face is perpendicular to theweld axis. The choice of the test load depends on thegrade of material concerned.

2. Normally, the test shall take the form of rowsof hardness measurements, one row for fillet weldsand at least two rows for butt welds, one of which isat the root and one in the area of the cover pass.Should this be insufficient for an adequate assessmentof the hardness of the welded joint, a test with a fur-ther row of measurements shall be performed, e.g. inthe area of the root and capping passes in the case ofbutt welds. The arrangement of the rows of hardnessmeasurements shall be as shown in Fig. 5.14.

3. The impressions made by the hardness testershall be close enough together to give an accuratepicture of the hardness curve (cf. Fig. 5.15). Thecurve shall be plotted as a graph wherever possible.

4. If other test methods are to be used in ex-ceptional cases, the requirements shall be convertedin accordance with recognized standards, e.g.DIN 50150.

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G. Metallographic Inspections

1. The macro- and micro-structure shall beevaluated by reference to polished sections. Unlessotherwise agreed, the polished face of the sectionsshall be perpendicular to the weld axis (see also Fig.5.14).

2. The metallographic specimens shall be ofsuch a size and ground and etched in such a way as toreveal the nature and structure of the crystallization ofthe weld metal and the heat-affected zone as well asthe texture of the base metal and, in the case of mi-crographs, the grain boundaries in the area underexamination.

3. The polished sections shall be photographedand the photos appended to the inspection report.Macrographs shall normally be to a scale of 1 : 1 to1 : 3; if the cross-sectional area of the weld is small,they may be magnified.

For assessment of the microstructure, at least 3 pho-tographs shall be made of characteristic parts of theweld; these shall generally be the weld metal, thefusion line and the heat-affected zone. The magnifi-cation shall be at least 100 : 1.

II - Part 3GL 2000


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H. Inspection reports

1. The works must prepare reports on the tests,which must contain all the necessary details for as-sessing the method. These especially include:

– Type of inspection or test (e.g. welding proce-dure test)

– Dimensions and numbers of test pieces

– Base materials

– Weld preparation

– Welding processes and positions

– Welding consumables and their dimensions,auxiliary welding materials

– Welding current source

– Welding current strength and voltage

– Post-weld heat treatment

– Test methods and forms of specimens

– Test results

2. The reports shall be submitted to the Sur-veyor in at least two copies for his perusal. He shallconfirm the proper performance of the inspection andthe correctness of the results by applying his stampand signature.

II - Part 3GL 2000

Annex A Imperfections in Welded Joints in Steel Chapter 2Page A–1

Annex A

Imperfections in Welded Joints in Steel

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II - Part 3GL 2000

Annex B Imperfections in Welded Joints in Aluminium Chapter 2Page B–1

Annex B

Imperfections in Welded Joints in Aluminium

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II - Part 3GL 2000

Annex C Comparison of Equivalent, Internationally Recognized Film SystemClasses

Chapter 2Page C–1

Annex C

Comparison of Equivalent, Internationally Recognized Film System Classes

Manufacturer /Film type ASTM (1) DIN (4) EN (4) ISO (2) RCC-M (5) BS (3)

AGFA (6)

Structurix D2 special G1 C1 G I 1 A


Structurix D3 s.c. 1 G1 C2 G I 2 A


Structurix D5 1 G2 C4 G II 3 – 4 A



Fuji (6)

IX 25 1 G2 C3 G I 3 A

IX 50 special G1 C1 G I 1 A

IX 80 1 G2 C3 G I 3 A

IX 100 1 G2 C4 G II 3 – 4 A

IX 150 2 G4 C6 G III 4 – 5 B

Kodak (6)

DR special G1 C1 G I

M 1 G1 C2 G I

MX125 1 G2 C3 G I

T200 1 G2 C4 G II

AA400 2 G3 C5 G III

CX 3 G4 C6 G III

B W-B G III

(1) ASTM E 94-93 / ASTM E 94-84 A

(2) ISO 5579

(3) BS 2600: Type A: high contrast – very fine-grainType B: high contrast – fine grain

(4) Classification in accordance with DIN EN 584-1 as compared with DIN 54117 T1 which has been replaced.

(5) French standard

(6) Provided that the appropriate proof of suitability is furnished, equivalent film types produced by other filmmanufacturers may also be considered.


3 Welding

3 Welding in the Various Fields of Application

Edition 2000





Phone: +49 40 36149-0 Fax: +49 40 36149-200

[email protected]

www.gl-group.com




Table of Contents

Section 1 Welding of Hull Structures

A. General ....................................................................................................................................... 1- 1

B. Approval of Shipyards and Welding Shops, Welding Personnel ............................................... 1- 1

C. Quality Inspection, Responsibility ............................................................................................. 1- 2



F. Welding procedure, procedure qualification tests ...................................................................... 1- 5

G. Design, Dimensioning ................................................................................................................ 1- 24

H. Execution of Welds .................................................................................................................... 1- 34

I. Inspection of Welded Joints ....................................................................................................... 1- 41

Section 2 Welding of Steam Boilers

A. General ....................................................................................................................................... 2- 1

B. Approval of Welding Shops, Welding Personnel ....................................................................... 2- 1




F. Welding procedure tests ............................................................................................................. 2- 3

G. Welding Technique .................................................................................................................... 2- 5

H. Post-Weld Heat Treatment ......................................................................................................... 2- 7

I. Inspection of Welded Components ............................................................................................ 2- 8

Section 3 Welding of Pressure Vessels

A. General ....................................................................................................................................... 3- 1







H. Post-Weld Heat Treatment ......................................................................................................... 3- 9

I. Inspection of Welded Components ............................................................................................ 3- 10

Section 4 Welding of Pipelines

A. General ....................................................................................................................................... 4- 1


C. Quality inspection responsibility ................................................................................................ 4- 2





H. Heat treatments after cold or hot working and welding .............................................................. 4- 8

I. Inspection of Welded Pipelines .................................................................................................. 4- 10

II - Part 3 GL 2000


Section 5 Welding of Machinery Components

A. General ........................................................................................................................................ 5- 1


C. Quality Inspection, Responsibility .............................................................................................. 5- 2


E. Welding Consumables and Auxiliary Materials .......................................................................... 5- 3

F. Welding procedure tests .............................................................................................................. 5- 3

G. Design, Welding Technique ........................................................................................................ 5- 8

H. Post-Weld Heat Treatment .......................................................................................................... 5- 9

I. Inspection of Welded Components ............................................................................................. 5- 9

Chapter 3 Page 4


II - Part 3GL 2000

Section 1 Welding of Hull Structures Chapter 3Page 1–1

B

Section 1

Welding of Hull Structures

A. General

1. Scope

1.1 These rules apply to all welding work carriedout on the ship's hull, including the superstructure anddeckhouses, its internal and external structures, andequipment components forming part of the ship'sstructure, e.g. hatch covers, masts, king posts or cranesubstructures welded to the ship's hull. See also Chap-ter 1, Section 1, A.1. and A.2.

1.2 They also apply in analogous manner to cargotanks which are not an integral part of the ship's hulland are not pressure vessels within the meaning ofSection 3 (e.g. prismatic type A tanks, according to theRules for Construction I, Part 1, Chapter 6).

2. Other relevant rules and regulations

The design and dimensioning of welded joints is alsogoverned by the provisions of the Rules for Construc-tion I, Part 1, Chapter 1, Sections 19 "Welded Jointsand 20 "Fatigue Strength" and the performance of thework is also subject to the provisions of Section 1, N.of the said Rules for Construction. For other relevantstandards, see Chapter 1, Section 1, B. of these Rulesfor Welding.

3. Weld performance

Welded joints in hull structures shall be prepared,made and inspected in such a way that their qualitycharacteristics are equivalent to those of the base ma-terials to be joined. This means that they may notdeviate from the prescribed form and internal condi-tion by more than the limits allowed by the prescribedweld quality grades according to Table 1.9 or by theevaluation categories used as a basis for the notchcategory classification for the proof of fatigue strength(cf. Rules for Construction I, Part 1, Chapter 1,Section 20). The same applies in analogous manner tothe other quality characteristics; cf. also C.

B. Approval of Shipyards and WeldingShops, Welding Personnel

1. Works and subworks

1.1 In the following paragraphs, the term "weld-ing shop" refers to the shipyard or welding fabricationshop which may be considered an independent unitwith regard to its physical and organizational situation.

1.2 Branches and subcontractors are thus gener-ally deemed to be "independent" welding shops whichhave to satisfy the requirements prescribed below. Inparticular, every welding shop must have a weldingsupervisor who is a permanent member of the weldingshop staff (cf. Chapter 1, Section 2).

1.3 Outside firms working in welding shops maybe granted approval as independent welding shops. Onthis and on temporary workers, see also C.3. andChapter 1, Section 1, F.

2. Requirements, scope of approval

2.1 All shipyards and welding shops intending toperform welding work covered by these rules mustsatisfy the requirements relating to the welding shopand its personnel set out in Section 2 and must havebeen approved for this work by the Society. Applica-tions for approval shall be submitted by the shipyardsand welding shops in good time before starting thewelding work, enclosing the information and docu-mentation prescribed in Chapter 1, Section 2, A.3.

2.2 Welding personnel (welders, operators andsupervisory staff) and where applicable inspectors andtest supervisors must meet the requirements set out inChapter 1, Section 2, B.2., B.3. and B.4. and be rec-ognized by the Society. For welder’s qualificationtests, see Chapter 1, Section 3.

2.3 The scope of the approval is determined bythe capabilities of the welding shop and by the in-tended range of application (materials, welding proc-esses, welding positions, etc.). The intended range ofapplication shall be specified in the application forapproval; cf. the form "Description of Welding Shop"attached at Annex B of Chapter 1. For the period ofvalidity of the approval, see Chapter 1, Section 2, A.4.and A.5.

Chapter 3Page 1–2

Section 1 Welding of Hull Structures II - Part 3GL 2000

D

3. Basic approval, extensions

3.1 For welding hull structures, as a general rule(basic) approval is granted first of all on the basis of aworks inspection and, if necessary, welder's qualifica-tion tests in accordance with Chapter 1, Section 3 (seealso H.2.) normally for manual arc welding (weldingprocess 111) and/or for semi-mechanized metal-arcactive gas welding using solid and flux-cored wireelectrodes (welding processes 135 and 136) of normal-strength hull structural steels A to D and other compa-rable grades of forged and cast steel. The thicknessrange is in this case determined by the scope of thevalid welder’s qualification tests.

3.2 Exceptions to this rule are single-side weldingand vertical-down welding using these processes (111,135, 136), for which welding procedure tests shall beperformed in every case. Cf. F. One-wire submerged-arc welding (welding process 121) may also be cov-ered in the basic approval described in 3.1 on the basisof documentary proof in accordance with F.1.4 (forconventional welding in one run on each side [two-runtechnique] on plates 4 to 25 mm thick and for multi-pass welding up to 40 mm).

3.3 Basic approval may be extended to includeany welding procedure approvals on the basis ofwelding procedure tests as set out in Chapter 1,Section 4 (cf. also F.); in exceptional cases, however,limited approval may also only be granted (in con-junction with a works inspection) for a specific mate-rial and/or welding process.

C. Quality Inspection, Responsibility

1. Shipyards and welding shops shall ensure bymeans of regular in-house quality inspections duringfabrication and on completion of the welding work thatthis work has been performed competently and satis-factorily (cf. Chapter 1, Section 1, F.). For the dutiesand responsibilities of the welding supervisor, see alsoEN 719/ISO 14731.

2. The shipyards and welding shops are respon-sible for ensuring that the welding work conforms tothese Rules, the approved manufacturing documents,any conditions stipulated in the approval documents,good shipbuilding practice and the latest state ofwelding practice. The inspections and checks to beperformed by the Society’s Surveyor do not relieve thewelding shops of this responsibility.

3. With regard to quality inspections and theresponsibilities involved in awarding subcontracts toindependent branches or suppliers or to approved or

non-approved outside firms working in the weldingshop (subcontractors), see Chapter 1, Section 1, F.Subcontracting of work or employment of temporaryworkers shall be notified to the Society.

4. The scope of the required quality inspectionsdepends on the construction project in question. It isessential to ensure, however, that the intended materi-als, welding consumables and auxiliary materials areused and that the weld preparation, assembly, execu-tion of the tack and final welds and the dimensionalaccuracy and completeness of the welded joints meetsthe requirements stated in para. 2. For non-destructivetesting of the welded joints, see I.

5. Following inspection and, if necessary, repairby the welding shop, the components shall be pre-sented to the Society's Surveyor for checking at suit-able stages of fabrication. For this purpose they shallbe readily accessible and shall normally be uncoated.Where the previous inspection has been inadequate,the Surveyor may reject components and require thatthey be presented again after satisfactory workshopinspection and any necessary repair work has beenperformed.

6. If the quality or good working order of acomponent cannot be guaranteed or is in doubt due toinadequate or missing information in the manufactur-ing documents (e.g. production drawings), the Societymay demand appropriate improvements. This appliesin analogous manner to supplementary or additionalcomponents (e.g. reinforcements), even if these com-ponents were not stipulated when the drawings werescrutinized or could not be stipulated due to insuffi-ciently detailed representation in the "class plans" (cf.the Rules for Construction I, Chapter 1, Section 1, G.).

7. The Society is not responsible for guarantee-ing that all the components and welded joints in-spected to the prescribed extent (generally on a ran-dom basis) by its surveyors have been fabricated inaccordance with the conditions and meet the require-ments in every respect. Components or welded jointswhich subsequently turn out to be defective may berejected or their repair may be demanded even if ac-ceptance testing has already been carried out.


1. Welded structures may only be fabricatedusing base materials of proven weldability. Materialsmust comply with the Society’s Rules for Materials(Code II/1/-5). Other comparable materials (e.g.structural steels conforming to EN 10025) may only be

II - Part 3GL 2000


E

used after the Society has given its approval in eachindividual case.

2. Any conditions relating to working andwelding imposed by the approval certificate and therecommendations of the material producer shall becomplied with. For the selection of materials for theship's hull, see the Rules for Construction I, Part 1,Chapter 1, Section 2.

3. The weldability of normal-strength hullstructural steels of quality grades A, B, D and E testedby the Society is considered proven. No measuresabove and beyond the provisions of these Rules forWelding are necessary when welding these steels.

4. The weldability of the higher-strength hullstructural steels of quality grades A 32 to F 40 ap-proved and tested by the Society in accordance withthe Rules for Materials has been checked and can betaken for granted if the work is carried out in accor-dance with normal shipbuilding practice.

5. High-strength (quenched and tempered) fine-grained structural steels, steels tough at subzero tem-peratures, stainless structural steels and other (alloy)structural steels have to be specially approved by theSociety. The weldability of the steel in question musthave been verified in combination with welding proc-esses and welding consumables.

6. Steel castings and forgings shall comply withthe Rules for Materials and shall have been tested bythe Society. The carbon content of components madefrom carbon and carbon-manganese steels/castings forwelded structures shall not exceed 0,23 % C at ladleanalysis (check analysis: max. 0,25 % C).

7. Light metal alloys must have been tested bythe Society in accordance with the Rules for Materials.Their weldability must have been verified in combina-tion with welding processes and welding consumables.It can generally be taken for granted in the case of thealloys mentioned in the Rules for Materials.


1. All the welding consumables and auxiliarymaterials used (e.g. covered electrodes, wire-gas com-binations, wire-flux combinations, etc.) must havebeen approved by the Society in accordance withChapter 1, Section 5. The quality grade required de-pends on the base materials to be welded and is shownin the relevant tables in Chapter 1, Section 5, except

for hull structural steels and other comparable struc-tural steels, forged steels and cast steels.

2. The correlation of the required quality gradesof welding consumables and auxiliary materials forwelding hull structural steels to the respective hullstructural steel quality grades is shown in Table 1.1.The correlation to other comparable structural steels,forged steels and cast steels shall be undertaken inanalogous manner.

3. For welding of different quality grades of hullstructural steel, welding consumables and auxiliarymaterials shall be correlated to the steels by theirquality grades and added symbols as follows:

a) Normal-strength hull structural steels of differentquality grades:

Welding consumables and auxiliary materials forwhichever is the higher-quality (tougher) hullstructural steel, e.g. A with D: quality grade 2 ....

b) Higher-strength hull structural steels of the samestrength but with different quality grades:

Welding consumables and auxiliary materials forwhichever is the higher-quality, (tougher) hullstructural steel, e.g. A 36 with E 36: qualitygrade 3 Y ....

c) Normal-strength with higher-strength hull struc-tural steels with comparable quality grades:

Welding consumables and auxiliary materials forthe normal-strength hull structural steel qualitygrade in question, e.g. D with D 36: qualitygrade 2 .... (without added symbol Y)

d) Normal-strength with higher-strength hull struc-tural steels with non-comparable quality grades:

Welding consumables and auxiliary materialshaving a quality grade for the higher-quality(tougher) hull structural steel but the strength ofthe normal-strength steel, e.g. A with D 36:quality grade 2 .... (without added symbol Y).

4. For welding very thick-walled, rigid compo-nents (approx. 30 mm and over) and welding of forg-ings and steel castings, hydrogen-controlled weldingconsumables and auxiliary materials of quality grade 3H15(H) shall be used (for higher-strength hull struc-tural steels, 3Y H10(HH)).

5. The use of hydrogen-controlled welding con-sumables and auxiliary materials is recommended forwelding of higher-strength hull structural steels to oneanother (and to lower-strength steels) if the carbonequivalent of these steels is over 0,41 %. See also H.5.

Chapter 3Page 1–4


E

Table 1.1 Correlation of welding consumables and auxiliary materials to hull structural steel qualitygrades

Hull structural steel quality gradesQuality gradesof welding

consumablesand auxiliary

materials(cf. also E.3.)

A B D E A 32/36 D 32/36 E 32/36 F 32/36 A 40 D 40 E 40 F 40

1; 1S, 1T, 1M,1TM, 1V ×

1YS, 1YT,1YM, 1YTM,1YV

× 1 × 2, 3

2, 2S, 2T, 2M,2TM, 2V × × ×

2Y, 2YS, 2YT,2YM, 2YTM,2YV

× × × × 3 × 3

2Y40, 2Y40S,2Y40T, 2Y40M,2Y40TM,2Y40V

1 1 1 × 3 × 3 × 3 × 3

3, 3S, 3T, 3M,3TM, 3V × × × ×


× × × × × 3 × 3 × 3

3Y40, 3Y40S,3Y40T, 3Y40M,3Y40TM,3Y40V

1 1 1 1 × 3 × 3 × 3 × 3 × 3 × 3


× × × × × 3 × 3 × 3 × 3

4Y40, 4Y40S,4Y40T, 4Y40M,4Y40TM,4Y40V

1 1 1 1 × 3 × 3 × 3 × 3 × 3 × 3 × 3 × 3

1 Not to be used if possible, otherwise only with the Society’s approval; cf. Chapter 1, Section 5; A.4.1 and A.4.2 apply inanalogous manner.

2 For A 32/36, welding consumables and auxiliary materials of quality grade 1 Y ... should where possible only be used whenwelding thinner plates (up to 25 mm max.).

3 For plates over 50 to 70 mm thick, welding consumables and materials with one quality grade higher shall be used and for thoseover 70 and up to 100 mm thick those with two quality grades higher shall be used in each case in compliance with the higherbase material requirements, cf. Rules for Materials.

Note:

For steels F 32, F 36 and A 40 to F 40, no provision is made in the Rules for Materials for plates above 50 mm thick, but these shallbe subject to special agreements where appropriate.

II - Part 3GL 2000


F

6. Hydrogen-controlled welding consumablesand auxiliary materials should also be used for com-ponents which are subjected to full load immediatelyafter welding (e.g. lifting lugs or as a result of pressuretests) or where allowance has to be made for a highdegree of residual stress due to the rigidity of thestructure and, where applicable, a high yield strengthor strength of a structure.

7. Hydrogen-controlled welding consumablesand auxiliary materials shall always be used for weld-ing high-strength (quenched and tempered) fine-grained structural steels and steels tough at sub-zerotemperatures, cf. Chapter 1, Section 5, F.4. For steelswith a yield strength or 0,2 % proof stress of up to500 N/mm², welding consumables and auxiliary mate-rials with the maximum added symbol H 10 (HH)should be used and for steels with a yield strength or0,2 % proof stress of over 500 N/mm² those with amaximum added symbol H 5 (HHH) should be used.

8. For welding of austenitic stainless steels toone another and to hull structural steels, welding con-sumables and auxiliary materials shall be selected inaccordance with Tables 5.21 to 5.23 in Chapter 1,Section 5 and the manufacturers' recommendations,taking the corrosion resistance and strength require-ments and the welding metallurgy (including resistanceto hot cracking) into account, and specified in a weld-ing schedule, which is to be submitted for approval.

9. For welding aluminium alloys, the weldingconsumables and auxiliary materials shall be selectedaccording to the type and condition of the material (cf.Rules for Materials, II/1/3) in accordance with Table5.28 in Section 5 of Chapter 1 taking the requiredmechanical properties of the welded joints into ac-count (cf. Rules for Construction I, Part 1, Chapter 1,Section 19, C.2.8) and shall be indicated in the pro-duction documents to be submitted for approval.

10. Welding consumables and auxiliary materialsspecified in a welding shop or procedure approval (cf.F.) may only be replaced by equivalent consumablesapproved by the Society with an appropriate qualitygrade if this is explicitly stated in the respective ap-proval document. Failing this, the Society's agreementshall be obtained.

11. The welding consumables and auxiliary mate-rials may only be used in the approved welding posi-tions. The manufacturer's recommendations and in-structions for welding (e.g. type of current and polar-ity) shall be followed.

12. The welding consumables and auxiliary mate-rials (especially hydrogen-controlled, basic covered

electrodes and basic welding fluxes) shall be re-driedbefore use in accordance with the manufacturer's in-structions (observe maximum drying time!) and storedin a dry place (in heated containers or the like) at theworkplace.

Note:

The guideline DVS 0504 "Handling, storage and re-drying of covered electrodes" and guideline DVS 0914"Use and storage of welding fluxes for submerged-arcand electro-slag welding" issued by the GermanWelding Society (Deutscher Verband für Schweiß-technik e.V) contain detailed instructions for this.

F. Welding Procedures, Welding ProcedureTests

1. General

1.1 Only welding procedures whose suitability forthe application in question is evident from generalexperience or has been verified by means of a weldingprocedure test in accordance with Chapter 1, Section 4and the following provisions may be used. Table 4.1 inChapter 1, Section 4 gives a list of the requisite verifi-cations. The welding procedure must have been ap-proved by the Society for the welding shop in question(cf. also B.).

Note:

In principle, the Society recognizes all welding proc-esses which satisfy the above conditions. Generalreservations only exist to the extent that the opera-tionally safe handling of these processes and thequality attainable under field conditions is called intoquestion or contradicted by practical experience. Forinstance, at present no approvals are being grantedfor vertical-down gas-shielded welding with solidwires under mixed gas containing less than approxi-mately 30 % CO2 due to the risk of lack of side wallfusion. Exceptions to this rule are possible if weldingusing robots is required, for which the welding pa-rameters and the manipulation of the torch may beprescribed and followed so precisely that it can beverified that welding has been performed with goodpenetration within the narrow "safe" area.

1.2 The Society may approve specific weldingprocesses such as vertical-down welding, build-upwelding on rudderstocks or underwater welding (cf.H.13.3), the use of which is, however, dependent uponauthorization, for example following an examinationof the load conditions, in each individual case. Forwelding processes or applications of this nature, theSociety may also stipulate restrictions in the operationof the vessel (e.g. in the operating area).

Chapter 3Page 1–6


F

1.3 Welding procedure tests supervised by theSociety for verification of satisfactory operationalhandling and a trouble-free execution of the procedure,and also adequate quality properties for the weldedjoints made under production conditions at the user'sworks are in general required for:

– materials 1 other than "simple-to-weld" hullstructural steels A to D and comparable struc-tural steels, forged steels and cast steels and alsofor composite materials,

– welding processes 2 other than those stated inB.3., which are adequately covered by generalexperience, welder's qualification tests and ap-proved welding consumables,

– single-side welding on ceramic, flux or similarbackings,

– welding in the vertical-down position.

1.4 For conventional single-wire submerged-arcbutt welding processes using solid wire for weldingnormal-strength hull structural steels A to D, compara-ble structural steels, forged steels and cast steels fromboth sides, proof prior to initial use of the reliabilityand technical suitability of the method by means oftrial welds and non-destructive (e.g. radiographic) testsas directed by the Surveyor is sufficient. The weldingconsumables and auxiliary materials used must havebeen approved by the Society.

1.5 The Society may additionally require weldingprocedure tests for specific (difficult) componentshapes or combinations of materials, environmental

––––––––––––––1 Materials:

Normal-strength hull structural steels E and F, higher- strengthhull structural steels and comparable grades of forged steels orsteel castings, high-strength (quenched and tempered) fine-grained structural steels, steels tough at subzero temperatures,stainless and clad steels, aluminium alloys and other non- fer-rous metals.

2) Welding Processes:

Manual welding processes:

Vertical-down welding, deep penetration welding, single-sidewelding with backing, etc.

Semi-mechanized welding processes:

Gravity arc or auto-contact welding, single-side welding withbacking, flux-cored wire metal-arc welding without shieldinggas, etc.

Fully-mechanized welding processes:

Submerged arc welding, fusarc and flux-cored wire metal-arcwelding, multiple-electrode submerged arc welding, single-sidewelding, fillet and double-fillet welding, electroslag weldingwith and without fusible wire guide nozzle electrode(s), gas-shielded metal-arc welding, electrogas welding etc.

Special welding processes or special applications:

Stud welding, flash butt welding, friction welding, laser-beamwelding, build-up welding, orbital welding of circumferentialpipe welds, robot welding, etc.

conditions (e.g. underwater welding), particular weldshapes, process variants or combinations, and also forparticular welding consumables and auxiliary materi-als. The same applies in analogous manner to otherjoining processes or (surface) finishing operationssuch as thermal cutting or flame straightening.

1.6 The information in the preceding and fol-lowing paragraphs, especially the information on testpieces, specimen shapes, tests and requirements, ap-plies to the normal materials, welding processes andweld shapes in current use in shipbuilding, the behav-iour of which under service conditions has been veri-fied by experience and/or test results. In cases ofdoubt, the Society may call for additional and/or dif-ferent test pieces, specimen shapes or tests to verifysatisfactory suitability for use.

1.7 In the case of welding processes whose char-acteristics result in weld shapes other than those veri-fied by experience and/or test results (e.g. those with aconsiderable notch effect), the influence of the weldshape on the fatigue strength behaviour of the weldedjoints may be investigated in addition to carrying outthe prescribed tests. The same applies in analogousmanner to other characteristics of the welded joints,e.g. corrosion resistance.

2. Scope of tests, test schedule, limits of appli-cation

2.1 Test schedule, test details

2.1.1 The scope of the welding procedure tests (testpieces, specimens, tests) shall be laid down in a testschedule to be submitted for approval in good timeprior to testing, in accordance with Chapter 1, Section4, B.1. Depending on the nature and application of awelding process, the process details stipulated inChapter 1, Section 4, B.1.1 shall be taken into accountin the tests. Where no further details on the weldingprocedure tests are given in the following paragraphs,the provisions of Chapter 1, Section 4 and the stan-dards of the series EN 288 / ISO 9956 shall apply.

Note:

The following rules relating to the welding proceduretests comply with, borrow from in part or refer to thestandards of the series EN 288/ISO 9956. Comparedwith the previous versions of these Rules for Welding,all the details relating to the welding procedure testswhich, from the shipbuilding aspect, have been satis-factorily covered in the standards, are no longer con-tained in these Rules or only by reference to thesestandards, especially to EN 288-3/ISO 9956-3 "Weld-ing procedure tests …….. Steels" and EN 288-4/ISO 9956-4 "Welding procedure tests ……aluminiumalloys"

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Details specific to shipbuilding, such as materialgroupings, single-side welding or the inclusions andexclusions for welding positions (vertical-down weld-ing) requiring special and specific experience andproven manipulation and which are only inadequatelycovered in the standards are dealt with in the follow-ing paragraphs as a departure from the standards.Under the provisions of the regulations applicable toother ranges of application (e.g. for pressure equip-ment), the Rules issued by the Society for shipbuildingshall be regarded as the predominant codes of prac-tice.

2.1.2 Depending on the nature of the base materialor the influence of the characteristics of the process,the Society may set out specifications which go be-yond or deviate from the stipulations given in theserules or in the standards and call for different or addi-tional tests, stipulate requirements or change the scopeof application. The Society also reserves the right tointerpret the standards accordingly. Where the stan-dards contain information which is different from orcontradicts these rules, these rules shall take prece-dence.

2.2 Base materials, material groups

2.2.1 The welding procedure test shall in principlebe carried out by welding the base materials for whichapplication for approval was made. Except for hullstructural steels and austenitic-ferritic duplex steels,the base materials for the welding procedure tests maybe grouped into material groups in accordance with thestandards of the series EN 288/ISO 9956 and the testperformed using representative materials from thisgroups. The provisions set out in the following para-graphs apply to hull structural steels. Duplex steels areregarded as an independent material group and are notcovered by the group of austenitic stainless steels

Note:

The provisional standard DIN V 1738, the Germanlanguage version of the CEN report CR 12187(shortly to be available in a revised version as Euro-pean standard CR TR 15608 or as ISO standard)classifies weldable materials (for general use) intocategories with comparable, identifying properties.These categories are finely graded to include in addi-tion special properties such as the behaviour of mate-rials during heat treatment.

Austenitic stainless steels and austenitic-ferriticstainless steels are therefore classified into differentgroups. In preference to the rough classification fa-voured by the standards of the series EN 288/ISO9956 (the same applies in analogous manner to thewelder’s qualification tests conforming to EN 287/ISO9606), it is therefore advisable to use the classification

given in CEN report 12187 or the anticipated follow-on standards. The Society may stipulate this.

2.2.2 If a welding procedure test is to be carried outfor several base materials simultaneously, materialswhich cover both the various strength categories (...-,...32, ...36, ...40) and the various degrees of toughness(A/A..., B, D/D..., E/E..., F...) shall be selected for hullstructural steels, taking the wall thicknesses into ac-count. The same procedure shall apply in analogousmanner to other materials.

2.2.3 Based on their chemical composition (be-haviour during welding) and their mechanical charac-teristics the various hull structural steels may be classi-fied or, as the case may be, grouped into the followingthree (strength) categories:

– Normal-strength hull structural steels A, B, Dand E (includes comparable, general structuralsteels, forged steels and cast steels with mini-mum yield strengths up to 280 N/mm2)

– Higher-strength hull structural steels A 32, D 32,E 32, F 32, A 36, D 36, E 36 and F 36 (includescomparable general-purpose structural steelswith minimum yield strengths of over 280N/mm2 up to and including 355 N/mm2)

– Higher-strength hull structural steels A 40, D 40,E 40, F 40 (includes comparable, general-purpose structural steels with minimum yieldstrengths of over 355 N/mm2 up to and including390 N/mm2).

2.2.4 Unless otherwise specified in a particular case(e.g. for welding processes with a very high heat input,such as electrogas or electroslag welding), the follow-ing conditions also apply to the selection of materials:

– Within each of the three strength categories inpara. 2.2.3, a satisfactory welding procedure teston a material with a higher degree of toughnessalso covers one steel with a lower degree oftoughness

– Within the same degree of toughness (e.g. A,A 32, A 36, A 40), a satisfactory welding proce-dure test on a steel of higher strength also coversone steel of lower strength.

2.2.5 If the range of application of a welding pro-cedure encompasses several steels belonging to onestrength category or one group of degrees of tough-ness, the welding procedure test shall be performed onat least two steels from each strength category or eachdegree of toughness, as applicable. Of these, one shallrepresent the lowest category or degree and one thehighest category or degree.

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2.2.6 However, the Society may, when testing sev-eral base materials at the same time, dispense withtesting certain steels if their influence on the quality ofthe welded joints is adequately covered by the tests ofthe other steels (in combination with the various testpiece thicknesses if necessary). Some examples ofmaterial selection (without taking into account specificprocess characteristics or as-delivered conditions ofmaterials) are shown in Table 1.2.

2.2.7 Where the characteristics of the process or thebase materials have no appreciable influence on thetest results due to the shape of the test piece or speci-men or the tests performed, the Society may agree to arestriction to a few base materials or only to one. Anexample of this is the testing of the fillet welding proc-ess using cruciform tensile specimens, macrographicspecimens and hardness measurements; in this case itis sufficient to perform the test on a steel from thehighest strength category intended for the applicationand with the maximum possible carbon equivalent.

Table 1.2 Base material categories (hullstructural steels, examples)

Range of application Base material

Quality grades A and BQuality grades A to DQuality grades A to E

A or BA and DA and E

Quality grades A 32 to D 36Quality grades A 32 to E 36Quality grades A 32 to F 36

A 36 and D 36A 36 and E 36A 36 and F 36

Quality grades A 40 to D 40Quality grades A 40 to E 40Quality grades A 40 to F 40

A 40 and D 40A 40 and E 40A 40 and F 40

Quality grades A to Dand A 32 to D 36

A, D and D 36or

A, A 36 and D 36

Quality grades A to Eand A 32 to E 36

A, D and E 36or

A, E and E 36or

A, A 36 and E 36

2.3 Thicknesses of test pieces, range of wallthicknesses

2.3.1 The thicknesses of the test pieces shall begeared to the range of application and the weldingprocess in such a way as to comply with the conditionsspecified in Table 1.3. As a general rule, test pieces ofat least two different thicknesses shall be welded andtested for each range of application according to Table1.2 (each base material group). For vertical-downwelding, the upper thickness limit for the intendedrange of application shall be used for the thickness ofthe test piece.

2.3.2 In conjunction with the test piece thicknessesstated in para. 2.3.1, (cf. also 3.2), the throat thick-nesses "a" of fillet welds shall be established such thatthe approval range from "0,75a" to "1,5a" covers thedesired range of application. The throat thicknesses forthe test piece shall therefore be selected so that the "a"dimension roughly equals half the thickness of the testpiece (half the thickness of the thinner plate where thethicknesses of the plate are unequal). For (test piece)throat thicknesses of 10 mm or more, a range of appli-cation a ≥ 10 mm applies.

2.3.3 Where, for subsequent use, relatively thinfillet welds are to be applied to very thick components(cf. G.10.3.3), similar test pieces are to be welded andexamined for hot cracking, underbead cracks or hard-ening cracks. This requirement is specially applicableto higher- and high-strength grades of steel and caststeel.

2.3.4 For the reduction of the specified fillet weldthroat thicknesses where specially deep penetration isproved, see G.10.3.5. With regard to the increase ofthe "a" dimension when overweldable shop primerswhich are particularly liable to cause porosity or proc-esses with inadequate root penetration are used, seeG.10.3.6.

2.3.5 Where a fillet welding process is to be ap-plied to plates or sections coated with overweldableshop primer, similarly coated plates are to be used forthe fillet weld test pieces required for the weldingprocedure test. The type and thickness of the coatingof shop primer shall be stated in the test report.

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Table 1.3 Test piece thickness

Range of application 2, 3

Test piece thickness t 1 Single-run welding (single bead) andwelding in one run on each side

(Two-run technique)Multi-run technique

t ≤ 3

3 < t ≤ 12

12 < t ≤ 100

t > 100

0,8 t to 1,1 t

0,8 t to 1,1 t

0,8 t to 1,1 t

0,8 t to 1,1 t

t to 2 t

3 mm to 2 t

0,5 to 2 t, max. 150 mm

0,5 t to 1,5 t

1 If special cooling conditions have to be complied with or particular weld shapes are prescribed, they shall be taken into accountwhen selecting the test piece thickness; cf. also Chapter 1, Section 4, B.4.

2 For unequal plate thicknesses the following applies:

For butt welds, the average of the two plate thicknesses in the weld area ≈ weld thickness is the ruling dimension. For fillet weldjoints, the lower limit of the range of application of 0,8 times the smaller test piece thickness t1 (e.g. web thickness) and the upperlimit of 1,1 times the larger test piece thickness t2 (e.g. flange thickness) is the ruling dimension, but the ratio of plate thicknessest2 to t1 shall not exceed 3.

3 For the vertical-down welding, the test piece thickness t is always taken as the upper limit of the range of application.

3. Test pieces, dimensions, direction of roll-ing, welding positions

3.1 Shape and size of test pieces, direction ofrolling

3.1.1 Unless other provisions are given in the para-graphs below, the shape and size of test pieces shall beselected in accordance with the series of standards EN288/ISO 9956. The length of the test pieces shall beappropriate for the welding process and the number ofspecimens. Where scheduled in the fabrication workfor the particular welding process in question, bothbutt-weld and fillet-weld test pieces shall be made.The direction of rolling of the plates for the test piecesshould be parallel to the direction of the weld.

3.1.2 The length of test pieces (length of weld) formanual and semi-mechanized welding processes (cf.F.1.3 2 shall not be less than 350 mm and for fullymechanized and/or automatic welding processes thelength of the test piece shall be the same as the weldlength to be deposited during later fabrication work,subject to a minimum length of 1000 mm.

3.1.3 For welding in (clamping) jigs, the size of thetest piece shall conform to the size of the jig. For sin-gle-side welding processes and the fully mechanizedand/or automatic double fillet welding (e.g. for stiffen-ers on platings), the test piece shall be at least3000 mm long.

3.1.4 In the case of vertical welding, the length ofthe test piece (the weld length) shall conform to thesize of the jig used in fabrication. For jigs using a

fusible wire-guide electrode, the length of the testpiece shall conform to the length of the wire-guideelectrode or the height of the components to bewelded. Any special features affecting the applicationof these processes (e.g. welding operations performedthrough the deck) shall be allowed for in the configu-ration of the test piece.

3.1.5 Where, in order to establish the mechanicaland technological characteristics of the welded joints,especially in fully mechanized and/or automaticwelding processes, test piece lengths are selectedwhich are considerably smaller than the weld lengthsto be laid down during later fabrication, the first fabri-cation welds shall be included as part of the weldingprocedure tests and, as a minimum requirement, shallbe subjected to a visual inspection and non-destructivetesting to ensure a trouble-free welding procedure andto detect any imperfections in the weld.

3.2 Fillet-weld test pieces (T-joint and/or dou-ble T-joint (cruciform) test pieces)

3.2.1 Fillet-weld test pieces (T-joint and double T-joint (cruciform) test pieces) shall be joined with airgaps not greater than 0,5 mm. Depending on subse-quent practice, tacks shall also be included in the test(and overwelded where applicable). The throat thick-ness of the fillet welds should correspond to thoseused in subsequent fabrication but should not begreater than 0,5 × plate thickness (cf. 2.3.2 to 2.3.4).For shop primers, cf. 2.3.5.

3.2.2 Double T-joint test pieces as shown in Fig.1.1 or Fig. 1.2 (cruciform test pieces) are always re-



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quired when the welding procedure test relates to ver-tical-down welding or to the welding of high-strengthsteels with minimum yield strengths over 460 N/mm2,clad plates and non-ferrous metals. The Society mayalso require cruciform test pieces for other processesand/or materials.

The throat thickness of the fillet weld "a" shall notexceed 0,5 times the plate thickness.

3.2.3 In order to simplify the process where the testpieces are broken open on alternate sides, welding maybe performed on one side only of the double T-joint(cruciform) test pieces on alternate sides in the fracturearea, in analogous manner to the stipulations of thecodes of practice DVS 1702.

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Fig. 1.1 Double T-joint (cruciform) test piece formanual and semi-mechanized weldingprocesses

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Fig. 1.2 Double T-joint (cruciform) test piece forfully mechanized welding processes

3.3 Weld shapes, welding positions, heattreatment, non-destructive testing

3.3.1 Weld forms which may differ in their mannerof joining (e.g. butt weld or T-joint) and plate thick-ness shall be included in the test. Where weld forms,welding parameters and run build-up (e.g. in sub-

merged-arc welding from square butt weld via single-V butt weld to double-V butt weld) are changed duringa welding process within the range of application forwhich application for approval is made, these "shifts"in procedure shall also be allowed for by means ofappropriate test pieces.

3.3.2 T-joints with full penetration welded single-bevel or double-bevel butt joints are normally re-garded as butt joints, i.e. they are covered by the buttweld test pieces. For welds with incomplete penetra-tion and for special weld forms (e.g. the deep, acute-angled open single-V butt welds used in branchpieces) the Society may, however, call for additionaltest pieces to at least verify adequate weld penetrationand penetration conditions.

3.3.3 Test pieces are normally welded in all theconventional welding positions (for which applicationfor approval is made). For single-side welding, a testpiece which has been welded in the PC (h-v) positionmust always be provided. For information on thewelding procedure for the test pieces, any post-weldheat treatment or other finishing work which may berequired and the non-destructive tests, cf. the corre-sponding provisions in Chapter 1, Section 4, B.

4. Sets of specimens, test specimens, mechani-cal and technological tests

4.1 Set of test specimens for butt welds - gen-eral provisions

4.1.1 For standard manual and semi-mechanizedwelding, one set of test specimens shall be taken fromthe butt-welded test pieces in accordance with theabove-mentioned standards. For fully-mechanizedand/or automatic welding, at least one set each shall betaken from the start and end of the weld, cf. Chapter 1,Section 4, B.8.3. The division of the test pieces intosections (preparation of specimens, marking) and theperformance of the mechanical and technological tests,etc. shall be carried out in accordance with the stan-dards or Chapter 2, Section 5 as applicable.

4.1.2 Unless otherwise agreed in a particular case,one set of butt weld specimens shall comprise thefollowing specimens. The specimen shapes and dimen-sions shall conform to the provisions of the standardsor Chapter 2, Section 5 as applicable:

– 2 transverse tensile test specimens in accor-dance with EN 895/ISO 4136 (for larger platethicknesses a correspondingly greater number ofspecimens shall be provided to cover the fullcross-section),

– 1 round tensile test specimen by analogy to theprovisions of Chapter 1, Section 5, B.2.3 (Fig.5.1 and 5.2) taken lengthwise from the weld

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metal if welding consumables and auxiliary ma-terials not approved by the Society are to beused (cf. Chapter 1, Section 4, B.3.2) or if thecharacteristics of the welding process suggestthat the weld metal itself is likely to be consid-erably affected.

A round tensile test specimen is to be preparedin every case (except for aluminium alloys)where the mechanical properties of the weldmetal are inferior to those of the base material(e.g. when welding high-strength steels). The di-ameter "d0" of the specimen shall be as large as

possible (but not more than 10 mm) and thegauge length "L0" shall be 5 � d0. The provi-

sions of Chapter 1, Section 5, B.2. are to be ap-plied in analogous manner.

– 4 transverse bend test specimens, in accor-dance with EN 910/(ISO 5173) half to be bentwith the final pass in tension (FBB) and halfwith the root pass in tension (RBB),

or

– 2 transverse bend test specimens as before and

2 side bend test specimens taken at right anglesto the butt weld (SBB) in accordance withEN 910/(ISO 5173) in the case of test piecesover 12 mm thick

or:

– 4 side bend test specimens (SBB) in the case oftest pieces 20 mm thick and welding processesliable to give rise to segregations, lack of fusionor similar defects inside the weld (e.g. single-side and vertical-down welding).

Note:

In the case of pairs of materials which differ instrength, it may be advisable to use butt-weldedlongitudinal bend test specimens (FBB andRBB) in accordance with EN 910/(ISO 5173)with the weld seam in the centre of the specimeninstead of butt-welded transverse bend testspecimens. See also Chapter 2, Section 5. Thedetails of this test and the requirements (as arule a qualitative assessment of the bending be-haviour) shall be agreed on a case-by-case ba-sis.

– 3 notched bar impact test specimens each(Charpy V-notch specimens with the notch per-pendicular to the surface of the plate) in accor-dance with EN 875/ISO 9016, from the centre ofthe weld (VWT 0/1), from the fusion bound-ary/transition zone (VHT 0/1) and from the heat-affected zone (VHT 2/1). The notched bar im-pact test specimens shall be taken from the lastside welded, and with larger plate thicknesses

they shall be taken from both sides. With verylarge plate thicknesses and welding processes li-able to cause segregation in the central zone, anadditional 3 notched bar impact test specimensof each type shall be taken from the same areasin middle of the plate thickness.

The dimension "a" (cf. EN 875/ISO 9016) shallbe such that the point of intersection of the cen-tre line of the specimen and the middle of thenotch lies in the coarse-grained area of the heat-affected zone. This dimension may be generallytaken as 2 mm. Where welding procedure testsare performed on steels tough at subzero tem-peratures, test specimens with notches located ata = 1 mm, a = 3 mm and a = 5 mm shall be pre-pared, unless otherwise specified in an individ-ual case.

Depending on the base material and weldingprocess concerned, further notched bar impacttest specimens from other areas may be stipu-lated. Notched bar impact test specimens may bepartly or wholly dispensed with where the resultsof these tests in connection with the use of aparticular welding process are of minor signifi-cance for certain materials (e.g. austenitic stain-less steels or aluminium alloys, except for low-temperature applications).

– 2 macrographic (if necessary, micrographic)specimens for evaluating the grain structure.

– Hardness tests (Vickers HV5 or HV10) in ac-cordance with EN 1043-1 (EN 1043-2 in thecase of laser welding) shall be carried out where,having regard to the base material and thewelding process, the possibility cannot be dis-counted that preheating and/or the heat flowduring welding may affect the hardness values insuch a way as to impair the toughness or strengthcharacteristics of the weld. Hardness measure-ments shall always be performed on higher-strength hull structural steels and on high-strength (quenched and tempered) fine-grainedstructural steels with minimum yield strengths ofmore than 355 N/mm2.

4.2 Set of butt weld test specimens for single-side welding processes

4.2.1 Sets of test specimens as specified in para.4.1.1 and 4.1.2, but subject to the differences listedbelow, shall be taken from butt-weld test pieces forsingle-side welding processes (e.g. manual or semi-mechanized welding using ceramic backing or sub-merged-arc welding with flux backing):

– 2 transverse tensile test specimens, cf. para.4.1.2.



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– 1 round tensile test specimen taken lengthwisefrom the weld metal. This is also required whenadditional welding consumables (e.g. in the formof iron powder and the like) are employed orwhere the possibility of a metallurgical reactionbetween the weld metal and the backing materialcannot be discounted (cf. 4.1.2)

– 2 transverse bend test specimens (one FBBand one RBB) and

2 side bend test specimens (SBB), cf. 4.1.2.

– 3 notched bar impact test specimens eachadditionally from the root zone: from the centreof the weld seam (VWT 0/t-1), the fusionboundary/transition zone (VHT 0/t-1) and heat-affected zone (VHT 2/t-1). Cf. para. 4.1.2.

– 2 macrographic specimens at least one ofwhich - for manual and semi-mechanized weld-ing processes - must pass through a startingpoint of welding (cf. 4.1.2).

– Hardness tests, cf. para. 4.1.2

4.2.2 By analogy with the provisions of para. 4.2.1,the following test specimens shall be taken from butt-welded test pieces prepared by manual or semi-mechanized welding processes already approved bythe Society for the range of application concerned(base materials, welding positions) for the sole pur-pose of extending the said approval to single-sidewelding with backings:

– 2 transverse bend test specimens with the rootin tension (RBB) and 2 side bend test speci-mens (SBB). Cf. 4.1.2

– 3 notched bar impact test specimens each onlyfrom the root zone: from the centre of the weldseam (VWT 0/t-1), the fusion bound-ary/transition zone (VHT 0/t-1) and heat-affected zone (VHT 2/t-1) where normal-strength, hull structural steel grade E and/orhigher-strength hull structural steels are to bewelded or where stipulated for other materials(cf. 4.1.2)

– 2 macrographic specimens, at least one ofwhich must pass through a starting point ofwelding in the case of manual and semi-mechanized welding processes. (cf. 4.1.2).

– hardness tests, cf. para. 4.1.2.

4.3 Set of butt weld specimens for verticalwelding processes

In accordance with Chapter 1, Section 4, B.8.3, one ormore sets of test specimens as described in paras. 4.1.1and 4.1.2 shall be taken from butt-weld test pieces forvertical welding processes (e.g. electrogas or elec-troslag welding) as follows:

– 2 transverse tensile test specimens, cf. para.4.1.2.

– 1 round tensile test specimen taken lengthwisefrom the weld metal. This is also required whenadditional welding consumables (e.g. in the formof iron powder and the like) are employed (cf.4.1.2).

– 2 transverse bend test specimens (one FBBand one RBB) and

2 side bend test specimens (SBB), cf. 4.1.2.

– 3 notched bar impact test specimens eachfrom the centre of the weld seam (VWT 0/2), theedge of the weld seam (VWT a/2), the fusionboundary/transition zone (VHT 0/2) and heat-affected zone (VHT 2/2). The dimension "a"shall be such that the notch lies in the coarse-grained area of the weld metal (normally about2 – 3 mm). With very large plate thicknesses andwelding processes liable to cause segregation inthe central zone, an additional 4 notched bar im-pact test specimens of each type shall be takenfrom the same areas in the middle of the platethickness. Cf. 4.1.2.

– 2 macrographic specimens at least one ofwhich must pass through a starting point ofwelding (cf. 4.1.2).

– Hardness tests, cf. para. 4.1.2

4.4 Set of fillet weld test specimens (set ofT-jointed test pieces)

4.4.1 By analogy with para. 4.1.1, two or moremacrographic specimens, as applicable depending onthe length of the test piece, shall be taken from thesimplified (T-jointed) fillet-welded test pieces in ac-cordance with EN 288/ISO 9956 to evaluate the pene-tration conditions, any irregularities in the test pieceand the grain structure. If necessary, hardness meas-urements as described in EN 1043-1 and -2 shall beperformed (cf. 4.1.2).

4.4.2 The remainder of the test pieces is to be di-vided into convenient portions which, after removal ofone of the welds, are to be broken open on alternatesides for evaluation of the fracture (cf. EN 1320).

4.5 Set of fillet weld specimens (set of double-Tjointed (cruciform) test pieces)

4.5.1 As shown in Figures 1.1 and 1.2, one or moresets of test specimens shall be taken from the (cruci-form) fillet-welded test pieces as called for in 4.1.1depending on the length of the test piece as shown inFig. 1.3. Preparation of specimens, marking, perform-ance of mechanical and technological tests, etc. shall

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be carried out in accordance with the provisions ofChapter 2, Section 5.

4.5.2 A set of (cruciform) fillet weld test specimensas called for in 4.5.1 shall comprise the followingspecimens. The specimen shapes and dimensions shallconform to the provisions of Chapter 2, Section 5.

– 3 cruciform tensile test specimens (Z) asshown in Fig. 1.4 for determining the tensile-shear strength of the weld metal

– 2 macrographic specimens (M) for evaluatingthe penetration conditions, any irregularities inthe specimens and the grain structure. If neces-sary, hardness measurements (cf. 4.1.2) shallbe performed in accordance with EN 1043-1 and-2 (cf. 4.1.2).

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Fig. 1.3 Set of double-T (cruciform) test speci-mens

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Fig. 1.4 Cruciform tensile test specimen (weldcross section)

4.5.3 The remainder of the test pieces is to be di-vided into convenient portions which, after removal ofone of the welds, are to be broken open on alternatesides for evaluation of the fracture, cf. EN 1320.

5. Requirements

5.1 Hull structural steels

5.1.1 In welding procedure tests and tests on pro-duction specimens relating to hull structural steels,butt weld specimens must meet the minimum require-ments shown in Table 1.4. Equivalent structural steels,forged steels and cast steels shall be classified inanalogous manner according to their chemical compo-sition and mechanical characteristics.

5.1.2 The minimum impact energy values shown inTable 1.4 apply to the centre of the weld metal, thetransition zone/fusion boundary and the heat-affectedzone. The values for manual and semi-mechanizedwelding apply to all positions except the vertical-upposition (PF). The values applicable to the verticalposition (PF) are those for fully mechanized welding(34 J or 41 J resp.).

Note:

In the fusion boundary/transition zone and/or the heataffected area of "simple" steels, (for example Grade Asteels), difficulties may possibly arise in meeting therequired values listed in Table 1.4 which have beenderived from the requirements relating to weldingconsumables. In such cases, the values establishedduring the testing of the base material and duringappropriate monitoring checks may be used as refer-ence values. The values established on the weldedjoint should not fall below these reference values.

5.1.3 In special cases (e.g. where the working tem-perature of the component is below – 10 °C), the testtemperatures and impact energy values laid down inthe material specifications for the testing of the steelsconcerned may also be stipulated for welding proce-dure tests in place of the test temperatures and impactenergy values shown in Table 1.4. Unless otherwiseagreed, these values shall then apply to all weldingpositions and notch positions.

5.1.4 Where the plate thickness is less than 10 mm,notched bar impact test specimens with a width corre-sponding to the plate thickness, and wherever possible7,5 mm or 5 mm, may be used. In such cases the im-pact energy values specified in Table 1.4 shall bereduced in accordance with Table 1.5.

The notched bar impact test is generally dispensedwith for plates less than 5 mm thick. However, othertests of resistance to brittle fracture may be stipulated.



F

Table 1.4 Requirements applicable to hull structural steels

Impact energy 1

[J]

Grade

Yieldstrength

(weld metal)

[N/mm2]

Tensilestrength

[N/mm2]

Elongation(weld metal.L0 = 5 d0)

[%]

manual andsemi-

mechanized.

fullmechanized

Temp.

[°C]

Bendingangle

(D = 3 t) 2

Bendingelongation

gaugelength2 LS 3

[%]

A/B + 20

D ± 0

E

305 400 22 47 34

– 20

180° 22

A 32 + 20

D 32 ± 0

E 32 – 20

F 32

335 440 22 47 34

– 40

180° 22

A 36 + 20

D 36 ± 0

E 36 – 20

F 36

375 490 22 47 34

– 40

180° 22

A 40 + 20

D 40 ± 0

E 40 – 20

F 40

400 510 22 47 41

– 40

180° 22

1 Charpy V-notch specimens, average value of three specimens. For minimum individual values and retests, see Chapter 1, Section 4, C.2.3.With regard to the notch position and the welding positions, see 5.1.2.

2 The Society may consent to the use of a mandrel with a diameter D equal to D = 4 × t if this does not adversely affect the reliability of thetest results. For bending angles, see 5.1.5.

3 The gauge length (L0) = the weld width (LS) + half the plate thickness (a/2) on each side adjacent to the weld, cf. EN 910/(ISO 5173).

Table 1.5 Required impact energy values withspecimens of reduced width

Specimen section[mm ×××× mm]

Specified impactenergy value to be

multiplied by:

10 × 7,5 5/6

10 × 5,0 2/3

5.1.5 The bending tests are to be performed using amandrel with a diameter equal to 3 times the thickness(t) of the specimen. The Society may instead consentto the use of a mandrel with a diameter D of 4 × t ifthis does not impair the reliability of the test results.The required bending angle of 180 ° under the testconditions specified in EN 910 is deemed to have beenattained when the specimen has been thrust betweenthe supporting rolls to the minimum distance indicatedin this standard. The required bending elongation mustbe attained before the first incipient crack appears.

Minor pore exposures or the like up to a maximumlength of 3 mm may be tolerated. The fracture surfacesof ruptured test specimens shall be evaluated.

5.1.6 Measured on cruciform tensile test speci-mens, the minimum tensile (tensile-shear) strength ofthe weld section (fracture section in accordance withFig. 1.4) shall meet the requirements stated in Table1.6.

Table 1.6 Requirements applicable to cruciformtensile specimens

Grades Tensile-shear strength[N/mm2]

A – E 350

A 32 – F 36 430

A 40 – F 40 450

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5.2 High-strength (quenched and tempered)fine-grained steels

5.2.1 For welding procedure tests and tests on pro-duction specimens relating to high-strength (quenchedand tempered) fine-grained steels, the minimum prop-erties specified in Chapter 1, Section 5, F. for thetesting of welding consumables and auxiliary materialsmust be met for butt-weld specimens. Unless otherwiseagreed in an individual case, a bending mandrel di-ameter of 4 times the specimen thickness shall be usedfor the bending tests. Test temperatures of – 20 °C orbelow shall be selected for the notched bar impact test.

5.2.2 Measured on cruciform tensile test specimens(cf. 3.2.2), the minimum tensile strength (tensile-shearstrength) of the weld section (fracture section as shownin Fig. 1.4) shall satisfy the requirements relating tothe welded joint stipulated in Chapter 1, Section 5, F.

5.3 Austenitic stainless (clad) and austenitic-ferritic (duplex) steels

5.3.1 For welding procedure tests and tests on pro-duction specimens relating to austenitic stainless (clad)and austenitic-ferritic (duplex) steels, the minimumproperties specified in Chapter 1, Section 5, I. for thetesting of welding consumables and auxiliary materialsmust be met for butt weld specimens. In the case ofjoints between different types of steel, the strengthvalues of the base material which has the lowerstrength shall be used.

5.3.2 Unless otherwise agreed in an individual case,a bending mandrel diameter of 3 times the specimen

thickness may be used for the bending test and a testtemperature of + 20 °C for the notched bar impact testperformed on austenitic stainless steels. Austenitic-ferritic (duplex) steels shall be tested at a temperatureof – 30 °C.

5.3.3 Measured on cruciform tensile test specimens(cf. 3.2.2), the minimum tensile strength (tensile-shearstrength) of the weld section (fracture section as shownin Fig. 1.4) shall satisfy the requirements relating tothe welded joint stipulated in Chapter 1, Section 5, I.The throat thickness of the fillet welds on clad platesshall be such (≤ 0,5 × plate thickness) that the fracturealways occurs in the weld seam.

5.4 Aluminium alloys

5.4.1 For welding procedure tests and tests on pro-duction specimens relating to aluminium alloys, thevalues specified in Table 1.7 shall be used as guidevalues for butt weld specimens taken from 5000 and6000 series alloys as stipulated in the Society’s Rulesfor Materials. The tensile strength of the specimensmay not on any account be less than the minimumstipulated value for the base material in its "soft" con-dition. Different values shall be allowed for whereapplicable in the design and dimensioning operations.The stipulated tensile strength values apply to testspecimens retaining the weld reinforcement. Otheraluminium alloys shall be classified in analogous man-ner and the requirements for these are specified on acase-by-case basis allowing for the characteristics ofthe base material and the joint efficiency factorsstipulated in EN 288-4/ISO 9956-4.

Table 1.7 Requirements applicable to aluminium alloys

Base material Welded joints 1

Alloy no. Material designation0,2 %-proof

stress 2

[N/mm2]

Tensilestrength[N/mm2]

Bendingangle 3

[degree]

Bendingelongation

[%]

EN AW-5083 AlMg4,5Mn0,7 125 275

EN AW-5086 AlMg4 100 240

EN AW-5383 AlMg4,5Mn0,7mod. 145 290

EN AW-5754 AlMg3 80 190

––– AlMg5,5Mn0,8ZnZr 160 300

18

EN AW-6005A AlSiMg(A) 115 165

EN AW-6061 AlMgSilCu 115 155

EN AW-6082 AlSilMgMn 125 185

180

10

1 Using a weld consumable of a quality grade in accordance with the base material according to Chapter 1, Section 5, J.2 As far as established (on additional samples which are to be agreed).3 Bending mandrel ∅ to be selected depending on the material group and condition according to EN 288-4/ISO 9956-4.



5.4.2 The required bending angle of 180° under thetest conditions specified in EN 910 is deemed to havebeen attained when the specimen has been forcedbetween the supporting rolls to the minimum lengthspecified in this standard. The required bending elon-gation must be attained before the first incipient crackappears. Minor pore exposures or the like up to amaximum length of 3 mm may be tolerated. The frac-ture surfaces of ruptured test specimens shall be evalu-ated.

5.4.3 Measured on cruciform tensile test speci-mens, the minimum tensile-shear strength of the weldsection (fracture section in accordance with Fig. 1.4)shall generally not be less than 60 % of the stipulatedtensile strength. For the allowances which may benecessary when dimensioning the fillet-welded joints(if this value is not attained), see G.10.3.2.

5.4.4 For the welding procedure tests and tests onproduction specimens relating to aluminium alloys,unless otherwise stipulated in individual cases, thenotch impact toughness test may be dispensed with.The requirements applicable to low temperature appli-cations will be specified separately.

5.5 Other materials

The requirements applicable to other materials or othertest methods will be determined on a case-by-casebasis in a manner analogous to that applied to thematerials covered earlier, on the basis of their chemi-cal composition, mechanical properties and othercharacteristics of the base materials and with due re-gard for the anticipated operating conditions, such asthe lowest anticipated service temperature (designtemperature).

G. Design, Dimensioning

Preliminary remark:

The contents of this section are largely identical to theprovisions of the Rules for Classification and Con-struction I, Part 1 " Seagoing Ships", Chapter 1 "HullStructures", Section 19 "Welded Joints". Because ofthe time separating the reissues of the different rules,some temporary divergences may arise and in suchcircumstances the more recent rules shall prevail.

1. General

1.1 The general design principles described inChapter 2, Section 1 shall be followed.

1.2 Welded joints shall be designed to ensure thatthe proposed weld type and quality (e.g. complete rootfusion in the case of single- and double-bevel butt

welds) can be satisfactorily achieved under the givenfabricating conditions. Failing this, provision shall bemade for welds which are easier to execute and the(possibly lower) load-bearing capacity of these weldsshall be allowed for in the dimensional design.

1.3 Severely stressed welded joints, which aretherefore normally subject to compulsory inspection,shall be designed such that the most appropriate in-spection technique for the detection of defects (radiog-raphy, ultrasonic or surface crack inspection) can beapplied without restriction so that tests offering reli-able results can be carried out.

2. Characteristics related to materials, corro-sion

2.1 Characteristics related to materials, e.g. the(inferior) strength of rolled products in the thicknessdirection (cf. para. 7.) or the softening of hardenedaluminium alloys when welded, are to be allowed forwhen designing and dimensioning the components andthe welded joints.

2.2 Clad plates where the efficiency of the bondbetween the support and the superimposed material isproven may generally be treated as solid plates (up tomedium plate thicknesses with mostly fillet welds).

2.3 In thermally stressed composite structuresmade of different materials (e.g. hull structural andstainless steels in the case of tank heating systems),due allowance shall be made for the differences in thethermal conductivities and especially the rates ofthermal expansion of the different steels.

2.4 Where pairs of different materials are ex-posed to seawater or other electrolytes, e.g. the weldedjoints between unalloyed and stainless steels in thewear linings of rudder nozzles and in build-up weldson rudderstocks, attention is to be paid to the increasedtendency towards corrosion, especially at the weld,due to the differences in electrochemical potential.

2.5 If welded joints of this kind cannot beavoided, they shall whenever possible be located atpoints where there is less danger of corrosion (e.g.outside tanks) or special corrosion protection shall beprovided (e.g. coating or cathodic protection).

3. Stress flow, transitions

3.1 All welded joints on primary supportingmembers shall be designed to provide as smooth astress profile as possible with no major internal orexternal notches, no discontinuities in rigidity and noobstructions to expansion (cf. also the Rules for Con-struction of Seagoing Ships, Chapter 1, Section 3, H.).

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3.2 This applies in analogous manner to thewelding of subordinate components onto primarysupporting members whose exposed plate or flangeedges should, as far as possible, be kept free fromnotch effects due to welded attachments. Regardingthe inadmissibility of weldments to the upper edge ofthe sheer strake, see the Rules for Construction ofSeagoing Ships, Chapter 1, Section 6, C.3.3. Thisapplies in analogous manner to weldments to the upperedge of continuous hatchway sidecoamings.

3.3 Butt joints in long or continuous externalstructures, such as bilge keels, fenders, slop coamings,crane rails, hatchway cover running rails, compressionbars, etc. attached to primary supporting members aretherefore to be welded over their entire cross section.Their ends shall be designed in analogous manner tothe ends of the doubling plates (cf. 6.4) with "smooth"transitions into the component underneath.

3.4 Wherever possible, welded joints (especiallysite joints) in girders and sections shall not be locatedin areas of high bending stress. Joints at the bucklingpoints of flanges are to be avoided. Full penetrationwelds uniting three plates with additional fillet weldsapplied from the rear side in analogous manner to Fig.1.18 on buckle stiffeners are generally acceptable.

3.5 The transition between differing componentdimensions shall be smooth and gradual. Where thedepth of web of girders or sections differs, the flangesor bulbs are to be bevelled and the web slit and ex-panded or pressed together to equalize the depth of themembers so that the flanges or bulbs, as applicable,may be satisfactorily welded together. The length ofthe transition should equal at least twice the differencein depth.

3.6 Where the plate thickness changes at jointsrunning perpendicular to the direction of the mainstress, differences in thickness greater than 4 mm(greater than 3 mm where the thickness of the thinnerplate is less 10 mm) must be accommodated by bevel-ling the proud edge in the manner shown in Fig. 1.5 ata ratio of at least 1 : 3 or less according to the notchcategory (cf. the Rules for Construction of SeagoingShips, Chapter 1, Section 20, Table 20.3). Differencesin thickness up to the values stated above may be ac-commodated within the weld.

3.7 For the welding on of plates or other rela-tively thin-walled elements, steel castings and forgingsmust be appropriately tapered or provided with inte-grally cast or forged welding flanges in accordancewith Fig. 1.6. Failing this, the Society may approve acorrespondingly thicker transition piece welded overits entire cross-section to the steel casting or forging ina manner analogous to that for shaft brackets (cf. Fig.

1.24 and 1.25) or to that for the horizontal ruddercoupling flanges (cf. Fig. 1.26)

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��!�

Fig. 1.5 Accommodation of differences in thick-ness

"

��#

Fig. 1.6 Welding flange on steel castings andforgings

3.8 For the connection of shaft brackets to thehub and the shell plating, see 13. and the Rules forConstruction of Seagoing Ships, Chapter 1, Section13, D.1.; for the connection of horizontal couplingflanges to the rudder body, see 14. For the thickenedrudderstock collar required with build-up welds andfor the connection of the coupling flange, see 9. and14. respectively and the Rules for Construction ofSeagoing Ships, Chapter 1, Section 14, D.2.4. Theconnection between the rudderstock and the couplingflange must be welded over the entire cross section.

4. Local clustering of welds, minimum spac-ing, socket weldments

4.1 Local clustering of welds and short distancesbetween welds are to be avoided. Where account hasto be taken of higher residual welding stresses due tothicker plates or welds and corresponding rigidity ofthe components, the preparation should allow for thefact that adjacent butt welds should be separated fromeach other by a distance of at least

50 mm + 4 × plate thickenss

Fillet welds should be separated from each other andfrom butt welds by a distance of at least

30 mm + 2 × plate thickenss

In this case, the applicable dimensions are edge offillet weld to edge of fillet weld or edge of fillet weldto centre of butt weld. The width of interchangeablesections (strips) of plates should, however, be at least300 mm or ten times the plate thickness, whichever is



the greater. Other dimensions shall be subject to ap-proval by the Society in each individual case as part ofthe examination of the drawings.

Note:

In special cases, for example where plating bendsover its length (e.g. the inner bottom plating in thefore section of the hull or lateral longitudinal bulk-heads in the fore and aft sections of the hull), espe-cially in the lower plate thickness range (up to approx.20 mm) it may be advisable, in order to improvebuckle stiffening - or where the weld throat thick-nesses are not too large (up to about 5 mm) - to re-duce the distances stated above or even position thebuckle stiffening section or the like directly on theplate weld causing the buckling.

Although the extra fillet welds on the butt joint pro-duce an additional clustering of welds and thus resid-ual welding stresses, this is relatively minor comparedwith the residual welding stresses which occur inlarger plate thicknesses and the correspondinglylarger number of passes and may therefore be accept-able as a way of increasing the strength properties ofthe design. For permitted tolerances, see H.3.

4.2 Reinforcing plates, welding flanges, drainunions, mountings and similar components socket-welded into plating should be of the following mini-mum size:

( )D 170 3 t 10 170 mmmin = + − ≥

where

D = Diameter of round or length of side of angularsocket weldments in [mm]

t = Plating thickness in [mm]

With angular socket weldments, the corner radiishould be at least 50 mm or the "longitudinal seams"should be extended beyond the "transverse joints".Socket weldments shall be welded to the surroundingplating over the entire cross-section. For the provisionsrelating to the increase in stresses due to possible dif-ferences in thickness, cf. the Rules for Construction ofSeagoing Ships, Chapter 1, Section 20, B.1.3.

5. Welding apertures

5.1 Welding apertures for the (later) execution ofbutt or fillet welds following the positioning of trans-verse members should be rounded (minimum radius25 mm or twice the plate thickness, whichever is thegreater) and (especially where the loading is mainlydynamic) should be shaped to provide a gentle transi-tion to the adjoining surface and adequately notch-freewelding should be carried out around the end faces asshown in Fig. 1.7.

$�%

$�%

��

��

Fig. 1.7 Welding apertures

5.2 Where the welds are completed prior to thepositioning of transverse members, no welding aper-tures are needed. Any weld reinforcements present areto be machined off prior to positioning the transversemember, or the members to be positioned are to benotched accordingly.

6. Local reinforcements, plate doublings

6.1 Where platings (including girder plates andtube walls) are subjected locally to increased stresses,thicker plates should be used wherever possible inpreference to plate doublings. Bearing bushes, hubs,etc. shall invariably take the form of thicker sectionswelded into the plating (cf. 4.2).

6.2 Where doublings cannot be avoided, thethickness of the doubling plate should not exceedtwice the plating thickness. Doubling plates whosewidth is greater than approximately 30 times theirthickness shall be plug-welded to the underlying plat-ing in accordance with 10.5 at intervals not exceeding30 times the thickness of the doubling plate.

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&��'��(�

Fig. 1.8 Weld at the ends of doubling plates

6.3 Along their (longitudinal) edges, doublingplates shall be continuously fillet welded with a throatthickness "a" of 0,3 × the doubling plate thickness. Atthe ends of doubling plates, the throat thickness "a" atthe end faces shall equal 0,5 × the doubling platethickness t, but shall not exceed the plating thickness(see Fig. 1.8).

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6.4 The weld joining the end faces to the platingshould make a smooth transition with the latter at anangle of 45° or less.

Where proof of fatigue strength is demanded, (cf.Section 20 of Chapter 1of the Rules for Constructionof Seagoing Ships) the ends of the doubling platesmust be designed so that they comply with the detailcategory selected.

6.5 Doubling plates are not acceptable in tanksfor flammable liquids, gases or chemicals.

7. Transverse members, stress in the thick-ness direction

7.1 Where, in the case of members lying trans-verse to each other, plates or other rolled products arestressed in the thickness direction by residual stressesdue to the welding and/or by applied loads, suitablemeasures shall be taken in the design and fabricationof the structures to prevent lamellar tearing (stratifiedfractures) due to the anisotropy of the rolled products.

7.2 Such measures include the use of suitableweld shapes with a minimum weld volume and anappropriate welding sequence designed to reducetransverse shrinkage. Other measures are the distribu-tion of the stresses over a larger area of the plate sur-face by using a build-up weld or the "joining togetherof several layers" of members stressed in the thicknessdirection, as exemplified by the deck stringer/sheerstrake joint shown in Fig. 1.17.

7.3 Where there are very severe stresses in thethickness direction (due, for example, to the aggregateeffect of the shrinkage stresses of bulky single- ordouble-bevel welds plus high applied loads), plateswith guaranteed through thickness strength propertiesare to be used (higher degree of purity and guaranteedminimum reductions in area of ≥ 20 % of tensile testspecimens taken in the thickness direction 3.

7.4 Sandwiched flat bar steel positioned trans-versely to the direction of force (e.g. for use as back-ings for plug welding or to accommodate excessive airgaps) are not permitted where components intersect.

––––––––––––––3 See the Rules for Materials and Welding, Part, 1, Metallic

Materials, Chapter 2, Section 1, I., and also Supply Conditions096 for Iron and Steel Products, "Plate, strip and universalsteel with improved resistance to stress perpendicular to theproduct surface" issued by the German Iron and Steel Makers'Association.

8. Welding of cold-formed sections, bendingradii

8.1 In structural steels with a tendency towardsstrain ageing, welding of the cold-formed sections withmore than 5 % permanent elongation 4 and the adja-cent areas with 5 × plate thickness should be avoidedwherever possible. In case of doubt the Society maydemand proof (e.g. in the form of notched bar impacttests) that cold forming and subsequent welding havenot caused any unacceptable reduction in toughnesscharacteristics.

8.2 Welding of the cold-formed sections andadjacent areas of hull structural steels and comparablestructural steels (e.g. quality groups S….J…. orS….K…. conforming to EN 10025) may be per-formed, provided that the minimum bending radii arenot less than those specified in Table 1.8.

Table 1.8 Minimum bending radii for weldingof cold-formed sections

Plate thickness tMinimum inner

bending radius r

4 mm or less

8 mm or less

12 mm or less

24 mm or less

over 24 mm

1 × t

1,5 × t

2 × t

3 × t

5 × t

Note:

The bending capacity of the material may necessitatea larger bending radius.

8.3 For other steels and, where applicable, othermaterials, the necessary minimum bending radiusshall, in case of doubt, be established by test. Proof ofadequate toughness after welding may be stipulated forsteels with minimum yield strengths of more than355 N/mm2 and plate thicknesses of 30 mm and abovewhich have undergone cold forming resulting in 2 %or more permanent elongation.

––––––––––––––4 Elongation � in the outer tensile stressed zone:

ε =+

100

1 2 r / t[%]

r = inner bending radius in [mm]t = plate thickness in [mm]



9. Build-up welds on rudderstocks andpintles

9.1 Wear-resistant and/or corrosion-resistantbuild-up welds on the bearing surfaces of rudder-stocks, pintles, etc. shall be applied to a thickenedcollar exceeding by at least 20 mm the diameter of theadjoining part of the shaft.

9.2 Where a thickened collar is impossible fordesign reasons, the build-up weld may be applied tothe smooth shaft provided that relief-turning in accor-dance with 9.3 is possible (leaving an adequate resid-ual diameter).

9.3 After welding, the transition areas betweenthe welded and non-welded portions of the shaft shallbe relief-turned with large radii, as shown in Fig. 1.9,to remove any base material whose structure close tothe concave groove has been altered by the weldingoperation and in order to effect the physical separationof geometrical and "metallurgical" notches.

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-��*��

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��

Fig. 1.9 Build-up welds applied to rudder-stocksand pintles

9.4 If, during a repair, a build-up weld is excep-tionally to be applied to the smooth shaft without reliefturning with the special permission of the Society, thisweld shall be made in analogous manner to 9.3 (at anadequate distance beyond the zone of maximumbending stress) as shown in Fig. 1.10 in such a waythat at least two passes of weld metal remain in thesmooth part of the shaft after machining. The transi-tion between the build-up weld and the shaft must bemachined cleanly and free of notches.

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Fig. 1.10 Repair made by build-up welding

9.5 Build-up welding may only be carried outusing a fully mechanized process approved by theSociety (e.g. 12, submerged-arc welding) in the cir-cumferential direction on a rotating fixture.

10. Weld shapes and dimensions

10.1 Butt joints

10.1.1 Depending on the plate thickness, the weldingprocess and the welding position, butt joints shall takethe form of square, V or double-V welds (double Vbutt joints) conforming to the standards (e.g. EN22553, EN 29629, DIN 8551 Part 4, DIN 8552 or DIN8553). The weld shapes shall be illustrated in thedrawings or in other production documents, togetherwith the standard symbols.

10.1.2 Where weld shapes are proposed other thanthose specified in the standards, these are to be spe-cially described in the drawings. Weld shapes forspecial welding processes (e.g. submerged-arc, single-side welding, electrogas or electroslag welding) musthave been tested and approved in the context of awelding procedure test.

10.1.3 As a matter of principle, the rear sides of buttjoints shall be grooved and welded with at least onebacking run (capping pass). Exceptions to this rule, asin the case of submerged-arc welding or the weldingprocesses mentioned in para. 10.1.1, require testingand approval in the context of a welding proceduretest.

10.1.4 Where the aforementioned conditions cannotbe met (e.g. where the welds are accessible from oneside only), the joints shall be executed as lesser bev-elled welds with an open root and an attached or anintegrally machined or cast permanent weld pool sup-port (backing), as shown in Fig. 1.11.

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Fig. 1.11 Single-side welds with permanent weldpool supports (backings)

10.1.5 The effective weld thickness is deemed to bethe plate thickness or, where the plate thicknessesdiffer, the lesser plate thickness. Where proof of fa-tigue strength is required (see para. 15.3), the detailcategory depends on the workmanship (geometry andquality) of the weld.

10.1.6 The weld shapes illustrated in Fig. 1.12 shallbe used for clad plates. These weld shapes shall beused in analogous manner for corner joints and forjoining clad plates to (unalloyed and low-alloy) hullstructural steels.

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1�2��+�� +��

/��+�� +��'�� +��

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Fig. 1.12 Weld shapes for welding of clad plates

10.2 Corner, T and double-T (cruciform) joints

10.2.1 Corner, T and double-T (cruciform) jointswith full root penetration connection of the abuttingplates shall be executed as single- or double-bevelwelds with a minimum root face and adequate air gap,as shown in Fig. 1.13, and with grooving of the rootand capping from the opposite side.

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Fig. 1.13 Single- and double-bevel welds with fullroot penetration

The effective weld thickness is deemed to be thethickness of the abutting plate. Where proof of fatiguestrength is required (see 15.3), the detail categorydepends on the workmanship (geometry and quality)of the weld. These welds are to be classified accord-ing to type 21 in accordance with Chapter 1, Section20, Table 20.3 of the Rules for Construction of Sea-going Ships.

10.2.2 Corner, T and double-T (cruciform) jointswith a defined incomplete root penetration "f", asshown in Fig. 1.14 shall be executed as single- ordouble-bevel welds, as described in para. 10.2.1, withcapping from the rear side but without grooving ofthe root.

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+

+(�

Fig. 1.14 Single- and double-bevel welds with de-fined incomplete root penetration

The effective weld thickness may be deemed to be thethickness t (- f) of the abutting plate, the assumedincomplete root penetration f = 0,2 t, max. 3 mm,being compensated for by means of additional filletwelds of at least equal size applied to each side. As apractical dimension, a leg length of z = h/3 at the rootof the weld may be prescribed where h is the depth ofthe weld as shown in the figure. If proof of fatiguestrength is required (see para. 15.3), these welds mayalso be placed in detail category no. 21 in accordancewith the Rules for Construction of Seagoing Ships,Chapter 1, Section 20, Table 20.3.

10.2.3 Corner, T and double-T (cruciform) jointswith an unwelded root face "c" and an incomplete rootpenetration "f" which is also to be allowed for shall beexecuted in accordance with Fig. 1.15.

The effective weld thickness is deemed to be thethickness of the abutting plate t – (c + f), where f is tobe assigned a value of 0,2 t subject to a maximum of3 mm. Where proof of fatigue strength is required (seepara. 15.3), and depending on the plate thickness toweld thickness ratio, these welds are to be classifiedaccording to type 22 or 23 in accordance with theRules for Construction of Seagoing Ships, Chapter 1,Section 20, Table 20.3.

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#

� �

�(� �(��(�

�(�

Fig. 1.15 Single- and double-bevel welds with un-welded root face and defined incompleteroot penetration

10.2.4 Corner, T and double-T (cruciform) jointswhich are accessible from one side only may be exe-cuted in accordance with Fig. 1.16 in a manner analo-gous to the butt joints referred to in para. 10.1.4 usinga weld pool support (backing) or as single-side single-bevel welds laid down in a manner similar to thatprescribed in para. 10.2.2.



The effective weld thickness shall be determined byanalogy with para. 10.1.5 or 10.2.2, as appropriate.Wherever possible, these joints should not be usedwhere proof of fatigue strength is required (see para.15.3).

�

��#

�

�*�

��#"

Fig. 1.16 Single-side welded T-joints

10.2.5 Where corner joints are flush, i.e. with neitherof the plates standing proud, the weld shapes shall beas shown in Fig. 1.17 with bevelling of the perpen-dicularly juxtaposed plates to avoid the danger oflamellar tearing (stratified fracture, cf. 7.). A similarprocedure is to be followed in the case of fitted T-joints (uniting three plates) where the perpendicularplate illustrated is to be socketed (between two hori-zontal plates).

�*�

��#

��#�*�

��#

��#

��#

Fig. 1.17 Flush fitted corner joints

10.2.6 Where, in the case of T-joints (uniting threeplates), the direction of the main stress lies in the planeof the horizontal plates (e.g. the plating) shown in Fig.1.18 and the connection of the perpendicular (web)plates is of secondary importance, welds uniting threeplates may be made in accordance with Fig. 1.18 (withthe exception of those subjected mainly to dynamicloads).

The effective thickness of the weld uniting the hori-zontal plates shall be determined by analogy with10.1.5. The requisite "a" dimension is determined bythe joint uniting the vertical (web) plates and shall,where necessary, be determined in accordance with theRules of Construction of Seagoing Ships, Chapter 1,Section 19, Table 19.3 or by calculation as for filletwelds.

��

��#

��

��#��

#

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Fig. 1.18 Welding together three plates

10.3 Fillet weld joints

10.3.1 Fillet welds shall normally be made on bothsides, and exceptions to this rule (as in the case ofclosed box girders and predominant shear stressesparallel to the weld) are subject to approval in eachindividual case. The throat thickness "a" of the weld(the height of the inscribed isosceles triangle) shall bedetermined in accordance with the Rules for Con-struction of Seagoing Ships, Chapter 1, Section 19,Table 19.3 or by calculation in accordance with 15.The leg length "z" of a fillet weld is to be not less than1,4 � the throat thickness "a". For fillet welds at dou-bling plates, see 6.3; for the welding of deck stringersto sheer strakes, see the Rules for Construction ofSeagoing Ships, Chapter 1, Section 7, A.2.1, and forbracket plate connections, see Section 19, C.2.7.

10.3.2 The relative fillet weld throat thicknessesspecified in the above-mentioned Table 19.3 relate tonormal- and higher-strength hull structural steels andcomparable structural steels. They may also be appliedto high-strength structural steels and non-ferrous met-als provided that the tensile-shear strength of the weldmetal used is at least equal to the tensile strength of thebase material. Failing this, the "a" dimension shall beincreased accordingly and the necessary incrementshall be established during the welding procedure test.Alternatively, proof by calculation taking account ofthe properties of the weld metal may be presented.

Note:

In the case of higher-strength aluminium alloys (e.g.AlMg 4,5 Mn), such an increment may be necessaryfor cruciform joints subject to tensile stresses, as ex-perience shows that in the welding procedure tests thetensile-shear strength of fillet welds (made withmatching filler metal) often fails to attain the tensilestrength of the base material. Cf. F.5.4.3.

10.3.3 The throat thickness of fillet welds shall notexceed 0,7 times the lesser thickness of the parts to bewelded (the web thickness, for instance). The mini-mum weld thickness is defined by the expression:

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G

at t

mm

not less than

min ,=+1 2

3

but 3 mm

where

t1 = lesser (e.g. the web) plate thickness in [mm]

t2 = greater (e.g. the flange) plate thickness in [mm]

Cf. Chapter 2, Section 1, E.2.

10.3.4 It is desirable that the fillet weld sectionshould be flat faced with smooth transitions to the basematerial. Where proof of fatigue strength is required(see para. 15.3), machining of the weld (grinding toremove notches) may be required depending on thedetail category. The weld should penetrate at leastclose to the theoretical root point (cf. Fig. 1.19).

10.3.5 Where mechanized welding processes areused which ensure deeper penetration extending wellbeyond the theoretical root point and where suchpenetration is uniformly and dependably maintainedunder production conditions, approval may be givenfor this deeper penetration to be allowed for in deter-mining the throat thickness. The effective dimension

a ae

mmdeep = +2

3

min

shall be ascertained in accordance with Fig. 1.19 andby applying the term "min e", which is to be estab-lished for each welding process by a welding proce-dure test. The throat thickness shall not be less thanthe minimum throat thickness related to the theoreticalroot point.

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��

��

�+��

Fig. 1.19 Fillet welds with increased penetration

Note:

In the case of welding processes where there is a par-ticularly deep, narrow penetration, as occurs for ex-ample in laser welding without welding consumable inwhich no significant fillet weld is produced but theentire welded joint is virtually shifted "inwards", theabove requirement for a specific minimum fillet weldthickness may be difficult or impossible to meet. Insuch cases the extent of the effect of the weld shape (ifany) on the characteristics of the welded joint (e.g.resistance to cracking, strength) shall be assessedand/or verified in the welding procedure test, takinginto consideration any fatigue strength requirements

which may be stipulated. The details of this shall beagreed with the Society on a case-by-case basis.

10.3.6 When welding on top of shop primers whichare particularly liable to cause porosity, an increase ofthe "a" dimension by up to 1 mm may be stipulateddepending on the welding process used. This is espe-cially applicable where minimum fillet weld throatthicknesses are employed. The size of the increaseshall be decided on a case-by-case basis allowing forthe nature and the severity of the loading according tothe results of the examination of the shop primer inaccordance with Chapter 1, Section 6 or of the weldingprocedure tests or production tests, as applicable. Thisapplies in analogous manner to welding processeswhere provision has to be made for inadequate rootpenetration.

10.3.7 Strengthened fillet welds continuous on bothsides are to be used in areas subjected to severe dy-namic loads (e.g. for joining the longitudinal andtransverse girders of the engine base to top plates closeto foundation bolts, cf. the Rules for Construction ofSeagoing Ships, Chapter 1, Section 8, C.3.2.5 andSection 19, Table 19.3) unless single- or double- bevelwelds are stipulated in these locations. In these areasthe fillet weld throat thickness "a" shall equal 0,7times the lesser thickness of the parts to be welded.

10.3.8 Intermittent fillet welds may be located oppo-site each other (chain intermittent welds, possibly withscallops) or may be offset (staggered welding), inaccordance with the Rules for Construction ofSeaoging Ships, Chapter 1, Table 19.3 (cf. Fig. 1.20).The use of different scallop shapes and dimensionsmay be agreed on for very small sections.

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�

�

��4��5

��

�� 6�

��4��5

+�

Fig. 1.20 Scallop, chain and staggered welds

In water and cargo tanks, in the bottoms of fuel tanksand of rooms where pools of condensation or spraywater may collect, and in hollow components (e.g.rudders) threatened by corrosion, only continuousfillet welds or intermittent welds with scallops shall be



used. The same applies in analogous manner to areas,components or compartments which are exposed toextreme weather conditions or to a corrosive cargo.

There shall be no scallops in areas where the plating issubjected to severe stresses (e.g. in the bottom sectionof the fore ship) and continuous welds are to be pre-ferred where the loading is chiefly dynamic.

10.3.9 The throat thickness au of intermittent filletwelds is to be determined according to the selectedpitch ratio b/� by applying the following formula:

a ab

mmu = ⋅ ⋅�

11,

where

a = necessary fillet weld throat thickness for acontinuous weld conforming to the Rules forConstruction of Seaoging Ships, Chapter 1,Table 19.3, or determined by calculation in[mm]

b = pitch = e + � in [mm]

e = interval between the welds in [mm]

� = length of fillet weld in [mm]

The pitch ratio b/� may not be greater than 5. Themaximum unwelded length (b – � with scallop andchain welds or b/2 – � with staggered welds) shall notexceed 25 times the lesser thickness of the parts to bewelded. However, the length of the scallops shall notexceed 150 mm.

10.4 Lapped joints

10.4.1 Lapped joints running transversely to themain direction of load should be avoided whereverpossible and may not be used for heavily loaded com-ponents. Lapped welds may be accepted for compo-nents subject to low loads (excluding, however, tanksfor chemicals, combustible liquids or gases) providedthat wherever possible, they are orientated parallel tothe direction of the main stress.

10.4.2 The width of the lap shall be 1,5 t + 15 mm(t = thickness of the thinner plate). Except where an-other value is determined by calculation, the fillet weldthroat thickness "a" shall equal 0,4 times the thicknessof the thinner plate, subject to the requirement that itshall not be less than the minimum throat thicknessprescribed in para. 10.3.3. The fillet weld must becontinuous on both sides and must meet at the ends.

10.5 Plug welding

10.5.1 In the case of plug welding, the plugs should,wherever possible, take the form of elongated holeslying in the direction of the main stress. The distancebetween the holes and the length of the holes may be

determined by analogy with the pitch "b" and the filletweld length "�" in the intermittent welds covered bypara. 10.3. The fillet weld throat thickness "au" may be

established in accordance with 10.3.9.

10.5.2 The width of the holes shall be equal to atleast twice the thickness of the plate and shall not beless than 15 mm. The ends of the holes shall be semi-circular.

10.5.3 Plates or sections placed underneath should atleast equal the perforated plate in thickness and shouldproject on both sides to a distance of 1,5 × the platethickness subject to a maximum of 20 mm. Whereverpossible, only the necessary fillet welds shall be made,while the remaining void is packed with a suitablefiller.

10.5.4 Lug-joint welding is not permitted.

11. Welding at the ends of girders and stiffeners

11.1 As shown in Fig. 1.21, the web at the end ofintermittently welded girders or stiffeners is to becontinuously welded to the plating or the flange plate,as applicable, over a distance at least equal to thedepth "h" of the girder or stiffener subject to a maxi-mum of 300 mm. Regarding the strengthening of thewelds at the ends, normally extending over 0,15 of thespan, see the Rules of Construction for Seagoing ShipsChapter 1, Section 19, Table 19.3.

� ��

+ ++

�'6�+��

Fig. 1.21 Welds at the ends of girders and stiffen-ers

11.2 The areas of bracket plates should be con-tinuously welded over a distance at least equal to thelength of the bracket plate. Scallops shall be locatedonly beyond a line imagined as an extension of the freeedge of the bracket plate.

11.3 Wherever possible, the free ends of stiffenersshall abut against the transverse plating or the webs ofsections and girders so as to avoid stress concentra-tions in the plating. Failing this, the ends of the stiffen-ers shall be cut off obliquely and shall be continuouslywelded in accordance with Fig. 1.21 over a distance ofat least 1,7 h, subject to a maximum of 300 mm. Dif-ferent dimensions may be agreed for very small sec-tions.

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11.4 Where butt joints occur in flange plates, theflange shall be continuously welded to the web on bothsides of the joint over a distance "b" at least equal tothe width of the flange.

11.5 In the case of girders lying transversely toeach other, e.g. as shown in Fig. 1.21, and sectionpassages, a continuous weld shall also be made, byanalogy with 11.1, on the girder depicted in section inthe figure on both sides of the point where the girderscross.

12. Joints between section ends and plates

12.1 Welded joints uniting section ends and plates(e.g. at lower ends of frames) may be made in the sameplane or lapped. Where no design calculations havebeen carried out or stipulated for the welded connec-tions, the joints may be made analogously to thoseshown in Fig. 1.22.

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��'��+��'6��+��'��+�

�

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+

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+

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+

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�

+�

�

Fig. 1.22 Joints uniting section ends and plates

12.2 Where the joint lies in the plane of the plate,it may conveniently take the form of a single-bevelbutt weld with fillet. Where the joint between the plateand the section end overlaps, the fillet weld must becontinuous on both sides and must meet at the ends.The necessary "a" dimension is to be calculated inaccordance with the Rules of Construction for Seago-ing Ships, Chapter 1, Section 19, C.2.6. The fillet weldthroat thickness shall not be less than the minimumspecified in 10.3.3.

13. Welded shaft bracket joints

13.1 Unless cast in one piece or provided withintegrally cast welding flanges analogous to thoseprescribed in 3.7 (see Fig. 1.23), strut barrel and strutsare to be joined to each other and to the shell plating inthe manner shown in Fig. 1.24.

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Fig. 1.23 Shaft bracket with integrally cast weld-ing flanges

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�7

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��4

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Fig. 1.24 Shaft bracket without integrally castwelding flanges



13.2 In the case of single-strut shaft brackets, nowelding may be performed on the arm at or close tothe position of constraint. Such components must beprovided with integrally forged or cast weldingflanges. Alternatively, a design in accordance with Fig.1.25 may be used, subject to the consent of the Societyin each individual case. If so, it is essential to keep theconcave groove free from welds or other notches.

��

Fig. 1.25 Single-strut shaft bracket

14. Rudder coupling flanges

14.1 Unless forged or cast steel flanges with inte-grally forged or cast welding flanges in conformitywith 3.7 are used, horizontal rudder coupling flangesare to be joined to the rudder body by plates of gradu-ated thickness and full penetration single- or double-bevel welds as prescribed in 10.2.1 (see Fig. 1.26). Cf.also the Rules for Construction of Seagoing Ships,Chapter 1, Section 14, D.1.4 and 2.4.

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��4

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Fig. 1.26 Horizontal rudder coupling flanges

14.2 Allowance shall be made for the reducedstrength of the coupling flange in the thickness direc-tion (cf. 2.1 and 7.). In case of doubt, proof by calcu-lation of the adequacy of the welded connection shallbe produced.

14.3 The use of horizontal couplings for spaderudders is permitted only if the specified thickness ofthe coupling flanges is less than 50 mm. If this is notthe case, taper couplings shall be used. Taper cou-plings are the only type permitted for high-performance spade rudders. Cf. also Rules for Con-struction of Seagoing Ships, Chapter 1, Section 14,D.1.4 and 2.4.

14.4 The welded joint between the rudder shaft(with thickened collar, cf. para. 3.8) and the flangeshall be made in accordance with Fig. 1.27 in such away that the concave groove at the transition to thethickened collar remains absolutely free of welds.Where necessary, the transition shall be machined toremove notches. For larger flange thicknesses, it isadvisable to carry out a single-U weld preparationinstead of a double- bevel butt weld.

��#

��

��=��

�� +��

�

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��

�

��=

��4 > �

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.

Fig. 1.27 Welded joint between rudder shaft andcoupling flange

15. Design calculations applied to weldedjoints

15.1 Any calculation relating to welded jointswhich is stipulated in the Rules or prescribed as analternative to the rules governing dimensions shall beperformed in accordance with the Rules for Construc-tion of Seagoing Ships, Chapter 1, Section 19, C.Calculations conforming to other rules, standards orcodes (e.g. DIN 15018, DIN 18800 or DIN EN V1993 (Eurocode 3)) are subject to the prior consent ofthe Society.

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H

15.2 Proof by calculation of adequate dimension-ing with mainly static loading (a general stress analy-sis) is required where the thickness of butt welds,T-joints or double-T (cruciform) joints cannot be re-garded as equal to the plate thickness (cf. 10.1.5,10.2.1 to 10.2.4, 10.2.6 and elsewhere) or the throatthicknesses of fillet welds do not conform to the tables(cf. the Rules for Construction of Seagoing Ships,Chapter 1, Section 19, Table 19.3).

15.3 For welded joints subjected to mainly dy-namic loads, the permissible loading shall be deter-mined by reference to the number of load alternations,the global loading conditions, the mean stress and thenotch category (proof of fatigue strength). The notchcategory is a function of the geometrical configurationof the welded joint. It is also associated with (gradu-ated degrees of) proof of the absence of serious inter-nal and external notches (welding defects). Cf. thenotch category catalogue in the Rules for Constructionof Seagoing Ships, Chapter 1, Section 20.

H. Execution of Welds

1. General

1.1 The general rules prescribed and the instruc-tions given in Chapter 2, Section 2 for the execution ofwelds shall be complied with.

1.2 For the necessary approvals, inspections andtests of welding shops, welders, welding procedures,welding consumables and auxiliary materials, over-weldable shop primers, etc., see the relevant sectionsand also A. to F. of this section.

2. Welders and supervisors

2.1 Welding work on components governed bythese Rules may only be performed by qualified weld-ers who have been approved by the Society and holdvalid qualification certificates. Welders and operators(cf.2.3 and 2.4) shall be adequately experienced in thepractice of the craft.

2.2 Welders for manual and semi-mechanizedwelding of normal-strength hull structural steels mustbe qualified for the relevant welding process andwelding positions on both butt welds and fillet weldsin accordance with Chapter 1, Section 3. Welders forvertical-down welding must also be qualified for thisposition.

2.3 Welders working with higher-strength hullstructural steels, special structural steels, stainlesssteels or aluminium alloys must be qualified for weld-ing these materials in analogous manner to the provi-sions of Chapter 1, Section 3.

2.4 Operators for fully mechanized and automaticwelding equipment must have received instruction andtraining in the use of the equipment and must be quali-fied in accordance with the provisions of Chapter 1,Section 3, A.1.3. The Society may demand that theoperators' qualifications be verified in the course ofthe welding procedure test (cf. Chapter 1, Section 4) orby means of production tests during fabrication.

2.5 Every workshop which performs weldingwork must have a welding supervisor who is an em-ployee of the workshop, proof of whose technicalqualifications shall be furnished (cf. Chapter 1,Section 2). The Society is to be automatically in-formed of any changes to the welding supervisors.

2.6 The welding supervisor shall supervise thepreparation and performance of the welding work in aresponsible manner (cf. C.). Wherever these differfrom the preceding and following conditions, require-ments, etc., he shall take steps to ensure that the qual-ity of the welded joints is consistent and adequate inconsultation with the Society.

3. Weld preparation and assembly

3.1 Overweldable shop primers

3.1.1 Only those overweldable shop primers maybe used for which the Society has issued a confirma-tion of acceptability based on a porosity test. See alsoChapter 1, Section 6 and the list of welding consum-ables and auxiliary materials approved by the Society,VI, 9, 3, Part II.

3.1.2 By means of suitable checks carried out in thecourse of production (e.g. measurements of coat thick-ness, production tests), workshops using shop primersshall ensure that the conditions of use on which theconfirmation of acceptability was based are adhered toand that, in fillet welding, no excessive pore formationoccurs which adversely affects the application. Seealso Chapter 1, Section 6 (notes).

3.2 Weld shapes, root openings (air gaps)

3.2.1 When preparing and assembling components,care shall be taken to ensure compliance with the weldshapes and root openings (air gaps) specified in themanufacturing documents. With single- and double-bevel welds especially, attention shall be paid to anadequate root opening in order to achieve sufficientroot penetration (cf. G.10.2.1 and G.10.2.2).



3.2.2 The root opening shall not exceed twice thespecified gap. If the size of the gap permitted by thisrule is exceeded locally over a limited area, the gapmay be reduced by build-up welding of the side walls,subject to the prior consent of the Surveyor. With filletwelds, the "a" dimension shall be increased accord-ingly, or a single- or double-bevel weld shall be used ifthe air gap is large. See also the note to 3.3.2.

3.2.3 With the Surveyor's agreement, large gapsmay be closed by means of a strip of plate with a widthof at least ten times the plate thickness or 300 mm,whichever is the greater (cf. G.4.).

3.3 Alignment of components, edge misalign-ment

3.3.1 Components which are to be united by buttjoints shall be aligned as accurately as possible. Sec-tions etc. welded to plating shall be left unfastened atthe ends for this purpose. Special attention shall bepaid to the alignment of (abutting) girders etc. whichare interrupted by transverse members. If necessary,such alignment shall be facilitated by drilling checkholes in the transverse member which are later seal-welded.

3.3.2 The permissible edge misalignment dependson the importance and loading of the component con-cerned (weld quality, cf. I.6.1). With heavily loadedseams (weld quality grade 1) running transversely tothe main direction of loading, the edge misalignmentof butt welds shall not exceed 10 % of the thickness ofthe plate or section, subject to a maximum of 3 mm.

Note:

A serviceable guide to permissible fabricating toler-ances is provided in the standards EN 25817/ISO5817 (Annex A of Chapter 2) relating to steel and EN30042/ISO 10042 (Annex B of Chapter 2) relating toaluminium and also in the IACS “Shipbuilding andRepair Quality Standard” and the "Fertigungsstan-dard des Deutschen Schiffbaus" (Manufacturing Stan-dard of the German Shipbuilding Industry). In thecase of the standards, the assessment category or theindividual evaluative criteria to be applied to compo-nents or welded joints have to be determined by refer-ence to their loading (cf. Table 1.9). The range ofassessment categories, particularly for dynamicloading, is given in code of practice DVS 0705.

GL has agreed to the "Manufacturing Standard" sub-ject to the reservation that in particular instances, e.g.where important, highly stressed components areconcerned or where there is an accumulation of de-viations from nominal dimensions, it may also imposedecisions which differ from the Standard and may callfor improvements to be carried out. Where the Societyraises no objection, the provisions of the Manufac-

turing Standard may therefore be considered to repre-sent the maximum permissible upper limit for devia-tions from the stipulated dimensions.

3.4 Tack welds, auxiliary fixtures

3.4.1 Tack welds should be used as sparingly aspossible and should be made by trained operators.Where their quality does not meet the requirementsapplicable to the subsequent welded joint, they are tobe carefully removed before the permanent weld ismade. Cracked tack welds may under no circum-stances be welded over.

3.4.2 Clamping plates, temporary ties, aligningpins, etc. must be made of (hull structural) steel ofgood weldability and should not be used more thannecessary. When the components have been perma-nently welded, they are to be carefully removed toprevent damage to the surfaces of the components.

3.4.3 Clamping plates, temporary ties, aligningpins, etc. may not be welded to components subject toparticularly high stresses (e.g. hatchway corners), norshall they be welded to the edges of flange plates or,especially, to the upper edges of sheer strakes andcontinuous hatchway sidecoamings. The same appliesto the welding of handling lugs and other auxiliaryfixtures.

3.4.4 Particularly with mechanized welding proc-esses, and invariably when end craters and defects atthe start and end of the weld have to be avoided, run-inand run-off plates of adequate section shall be attachedto components and cleanly removed on completion ofthe weld.

4. Weather protection, welding at low tem-peratures

4.1 The area in which welding work is performed- particularly outside - is to be sheltered from wind,damp and cold. Where gas-shielded arc welding iscarried out, special attention is to be paid to ensuringadequate protection against draughts. When workingin the open in unfavourable weather conditions, it isadvisable always to dry welding edges by heating.

4.2 At low temperatures (below 5 °C), suitablemeasures shall be taken to ensure the satisfactoryquality of the welds. Such measures include theshielding of components, extensive preliminary heat-ing and preheating, especially when welding with arelatively low heat input, e.g. when laying down thinfillet welds or welding thick-walled components.Wherever possible, welding work should be suspendedif the temperature falls below – 10 °C.

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5. Preheating

5.1 The need for and the degree of preheatingnecessary for welding (cf. Chapter 2, Section 3, D.)are governed by a series of factors. These factors dif-fer in their effect in the manner indicated in Chapter 2,Section 3, D.2.5 (Table 3.4), i.e. they raise or lowerthe necessary preheating temperature. For informationon the measurement of the preheating temperature andthe interpass temperatures to be maintained, see alsoChapter 2, Section 3, D.

5.2 Apart from the measures prescribed in para.4.1 and 4.2, normal-strength hull structural steels donot normally require preheating. However, with largecross sections (e.g. steel castings or forgings) andwhere difficult conditions with regard to design orwelding practice apply (e.g. severe distortion of com-ponents), it is advisable to carry out uniform prelimi-nary heating of the areas surrounding the weldedjoints. Cf. 4.1 and 4.2.

5.3 Higher-strength hull structural steels shallgenerally be preheated if the temperature of the work-piece is less than +5 °C. If it is higher than this, pre-heating shall be carried out upwards of a specificthreshold wall thickness, paying due regard to theother factors described in Chapter 2, Section 3, D.2.5(Table 3.4). For an average carbon equivalent and anaverage heat input (energy applied per unit length ofweld), the threshold wall thicknesses "t" and preheat-ing temperatures "T" shown in Fig. 1.28 may be usedas an initial guide. These values, however, are gov-erned by the influencing factors shown in the above-mentioned Table 3.4 and have to be adjusted in line

with the prevailing conditions. Where necessary, theneed for and degree of preheating shall be determinedin accordance with Chapter 2, Section 3, D. or bymeans of tests (e.g. during the welding proceduretests).

5.4 Tack and auxiliary welds shall be executed toa length of at least 50 mm and require preheatingwhenever it has to be carried out for the other welds.Exceptions to this are tack and auxiliary welds whoseheat-affected zone is reliably and completely remeltedduring subsequent welding, e.g. tack welds for sub-merged-arc welding.

5.5 Preheating shall be applied uniformlythroughout the thickness of the plate or component andto a distance of 4 times the plate thickness, but notmore than 100 mm, on both sides of the weld. Local-ized overheating is to be avoided. Preheating with gasburners should be performed with a gentle, though notsooty, flame. The preheating temperature shall be keptconstant throughout the duration of the welding work.

6. Welding positions, vertical-down welding

6.1 Welding should be performed in the optimumwelding position, and positional welding (e.g. in thePE or PD (overhead) positions) shall be limited to theindispensable minimum.

6.2 For similar and repetitive welding operations,it is advisable to use a (rotating) fixture enabling allwelds to be made as far as possible in “simple” posi-tions, such as the flat (PA) or horizontal vertical (PB)position.

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Fig. 1.28 Threshold wall thicknesses and preheating temperatures for higher-strength hull structural steels(guide values)



6.3 Even after a satisfactory welding proceduretest and approval of the process (cf. F.1.), vertical-down fillet welding may not be used:

– for joining together continuous primary sup-porting members interrupted by transversemembers (e.g. the longitudinal members of theupper and lower girder); the same applies wheretransverse loads predominate,

– for mainly dynamically loaded welded joints(e.g. in the area of engine baseplates, shaftbrackets and rudders),

– on crane components and other lifting gear in-cluding their substructures (e.g. crane pillars),

– at intersections of main girders and in the area ofthe supports or stoppers of hatchway covers.

Note:

Vertical-down welding may be used for joining secon-dary components (e.g. stiffeners) to primary support-ing members, for fillet-welding floor plates to con-tinuous bottom longitudinal girders, for fillet-weldingtransverse bulkheads to the shell plating, and forbetween-decks, interior partitions, etc. which do notaffect the longitudinal or local strength of the vessel.In case of doubt, the extent of the vertical-downwelding shall be agreed with the Society.

6.4 The Society may permit exceptions to theprovisions of 6.3 and increase the extent of vertical-down welding if the welding shop takes special meas-ures to ensure a satisfactory standard of workmanship(particularly the accurate assembly of componentswithout any significant air gaps, adequate root pene-tration and prevention of lack of fusion defects) evenunder normal conditions of fabrication. Such measuresinclude:

– choosing a suitable welding process and appro-priate welding consumables and auxiliary mate-rials which guarantee especially good penetra-tion (cf. F.1.1, note),

– special training and careful selection of weldersfor vertical-down welding (see also 2.2),

– conscientious monitoring of the weld prepara-tion, the welding parameters and the weldingwork (e.g. electrode control) while welding is inprogress,

– production tests at random (fillet weld fracturespecimens) during the course of fabrication.

The Society may demand proof that special measuresof this kind have been taken. In addition, the Societymay require more extensive monitoring or inspectionsof the vertical-down welds.

7. Welding sequence

7.1 The assembly and welding sequence shall bechosen to allow shrinkage to take place as freely aspossible and to minimize shrinkage stresses in thecomponent. Butt joints in areas of plating shall in-variably be fully welded, at least on one side, prior tothe fastening of girders, stiffeners, etc.

7.2 Where individual plates are later welded intoposition in areas of plating (as in the case of erectionholes in the deck or shell plating), the longitudinalseams shall be left unwelded, or shall be opened up, toa distance of approx. 300 mm beyond the transversejoints. The transverse joints shall be welded first, fol-lowed by the longitudinal seams.

7.3 The welding of patches (cf. G.4.2) may beperformed in analogous manner, unless angularpatches with rounded corners or round patches areused.

7.4 In special cases (e.g. when welding togetherparticularly rigid components) and for similar, repeti-tive welding operations (e.g. for the welding of mastsinto ships), it is advisable to set down the assemblyprocedure or welding sequence in a welding sequenceschedule.

7.5 Where welded and riveted joints meet (thesame also applies analogously to other mechanicalmethods of assembly), the welds shall invariably becompleted first, then the riveting adjoining the weldshall be carried out.

8. Performance of work

8.1 The areas of the components to be weldedmust be clean and dry. Scale, rust, cutting slag, grease,paint and dirt shall be carefully removed prior towelding (with regard to overweldable shop primers,see 3.1).

8.2 Components shall not be subjected to anyappreciable movements or vibrations during welding.Parts to be assembled while floating or suspendedfrom cranes shall be clamped prior to the tacking ofthe joint in such a way that no further movement of theparts is possible. Components which have not beenfully welded and are to be handled or turned must havewelded joints of adequate strength.

8.3 Cracked tack welds may not be welded over,but are to be machined out. In multi-pass welding, theslag of the previous run shall be completely removedbefore the next pass. Pores, visible slag inclusions andother welding defects and cracks may not be weldedover, but are to be machined out and repaired.

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8.4 The welding shop shall ensure that the speci-fied welding parameters are adhered to and that thewelding work is expertly performed by competentpersonnel (cf. 2.5 and 2.6).

8.5 Welds must have sufficient penetration andmust display a clean, regular surface with "gentle"transitions to the base material. Excessive weld rein-forcements and undercuts (cf. note to 3.3.2) togetherwith notches affecting the edges of plates and cutoutsare to be avoided.

8.6 Butt-welded joints must display full fusionover the entire cross section, unless a deviation fromthis is authorized in a particular case. For this purpose,the root shall normally be grooved and capped.

Following a successful welding procedure test con-firmed by the Society, single-side welds, e.g. usingceramic backings, may be regarded as equivalent tobutt welds executed from both sides.

Other joints welded on one side only, e.g. using per-manent backings, are subject to approval by the Soci-ety when scrutinizing the relevant drawings. For theevaluation of such welded joints see G.10.3.

8.7 Single- and double-bevel welds are to bemade according to the design specification either withgrooved roots as full-penetration welded joints or witha permitted incomplete penetration at the root or adefined, unwelded root face subject to the appropriatereduction factors (cf. G.10.2). The type of weld is tobe specified in the drawings in each case and musthave received the Society's approval when the draw-ings were scrutinized.

8.8 With fillet welds, particular attention shall begiven to good root penetration. The penetration mustextend at least to the immediate vicinity of the theo-retical root point (cf. G.10.3.4 to 10.3.6). The idealfillet weld section is that of an equal-sided flat-facedweld with smooth (notch-free) transitions to the basematerial. At the ends of web plates, at cutouts and atwelding apertures, the fillet welds shall meet to form acontinuous seam around the root face.

8.9 Major cases of faulty workmanship or defectsin the material may only be repaired with the Sur-veyor's agreement. Minor surface defects shall beremoved by shallow grinding. Defects which penetratemore deeply into the material (e.g. cracks, or tears leftby the removal of welded-on erection aids) shall becleanly machined, ground and repair-welded with anadequate heat input.

9. Welding of higher-strength hull structuralsteels and high-strength (quenched andtempered) fine-grained structural steels

Preliminary remark:

The following provisions apply in analogous mannerto the welding of low-alloy steels tough at subzerotemperatures used for structural members in ship-building, e.g. for cargo tank supports on gas tankers.The tanks themselves are subject to the Rules for Con-struction of Seagoing Ships, Chapter 6 "Liquefied GasTankers". See also Section 3 “Welding of PressureVessels”.

9.1 The steelmaker's instructions and recommen-dations 5 and any conditions arising from the weldingprocedure test shall be implemented when weldinghigher-strength hull structural steels and high-strength(quenched and tempered) fine-grained structural steels.For the use and working of thermo-mechanically rolled(TM) steels, see the appropriate Society rules 6.

9.2 The welding process, welding consumables,weld build-up and thermal practice (preheating, heatinput and interpass temperature) etc. shall be suited tothe base material being welded and shall be main-tained within the appropriate limits during welding.These parameters must match those used during thewelding procedure test. Any appreciable deviationsrequire the Society's consent and are normally contin-gent on additional tests. Wherever possible, multi-passwelding shall be used (particularly for high-strength(quenched and tempered) fine-grained structuralsteels), the final pass being laid down as a "temperbead" run some 2 mm away from the base material.

9.3 When welding high-strength fine-grainedstructural steels it may be necessary to verify not onlythe preheating but also the heat input during welding 7

and the interpass temperatures. These checks shallinvariably be carried out and recorded when weldinghigh-strength quenched and tempered fine-grainedstructural steels. The values must correspond to theenergy per unit length of weld established during thewelding procedure tests and to be laid down in thewelding schedule.

––––––––––––––5 See Stahl-Eisen-Werkstoffblatt 088 "Weldable fine-grained

structural steels: instructions for use with special attention towelding" issued by the German Iron and Steel Association.

6 Regulations for the use and working of thermo-mechanicallyrolled (TM) steels issued by Germanischer Lloyd.

7 Determination of heat input (energy applied per unit length ofweld) "E":

EU volts I amps welding time

length of weld mm

kJ

mm=

⋅ ⋅ ⋅

⋅��

[ ] [ ] [min]

[ ]

6

100



9.4 Special attention is to be paid to the generallymore sensitive hardening properties and the increasednotch sensitivity of higher-strength steels, and espe-cially of high-strength fine-grained structural steels.Unnecessary arc strikes on the surface of the plate,scarring of exposed edges, etc. are to be avoided at allcosts. Where necessary, such blemishes shall becleanly ground out and inspected for incipient cracks.The same applies analogously to auxiliary welds.

9.5 Additional thermal treatments involving ahigh heat input (e.g. flame gouging and flame straight-ening) shall not impair the properties of the materialsand welded joints and shall, if necessary, be avoidedcompletely. In doubtful cases, proof of the satisfactoryperformance of thermal treatments may be demanded.

Note:

Standard flame straightening carried out on higher-strength hull structural steels up to and including E 36may generally be regarded as acceptable providedthat the straightening temperature does not exceed700 °C and that localized overheating or heating ofthe whole area over a longer period of time (e.g. usingheating blocks) and abrupt cooling (e.g. with water)are avoided. The same applies in analogous mannerto the flame straightening of thermo-mechanicallyrolled (TM) steels. Prior to flame straightening ofhigh-strength (quenched and tempered) fine-grainedstructural steels, special agreement with the steelmanufacturer is required. Cf. also SEW 088 5.

10. Welding of stainless and clad steels

10.1 During the entire construction period, suitablemeasures shall be taken in transport, storage and fabri-cation to keep the surface of stainless steels free fromimpurities and extraneous metallic inclusions (due toabrasion from other components or auxiliary erectionsupports).

10.2 Welding processes and welding consumablesshall be selected with due regard to strength and corro-sion aspects, taking into account the recommendationsof the makers of the steel and the welding consum-ables. Unalloyed welding consumables may not beused for welding stainless steels.

10.3 Edges are to be prepared mechanically bycutting or planing. Where a thermal cutting techniquesuch as plasma cutting has to be employed, the edgesshall subsequently be machined clean.

10.4 Clad plates shall invariably be tack-welded onthe "black" side of the support material. Back-upplates are to be used sparingly and must be made ofthe material to which they are to be welded.

10.5 On the side of the cladding and at the cornerjoints of clad plates (as in the case of drain wells), atleast two layers of stainless weld metal are to be laiddown over the support material (cf. G.10.1.6). Wherenecessary, different welding consumables shall be usedfor the intermediate and final runs depending on thebase material.

10.6 Fused weld spatter is to be avoided for rea-sons of corrosion. Such fusion can be prevented byapplying suitable media (e.g. milk of lime) to the sur-face of the plate on both sides of the weld. Wherenecessary, weld spatter is to be machined off and thearea ground smooth.

10.7 To achieve corrosion-resistant seams, post-weld treatment (pickling or passivation) shall be car-ried out in accordance with the instructions issued bythe steelmaker or the manufacturer of the weldingconsumables.

11. Welding of steel castings and forgings

11.1 With steel castings and forgings of largesection, difficult welding or structural conditions,heavily distorted members and low workpiece tem-peratures, a sufficient area surrounding the weldedjoint shall be uniformly preheated throughout the sec-tion.

11.2 Welding operations on steel castings andforgings shall be performed continuously and withoutinterruption, if possible in a single heating cycle.Cooling shall take place gradually and appropriatemeasures shall be taken to prevent over-rapid cooling(screening, wind protection).

11.3 Repair welds (production welds) on steelcastings and forgings may only be undertaken with theSurveyor's consent. Where the work concerned isrelatively extensive, sketches and a description of therepair shall be submitted to the Society's head officefor approval, together with details of the welding pro-cess, welding consumables and auxiliary materials,heat treatment and composition of the base material.

11.4 The Society may stipulate stress relief heattreatment or, in special cases, normalizing heat treat-ment of the components after welding (e.g. for rudder-stocks). The preliminary remark to Chapter 1, Section5, B. applies in analogous manner to the necessaryproof of the properties of the welded joint in heat-treated condition.

11.5 Welds uniting hull structural steels or compa-rable forged or cast steels on the one hand to austeniticstainless steels on the other may not be heat-treated.The same applies in analogous manner to build-upwelds made with austenitic stainless welding consum-

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ables (e.g. on rudderstocks, pintles, etc.). Any post-weld heat treatment which may be required for build-up welds made with other (e.g. heat-treatable) weldingconsumables shall be specified on a case-by-case ba-sis.

12. Welding of aluminium alloys

12.1 The foregoing provisions relating to thewelding of steels apply in analogous manner to thewelding of aluminium alloys above and beyond theprovisions stipulated in the following paragraphs.Special attention is to be paid to cleanliness, thoroughdegreasing and the avoidance of extraneous metallicimpurities. For the use of various types of steel-aluminium welding transition joints (especially thethermosensitivity of the boundary layer between thesteel and aluminium), see Society’s working sheets.

12.2 As a rule, welding grooves are to be thor-oughly cleaned (e.g. with solvents and/or brushes)immediately before welding. Tools and equipmentshall not be used for working on other materials andshall not themselves leave behind extraneous metallicresidues. Welding grooves, welding consumables andauxiliary materials must at all costs be dry beforewelding begins.

12.3 Welded joints on aluminium alloy structuralcomponents used in shipbuilding shall, wherever pos-sible, be made by inert gas welding (MIG welding, or,possibly, TIG welding for small components) per-formed in welding bays protected from the weather.The weld pool must be safely shielded by an adequatesupply of inert gas. Winds and draughts are to beavoided. Care shall be taken to achieve the optimumwelding speed and to minimize the effect of the heaton the base material (softening).

12.4 To avoid end-crater cracking, especially whenmaking intermittent fillet-welded joints, it is advisable(unless welding equipment with crater-filling devicesis used) to retract the bead somewhat prior to with-drawal of the electrode or torch so that the end crateris moved back from the end of the seam to a point onthe weld and to fill the crater.

12.5 Extensive preheating of the faces to 100 °C –200 °C is recommended when welding thick alumin-ium alloy plates and sections. The welds are to beexecuted in a suitable sequence, smoothly and speedilyand, if possible, without a break.

12.6 Cold straightening operations should be per-formed only by pressing, not by hammering. Hotstraightening may only be carried out on alloys suit-able for that purpose in accordance with the aluminiumproducer's instructions. Heating and straightening areto be performed speedily. Temperatures are to be

carefully monitored so as to prevent fusion of thematerial.

13. Underwater welding

13.1 Under certain conditions, the Society mayapprove the welding (normally fillet welds) of compo-nents made of normal-strength hull structural steelswhich have water behind them. The temperature of thewater or component should not be less than 5 °C. Thewelding point must be dry and clean. At least twopasses must be laid down, the last of which shall berun as a "temper bead" over the first pass which hasbeen deposited on the "cooled" component such that itperforms a "post-weld heat treatment" function. Weldsexecuted in this manner shall be subjected to a cracktest.

13.2 As a general principle for underwater weld-ing, only those welding processes and/or weldingconsumables that guarantee a low hydrogen content inthe weld metal shall be used. Welding should be per-formed in a dry environment (chamber pressurized to1 bar or high-pressure chamber). The above applies inanalogous manner to the temperature of the compo-nent, the welding point and the crack test. For therequired welding procedure tests, see F.

13.3 Underwater arc welding in which the arcburns in the water or in a small gas vessel and whereallowance has to be made for a large amount of hydro-gen entering the weld metal may only be used with theexplicit authorization of the Society in each individualcase (even if welding procedure approval has beengranted) and then only for temporary repairs (e.g.sealing welds) to components which are subjected torelatively low loads. Welds executed in this mannershall be replaced by normal welds at the next availableopportunity and until such a replacement is made theSociety may prescribe restrictions in the operation ofthe vessel (e.g. in the operating area).

I. Inspection of Welded Joints

1. General

1.1 In addition to the following provisions, theinspection of welded joints in shipbuilding is governedby the provisions of Chapter 2, Section 4 concerningthe preparation and performance of non-destructiveweld tests.

1.2 As stipulated in Chapter 2, Section 4, D., aninspection schedule shall be submitted to the Societyfor approval before commencing the tests. The Societyreserves the right to modify this schedule even after it



has been approved, and in particular to extend thescope of the tests and/or change the individual testingpositions if necessitated by fabrication operationsand/or test results.

2. Workshop inspections, visual examination

2.1 Workshop inspections are to be carefullyperformed by trained personnel (e.g. welding supervi-sors, cf. C. and H.2.) to ensure the professionally com-petent and satisfactory execution (appearance anddimensional accuracy) and the integrity of the welds.

2.2 After welding operations have been com-pleted and subjected to workshop inspection, the workshall be presented to the Surveyor for checking atsuitable stages of fabrication. For this purpose, weldsshall be readily accessible and shall normally be un-coated. Wherever possible, the results of non-destructive tests shall be presented at this juncture.

2.3 Where the previous inspection has been in-adequate, the Surveyor may reject components andrequire that they be presented again after satisfactoryworkshop inspection and any necessary repair workhas been performed.


3.1 The necessary weld quality as stipulated inTable 1.9 shall be attested by non-destructive tests, thescope of which shall be at least that specified in 6.Should these tests reveal defects of any considerableextent, the scope of the tests shall be increased. Unlessotherwise agreed, tests shall then be performed on twofurther sections of weld of the same length for everyweld section tested and found to be in need of repair.Where it is not certain that a defect is confined to thesection of weld under test, the adjoining weld sectionsshall be additionally tested.

3.2 The Society may stipulate further tests, espe-cially in the event of doubts as to the professionallycompetent and satisfactory execution of the welds. Forthe purpose of monitoring and, where necessary, giv-ing instruction to welders, it is recommended that fromtime to time radiographic inspections should also becarried out on components which are not subject toregular testing.

3.3 The method of inspection to be applied ineach instance shall be selected with due considerationfor the test conditions (shape and dimensions of theweld, nature and location of possible defects, accessi-bility) so that any defects may be reliably detected.The method of inspection requires the Society'sagreement. The Society may stipulate that two or moreinspection techniques be used in conjunction.

3.4 Subject to the provisions of Chapter 2,Section 4, the testing appliances and equipment usedshall conform to modern technical practice and therelevant standards. The tests are to be performed byproperly qualified and experienced testers. For detailsof the prescribed proof of qualification of ultrasonictesters see Chapter 2, Section 4, C.1.).

4. Production specimens

4.1 Production specimens, i.e. test pieces weldedsimultaneously at specified intervals during fabrica-tion, may be called for where the base material, thewelding process and/or the loading conditions requireproof to be provided that the mechanical or othercharacteristics of the welded joints made under fabri-cation conditions are adequate.

4.2 Production specimens shall be welded andtested in a manner analogous to that prescribed inChapter 1, Section 4 and in F., as applicable, in con-nection with welding procedure tests. The scope of thetests and the requirements to be met shall be deter-mined on a case-by-case basis. For production speci-mens in connection with shop primers, see Chapter 1,Section 6, C.

5. Leakage tests

5.1 Where required, leakage tests on weldedseams are normally to be carried out in accordancewith the Rules for Classification and Construction,Part 1, Chapter 1 (e.g. Section 8, B.9.; 12, H.24;A.15., or the Rules for Construction of floating docks)prior to the application of any paint or cement.

5.2 In special cases, and with the approval of theSociety, the hydrostatic tests stipulated for the leakagetests may be replaced by other methods (e.g. testingunder compressed air or vacuum, gas detectionmethod). The Society may call for such methods as analternative or in addition to that stipulated.

6. Weld quality grades, scope of tests, testmethods, requirements

6.1 According to the nature and severity of theapplied loads and their role in ensuring the soundnessof the overall structure, welded joints are to be classi-fied by reference to the influencing factors, their mate-rials, design and service environment (e.g. operatingtemperature) into one of the three weld quality gradesshown in Table 1.9 and shall be identified in the in-spection schedule.

6.2 The individual welded joints are to be classi-fied into quality grades according to their position inthe component concerned, i.e. their position in relation

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to the direction of the main stress, as illustrated by theexamples cited in Table 1.9. Components and weldedjoints not mentioned in the Table or in para. 6.5 shallbe classified in an analogous manner.

6.3 The scope of the non-destructive tests to beapplied to welded joints with quality grade 1 (radio-graphic and ultrasonic inspection) shall be determinedby the following formula according to the type andconstruction of the ship. The number "A" of test posi-tions to be determined refers in the first place to radio-graphs with a (film) length of 480 mm. Where, inaccordance with para. 6.10 or 6.11, ultrasonic tests areperformed instead of radiographic inspection, 1 metreof weld is to be tested in each case in place of the 480mm length of film.

A A c A c A cL P B B H H= ⋅ ⋅ + ⋅0 8, � �

where

AL =L

16 a 0⋅

L = length of ship in [m]

a0 = L : , , [ ]500 0 48 1 0+ ≤ in m

cp = 1,5 with transverse frame construction

cp = 2,0 with mixed transverse and longitudinalframe construction (in the area of theupper and lower girder)

cp = 2,3 with longitudinal frame construction

AB =B

2 5,

B = breadth of ship in[m]

cB = 1,0 for single-hull tankers and comparablemain frame cross sections

cB = 1,3 for dry-cargo freighters and bulk carri-

ers

cB = 1,5 for container ships and double-hull

(chemical) tankers

AH =H2 5,

H = depth of ship in[m]

cH = 0,5 for dry-cargo freighters

cH = 1,3 for tankers, container ships and bulk

carriers

cH = 1,5 for double-hull tankers with additional

longitudinal bulkheads

6.4 The number "A" of test positions determinedin accordance with para. 6.3 shall be distributed insuch a way that roughly two-thirds of the number "A"established are positioned on the welded joints withquality grade 1 described in Table 1.9 and roughly theremaining third on those joints with quality grade 2.Appropriate consideration shall be given to the indi-vidual components specified in para. 6.5. Dependingon the loading conditions, a different inspection den-sity (a different distribution of the total number of testpositions) for the various weld quality grades or com-ponents may be expedient or may be demanded by theSociety.

6.5 The welded joints of the particular compo-nents listed below are to be classified and tested asfollows:

– Deck stringer/sheer strake joint within 0.5 L ofmidship: weld quality grade 1, 100 % ultrasonicinspection if full-penetration welding is requiredin accordance with G.10.2.1.

– Deck stringer/sheer strake joint outside of 0.5 Lof midship: weld quality grade 2, 10 % ultra-sonic inspection if full-penetration welding isrequired in accordance with G.10.2.1.

– Joints between horizontal rudder coupling plateand rudder body (cf. Fig. 1.26): weld qualitygrade 1, 100 % ultrasonic inspection and 100 %surface crack inspection.

– Joints between rudderstock and horizontal cou-pling plate (cf. Fig. 1.27): weld quality grade 1,100 % ultrasonic inspection and 100 % surfacecrack inspection.

– Full-penetration single- and double-bevel T-joints (cf. Fig. 1.13): weld quality grade 1 or 2depending on position of weld, 100 % or 10 %ultrasonic inspection respectively.

– Restarting points in electroslag or electrogaswelds: weld quality grade 1 or 2 depending onposition of weld, 100 % radiography or ultra-sonic inspection, the latter with the test sensitiv-ity increased by 12 dB (see also Chapter 2,Section 4, L.2.5).

– Welds for which proof of fatigue strength isrequired: weld quality grade and inspection de-pend on detail category (cf. catalogue of notchcategories, Rules for Construction of SeagoingShips, Chapter 1, Section 20, A.3. and Table20.3).

6.6 In the case of ships for which no special proofof (longitudinal) strength has to be submitted (gener-ally ships less than 65 m long; cf. the Rules for Con-struction of Seagoing Ships, Chapter 1, Section 5), thenumber "A" (of test positions) may be reduced to 70 %



of the figure prescribed in para. 6.3 and 6.4. The re-duction shall be agreed with the Society in every caseand is to be specially indicated in the inspectionschedule.

6.7 Where the conditions of fabrication remainunchanged, i.e. where to a large extent the same weld-ers are employed in welding the same or similar com-ponents (e.g. in repetition shipbuilding) by means ofthe same welding processes, welding consumables andauxiliary materials, the Society's head office may con-sent to a reduction of the scope of inspection specifiedin para. 6.3 and 6.4. This is conditional on proof beingsupplied of uniformly good results and a relatively lowincidence of repairs, as attested by the results of allinitial inspections performed on welded joints prior toany repairs.

6.8 Where radiographic inspections are per-formed randomly, they are to be carried out chiefly atthe intersections of longitudinal seams and transversejoints, at sectional joints and at joints presenting diffi-culty or requiring to be welded in a fixed position.Joints in girders and stiffeners are to be classifiedsimilarly to those in plating and are to be included inthe inspection.

6.9 Ultrasonic tests may be performed in place ofa proportion (to be specified in every case) of thenumber of radiographs prescribed in paras. 6.3 and6.4. For wall and plate thicknesses of 30 mm and over,ultrasonic testing is to be preferred to radiography as amethod of inspection.

6.10 In special cases, ultrasonic tests may bestipulated as an alternative, or additionally, to radio-graphic inspection, e.g. where certain defects, owing totheir nature and location or to the configuration of theweld, cannot be sufficiently reliably detected or as-sessed by radiography.

6.11 Surface crack inspections shall generally becarried out following the welding of large sections,particularly those of steel castings and forgings as wellas in the case of welds made under stress or at lowtemperatures, large-volume single- or double-bevelwelds (plate thicknesses of about 30 mm and over) andthick fillet welds, e.g. on stern posts, after welding-inof masts and welds on bulkhead stools.

6.12 For the inspection of particular componentsand their welded joints, see 6.5. The Society may, inaddition, call for further tests in conjunction with theapproval of drawings.

6.13 Welded joints and components not coveredby the foregoing provisions shall undergo non-destructive tests whose scope shall be specified in eachindividual case. Where certain components (e.g. themasts of cargo handling gear, liquefied gas tanks andthe pressure hulls of underwater vehicles) are gov-erned by special rules or codes of practice, the provi-sions contained in these shall be implemented.

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Table 1.8 Weld quality grades, scope of inspection, requirements

Weld quality grade 1 2 3

Loading, importance Welded joints which aresubjected to severe static ormainly dynamic stressesand/or which are essentialto the soundness of theoverall structure.

Welded joints which aresubjected to mediumstresses and/or whose fail-ure entails the loss of func-tion of individual compo-nents without endangeringthe structure as a whole.

Welded joints which aresubjected to minor stressesand/or whose failure doesnot entail the loss of func-tion of important compo-nents.

Components, positionof welded joints (forindividual details re-lating to particularcomponents andwelded joints, seepara. 6.5)

Transverse joints in thearea of the upper and lowerflange plate 1 within 0,5 Lof midship 2, e.g. in theouter bottom incl. bilgestrake, longitudinal girders,longitudinal frames,strength deck incl. sheerstrake. Longitudinal girdersand beams, longitudinalbulkheads incl. longitudinalstiffeners, hatchway sidecoamings incl. longitudinalstiffeners.

Joints in shell plating andstrength deck in the imme-diate vicinity of fittings andfixtures (traversing theplate), e.g. rudder heels,masts including the weldsuniting them to the first-named items. Joints in theflanges and webs of maingirders, e.g. in hatchwaycovers, hatch or cantilevergirders and in cantilevermasts. Joints in tank bulk-heads and the bottomstructures of bulk carriersincluding the bulkheadstools.

Joints in or on componentssubjected mainly to dy-namic loads, e.g. shaftstruts, rudder heels, ruddercouplings, (connectingthem to the rudder body)and the main girders of en-gine beds.

Longitudinal bulkheads 3

in the area of the upperand lower hull flange plate,transverse joints in the areaoutside 0,5 L of midship 2,and joints in the rest of theshell plating and in thedouble bottom.

Joints in watertight trans-verse bulkheads of dry-cargo freighters and in webframes.

Joints in hatchway covers,end bulkheads of super-structures and deckhouses,and joints in transversegirders.

Joints in subordinate com-ponents such as decks, par-titions and their stiffenersnot included in the mainstrength structure, decks ofsuper-structures and deck-houses, joints in bulwarks,etc.



Table 1.9 Weld quality grades, scope of inspection, requirements (continuous)

Weld quality grade 1 2 3

Scope and method ofinspection

Visual inspection and ran-dom dimensional checks.

Non-destructive tests in ac-cordance with 6. (randomchecks with greater inten-sity of inspection).

Leakage and other tests,where required.

Visual inspection, randomdimensional checks incases of doubt.

Non-destructive tests in ac-cordance with 6. (randomchecks with lesser intensityof inspection).


Visual inspection

In cases of doubt, non-destructive tests in accor-dance with 6.


Requirements, weldquality 4

Welded seams to be freefrom cracks, lack of fusionand root defects, slag lines,coarse pore clusters andslag inclusions, prominentundercuts, etc. in confor-mity with assessment cate-gory B in accordance withEN 25871/ISO 5817 relat-ing to steel (Annex A ofChapter 2) and EN 30042/ISO 10042 relating to alu-minium (Annex B ofChapter 2), as applicable.) 5

Welded seams to be freefrom cracks, major lack offusion and root defects,long slag lines, coarse slaginclusions, uninterruptedpores, coarse pore clusters,major undercuts, etc. inconformity with assess-ment category C in accor-dance with EN 25817/ISO5817 relating to steel (An-nex A of Chapter 2) andEN 30042/ISO 10042 re-lating to aluminium(Annex B of Chapter 2), asapplicable.5

Welded seams to be freefrom cracks, major root de-fects and slag inclusions,uninterrupted pores, severeundercutting, etc. in con-formity with assessmentcategory D in accordancewith EN 25817/ISO 5817relating to steel (Annex Aof Chapter 2) andEN 30042/ISO 10042 re-lating to aluminium(Annex B of Chapter 2),as applicable.5

1 In accordance with the Rules for Construction of Seagoing Ships, Chapter 1, Section 3, B., this is the area extending to at least 0.1 H and0.1 H' above and below respectively. The inspection shall, however, invariably cover the entire sheer strake and bilge strake area to-gether with continuous longitudinal members (e.g. hatchway side coamings and crane rails) above the strength deck. Where partial use ismade of higher-strength steel, the inspection shall embrace the whole area of this steel in terms of height, and in the case of containerships and similar vessels it shall cover the entire area of the upper box girders.

2 In ships with large deck openings, i.e. ships with large hatches (such as container ships), the transverse joints in the upper hull girderflange fore and aft of 0.5 L (generally the entire hatchway area) shall also be assigned to weld quality grade 1 where necessary (e.g. be-cause of the torsional stresses imposed).

3 At weld intersections the adjoining 300 mm of longitudinal seam are to be classified identically with the relevant transverse joints.4 See also the note to H.3.3.2. Comparable provisions contained in other standards, etc., may also be used for assessment purposes, subject

to the Society's consent.

Where components or welded joints have been dimensioned according to fatigue strength criteria on the basis of a specific detail cate-gory ∆σR (see Rules for Construction of Seagoing Ships, Chapter 1, Section 20, Table 20.3), the quality grade must also meet the re-quirements of this detail category. Code of practice 0705 issued by the Deutscher Verband für Schweißtechnik e.V. [German WeldingSociety] contains instructions for the classification of individual irregularities in correlation to the assessment groups in conformity withEN 25817/ISO 5817 relating to steel.

5 With regard to the requirements for ultrasonic testing, see Chapter 2, Section 4, L.5 (Table 4.4).

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Section 2 Welding of Steam Boilers Chapter 3Page 2–1

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Section 2

Welding of Steam Boilers

Preliminary remark:

The following rules relating to the welding of steamboilers comply with or incorporate the TechnicalRules for Steam Boilers (TRD). Subject to the ap-proval of the Society, other codes of practice such asthe ASME Boiler and Pressure Vessel Code, Section 1may also be adopted for the fabrication and testing ofwelded steam boilers (the following rules being appli-cable in analogous manner). Cf. also Chapter 1,Section 1, B.1.4.

A. General

1. Scope

1.1 These Rules apply to the fabrication andtesting of welded steam boilers, superheaters, feedwater preheaters and similar pressurized componentsof the steam boiler installation.

2. Other relevant rules

2.1 The provisions of the Rules for ConstructionI, Part 1, Chapter 2, Section 7a shall also be compliedwith in the design and dimensioning of steam boilercomponents.

2.2 For the fabrication and testing of steam boilerinstallations intended for ships sailing under the Ger-man flag, it is essential to comply with the "Technis-che Regeln für Dampfkessel" (Technical Rules forSteam Boilers) of series TRD 200 in conjunction withseries TRD 100.

3. Assessment of welds

3.1 Tensionally stressed longitudinal welds maygenerally be assessed with a weld factor up to V = 0,8,provided that they meet the requirements specified inChapter 1, Section 1 and 2 and the following para-graphs.

3.2 A higher assessment up to V = 1,0 may beapplied if a production test and non-destructive testingin accordance with para. I.11. have been successfullyperformed on the finished component.

B. Approval of Welding Shops, Welding Per-sonnel

1. All welding shops intending to performwelding work within the scope of these rules mustsatisfy the requirements applicable to welding shopsand personnel set out in Chapter 1, Section 2 and musthave been approved by the Society. Applications forapproval shall be submitted by the welding shops ingood time before starting the welding work, enclosingthe information and documentation prescribed inChapter 1, Section 2, A.3.

2. The welding personnel (welders and weldingsupervisors) and, where applicable, inspectors andinspection supervisors must satisfy the requirementsset out in Chapter 1, Section 2, B.2., B.3. and B.4 andbe recognized by the Society. For the welder’s quali-fication tests, see Chapter 1, Section 3.


1. The manufacturer shall submit to the Society,for inspection, drawings and other relevant documentscontaining at least the following information:

– The materials and welding consumables to beused,

– The welding process and the location and shapeof the weld,

– The type of heat treatment, if required,

– The acceptable working pressure,

– The design temperature,

– The operating temperature,

– The test pressure,

– The weld factor "V" used as a basis for calcula-tion,

– The nature and scope of the non-destructivetests,

– The nature and scope of the production tests.

2. If the quality or good working order of acomponent cannot be guaranteed or is in doubt due toinadequate or missing information in the manufactur-ing documents (e.g. production drawings), the Societymay demand appropriate improvements.

Chapter 3Page 2–2

Section 2 Welding of Steam Boilers II - Part 3GL 2000

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3. The welding shops shall ensure by means ofregular in-house quality inspections during fabricationand on completion of the welding work that this workhas been performed competently and satisfactorily (cf.Chapter 1, Section 1, F.). For the duties and responsi-bilities of the welding supervisor, see also EN 719/ISO 14731.

4. The welding shops are responsible for ensur-ing that the welding work conforms to these Rules, theapproved manufacturing documents, any conditionsstipulated in the approval documents and the lateststate of welding practice. The inspections and checksto be performed by the Society’s Surveyor do notrelieve the welding shops of this responsibility.

5. With regard to quality inspections and theresponsibilities involved in awarding subcontracts toindependent branches or suppliers or to approved ornon-approved outside firms working in the weldingshop (subcontractors), see Chapter 1, Section 1, F.Subcontracting of work or employment of temporaryworkers shall be notified to the Society.

6. The scope of the required quality inspectionsdepends on the construction project in question. It isessential to ensure, however, that the intended materi-als, welding consumables and auxiliary materials areused and that the weld preparation, assembly, execu-tion of the tack and final welds and the dimensionalaccuracy and completeness of the welded joints meetsthe requirements stated in para. 3. For non-destructivetesting of the welded joints and production tests haveto be performed, see I.

7. Following internal inspection and, if neces-sary, repair by the welding shop, the components shallbe presented to the Society's Surveyor for checking atsuitable stages of fabrication. For this purpose theyshall be readily accessible and shall normally be un-coated. Where the previous inspection has been inade-quate, the Surveyor may reject components and re-quire that they be presented again after satisfactoryworkshop inspection and any necessary repair workhas been performed.



1. The materials selected must be appropriatefor the intended purpose, with allowance made formechanical and thermal stresses. The characteristics ofmaterials subjected to further processing shall be suchthat they are able to withstand the operating loads.

2. Welded structures may only be fabricatedusing base materials of proven weldability. The in-tended materials must comply with the requirementsset out in the relevant sections of Part 1, Metallic Ma-terials, Chapter 2. Other comparable materials mayonly be used after the Society has given its approval ineach individual case.


1. The welding consumables must enable awelded joint to be made which is appropriate to thebase material, the operating temperature and the con-ditions of service. The suitability of the welding con-sumables must also have been verified under the con-ditions prevailing in further processing.

2. All the welding consumables and auxiliarymaterials used (e.g. covered electrodes, wire-gas com-binations, wire-flux combinations, etc.) must havebeen approved by the Society in accordance withChapter 1, Section 5. They may also, however, beapproved if tested at the same time as the weldingprocedure and restricted to the user’s works (cf.Chapter 1, Section 4, B.3.2 and Section 5, A.1.4).

3. For joints between different materials, thewelding consumable shall wherever possible begeared to the lower-alloyed material or the materialwith the lower strength.

4. Welding consumables and auxiliary materialsspecified in a procedure approval document with amaker’s or brand name (cf. F.3.5) may only be re-placed by equivalent consumables approved by theSociety with an appropriate quality grade if this isexplicitly stated in the respective approval document.Failing this, the Society's agreement shall be obtained.

5. The welding consumables and auxiliary ma-terials may only be used in the approved weldingpositions. The manufacturers' recommendations andinstructions for welding (e.g. type of current and po-larity) shall be followed.

6. The welding consumables and auxiliary ma-terials (especially hydrogen-controlled, basic-coveredelectrodes and basic welding fluxes) shall be re-dried

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before use in accordance with the manufacturer's in-structions (observe maximum drying time!) and storedin a dry place (in heated containers or the like) at theworkplace.

Note:

The DVS guideline 0504 "Handling, storage and re-drying of covered electrodes" and the DVS regulations0914 "Use and storage of welding fluxes for sub-merged-arc and electro-slag welding" issued by theGerman Welding Society (Deutscher Verband fürSchweißtechnik e.V) contain detailed instructions onthis subject.

F. Welding procedure tests

Preliminary remark:

In contrast to earlier issues of these Rules, weldingprocedure tests shall be performed in accordance withEN 288 or ISO 9956, as applicable. This paragraphessentially covers requirements applicable to thewelding of steam boilers over and above those set outin EN 288-3 and ISO 9956-3.

1. General

Only those welding procedures shall be employedwhose satisfactory operational handling and adequatequality properties have been verified as part of awelding procedure test under production conditions atthe user’s works. The general requirements set out inChapter 1, Section 4 shall be observed. The weldingprocedures must have been approved by the Societyfor the particular welding shop in question.

2. Welding of test pieces, welding procedurespecification (WPS)

2.1 A preliminary "manufacturer’s" weldingprocedure specification (pWPS) setting out all themajor parameters shall be produced by the weldingshop for the welding of test pieces in accordance withEN 288-2 or ISO 9956-2, as applicable (see Chapter 1,Annex D).

2.2 The Society’s expert shall select one of thewelders whose names are to be supplied by the manu-facturer to weld the test pieces.

2.3 The test pieces shall be made from materialswhose properties are proven in accordance with therequirements specified in Part 1, Metallic Materials,Chapter 2. Their strength shall be at least 40 N/mm2

higher than the minimum tensile strength of the mate-rial group. Pre-treatment and after-treatment of thewelded joints by preheating, heat treatment and thelike is only permitted if stipulated for these materialsduring actual fabrication.

2.4 The types of weld and welding positionsemployed in the fabrication process shall be qualifiedin the welding procedure test.

2.5 The form and dimensions of the test piecesare specified in EN 288-3/ISO 9956-3 or, where appli-cable, stipulated in para. 2.6.

2.6 For welding of sockets, nipples, etc., thefollowing shall be made:

– 2 socket welds in accordance with standardworkshop practice or

– 2 test pieces as shown in Figs. 2.1a) and 2.1b).

��

��

��

��

��

��

��

��

��

��

Fig. 2.1 Test pieces for welding of sockets andnipples, inserted (left) and through-type(right)

3. Test principles, delimitation of scope

The qualification of the welding procedure shall beascertained in accordance with EN 288/ISO 9956 Part1, para. 5.1.1 by means of welding procedure qualifi-cation tests, for steel in accordance with EN 288/ISO9956 Part 3.

The test is valid within the limits described in para.3.1 to 3.7.

The scope of the welding procedure test is specifiedby the Society in writing. Any exceptions require theperformance of a supplementary test, the scope ofwhich shall be decided by the Society. Productiontests may be recognized as supplementary tests.

3.1 Material groups

Above and beyond the grouping system of EN288/ISO 9956 Part 3, para. 8.3.1.1, Table 3, the fol-lowing provisions shall be observed:

a) For materials which have to satisfy particularcorrosion conditions (e.g. resistance to causticcracking) the welding procedure tests shall begeared to these.

b) A welding procedure qualification performed ongroup 1 killed steel does not apply to unkilledsteels unless they were welded using basic cov-ered electrodes or wire-flux combinations withbasic flux.

Chapter 3Page 2–4


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c) The materials 15NiCuMoNb5 and 17MnMoV6-4 shall be classified as group 2 materials.

Approval is also granted for the following furthermaterial combinations in addition to those stipulatedin EN 288/ISO 9956 Part 3, Table 4 but under thefollowing conditions (see Table 2.1).

Deviating from EN 288/ISO 9956 Part 3, Table 4, awelding procedure test available for the combinationgroup 9 welded to group 2 does not incorporate thecombination group 9 welded to group 3.

Depending on material composition and/or the type ofpost-weld treatment required, the Society may alsolimit the scope to the base material used in the weld-ing procedure test.

3.2 Welding process

Recognition applies only to the welding process em-ployed in the welding procedure test.

3.3 Gas welding

In gas welding a test performed on the wall thickness tshall apply to the wall thickness range 0,75 t to 1,25 t.

3.4 Welding parameters

Welding procedure tests performed on multi-passwelds do not apply to single-pass welds.

3.5 Welding consumables and auxiliary mate-rial

The requirements of EN 288/ISO 9956 Part 3, para.8.4.5 do not apply if the filler metal used is of thesame type and has been approved by the Society to beunder the scope of the welding procedure qualification(cf. E.4.).

3.6 Heat treatment

The welding procedure test applies to the heat treatedcondition existing at the time of the test. Heat treat-ment of the test piece shall be performed so that a heattreated condition is achieved which is comparable tothat of the component.

3.7 Special cases

For special cases, for example projection welds,welding of clad steels, stud welds and difficult repairsto be performed in the course of fabrication on steelswhich are susceptible to cracking due to hardening ofthe heat affected zone, welding procedure tests arenecessary which are geared to these particular cases.The tests required and their scope are specified by theSociety in each individual case.

4. Tests, scope of tests

Testing comprises both non-destructive and destruc-tive tests and shall be performed in accordance withEN 288/ISO 9956 Part 3, para. 7.

Deviating from EN 288/ISO 9956 Part 3, para. 7.1 andTable 1, the following specimens shall also be takenfrom the test pieces:

a) One all-weld metal tensile test specimen with adiameter of 10 mm and L0 = 5 d shall also betaken in the case of test pieces more than 20 mmthick in materials where the effect of the weldmetal caused by the welded joints may be sig-nificant.

This applies to steels in material groups 4 and 6and also for the steels specified in para. 3.1.c.

Table 2.1

Welding procedure qualification available for asteel group or combination joint Suitable for the following combination joints

5 (10CrMo9-10) welded with 44 welded with 5 (13CrMo4-5)4 welded with 14 welded with 2 (Re < 430 N/mm2)

55 welded with 15 welded with 2

6 welded with 46 welded with 56 welded with 26 welded with 1

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b) Notched bar impact test specimens shall betaken from the centre of the weld metal for eachwelding position in the case of:

– plates: all materials with a nominal wallthickness > 5 mm

– tubes:

– 14 MoV6-3 and X20CrMoV12-1 with anominal wall thickness > 10 mm,

– 16 Mo 3 with a nominal wall thickness> 20 mm,

– all other grades of steel conforming to DIN17175 and DIN 17177 with a nominal wallthickness > 30 mm,

– other grades of steel above the nominal wallthicknesses as specified in the standards or inthe GL approval document for the base mate-rial.

c) Micrographic specimen for alloy steels 1. Thestructure shall be described and verified bymeans of photographs.

d) Analysis of the weld metal for alloy steels 1.

5. Test requirements

The irregularities in the test piece must fall within thelimits specified for quality level B in accordance withEN 25817/ISO 5817, exceptions being: excessiveweld reinforcement (butt and fillet welds), excessiveroot reinforcement and excessive fillet weld thicknesswhich fall into quality level C.

For the mechanical and technological tests, Table 2.2applies.

6. Storage of specimens

The tested specimens and the remaining portions ofthe test pieces shall be stored until the report on thewelding procedure test has been completed (cf. alsoChapter 1, Section 4, C.3.).

7. Validity, extension of welding proceduretests

The validity of a welding procedure test is generally 1year provided that the preconditions under which itwas granted have not significantly changed. It may becontinued by means of regular production tests (seepara. I.11).

In addition to production tests and tests performed onwelded components (cf. para. I.) non-destructive testsmay, given certain preconditions, also be recognizedby the Society for continuing the validity.

––––––––––––––1 For the classification of steels (unalloyed and alloyed), see

EN 10020.

The welding procedure test shall be repeated if there isa break in the fabrication of steam boilers or steamboiler components lasting longer than one year.

G. Welding Technique

1. Welds must exhibit full penetration over theirentire cross section and must not have any cracks orlack of fusion defects. Wherever possible, the rootshall be grooved and capped.

2. When welding plates whose thicknesses dif-fer by more than 20 % or more than 3 mm, the thickerplate shall be bevelled to the thickness of the thinnerplate at a maximum angle of 30 °.

3. In the case of shells consisting of severalrings, the longitudinal seams shall be staggered.

4. Fillet welds on lapped joints are only permit-ted in special cases and are then to be made only asdouble-sided circumferential welds up to a wall thick-ness of 15 mm.

5. Corner welds and similar welded joints whichare subjected to considerable flexural stresses underadverse conditions of fabrication or service are onlyallowed if the Society raises no objection to themethod of execution.

6. Holes and cut-outs in or immediately adjacentto welds, especially longitudinal welds, shall beavoided wherever possible.

7. Welding of components in cold-formed areaswhere the outer fibres have been stretched by morethan 5 % (Dm < 20 × s for cylindrical shell rings) is

only allowed if the effects of cold-forming have beeneliminated by means of appropriate heat treatment.

This generally has to be accomplished by normalizingheat treatment or quenching and tempering. This re-quirement may be waived if proof is furnished that theproperties of the material are no more than insignifi-cantly impaired with regard to the intended use.

8. Every weld in a boiler component shall bemarked in such a way that its location remains recog-nizable and the welder concerned can be identified atany time. Both of these may be evidenced either bystamping the weld accordingly or by making entries indrawings, welding schedules or other records.

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Table 2.2 Requirements applicable to the mechanical and technological tests

Type of test Requirements

Tensile testtransversely to weld

As stipulated for the base material or in the test of product suitabil-ity for the welding consumable.

Hot tensile test on a specimentaken from the weld metal

As stipulated for the base material or in the test of product suitabil-ity for the welding consumable.


on specimen from centre of weld

As stipulated for the base material in transverse direction.

For welded joints in austenitic steels, ≥ 40 J with ISO-V-notch speci-mens..

The test shall be performed at room temperature.

Bendingangle Strength category 2 Mandrel

diameter

180° 3

Ferritic steels with a minimum ten-sile strength < 430 N/mm2

Minimum tensile strength≥ 430/Nmm2 to 460 N/mm2

2 × a

2,5 × a

180° 3High-temperature austenitic steelsFerritic steels with a minimum ten-sile strength ≥ 460/Nmm2

3 × a

If a bending angle of 180 ° is not attained, the following applies:

≥ 90°Elongation (L0 = width of weld + thickness, sym-metrical to weld) ≥ minimum elongation A5 of basematerial.

Technological bend test

or < 90°Elongation over width of weld > 30 % 4 and faultlessappearance of fracture.

Metallographic examination

The macrographic specimen of the welded joint must reveal a satis-factory weld build-up and full penetration of the weld.

The micrographic section is to be examined for cracks.

Cracks are not acceptable.

In the case of welded joints in austenitic steels, hot cracks are ac-ceptable provided that they are few in number and widely scattered.

Hardness testing

The hardness in the heat-affected zones shall not exceed 350 HV 10.Hardness peaks in excess of this figure in narrow transition zonesshall not give rise to complaints if the outcome of the technologicaltests meets the requirements.

1 For specimens less than the standard 10 mm in width, the impact energy requirements decrease in proportion to the cross section ofthe specimen.

2 The tensile strength applies to the area of least thickness.3 The 180° requirement is deemed to have been met if the bend test was performed according to EN 910/ISO 5173 (DIN 50121) and

pressure was applied by the supports without cracks appearing.4 Different values may be agreed on for steels not welded with matching filler.

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H. Post-Weld Heat Treatment

1. Welded components must be heat-treatedafter welding in accordance with the stipulations ofthe relevant standards or the Society's approval docu-ment.

1.1 The post-weld heat treatment shall normallyconsist of stress relief heat treatment.

1.2 Components fabricated from steels whichhave undergone normalizing heat treatment shall besubjected to normalizing heat treatment if:

– the required characteristics of the welded jointcan only be established by normalizing heattreatment

or

– the component has undergone hot-forming afterwelding, unless hot-forming was completedwithin a temperature range equivalent to nor-malizing heat treatment.

1.3 Components fabricated from quenched andtempered steels shall be subjected to quenching andtempering if:

– the required characteristics of the welded jointcan only be achieved by quenching and tem-pering

or

– the component has undergone hot-forming afterwelding.

If, in the case of air-hardened and tempered steels, thehot- forming of the component was on the whole per-formed under the conditions applicable to normalizingheat treatment, tempering alone is sufficient.

1.4 For such welded joints, preheating and treat-ment by quenching and tempering or by temperingalone should as a rule be carried out in accordancewith the instructions of the material or consumablemanufacturer. A special means of heat treatment shallbe specified if, for instance, the material or the weldmetal is hardened to an unacceptable degree duringwelding.

For high-alloy steels with a ferritic or austeniticstructure, the need for and method of heat treatmentshall be determined on an individual basis.

2. Post-weld heat treatment may be dispensedwith if the following conditions are met:

2.1 Prior to welding, the materials must be in theheat-treated condition specified in the relevant stan-dards or in the Society's approval document. Thiscondition is also deemed to be met if the required

heat-treated condition is only attained during subse-quent fabrication.

2.2 The nominal wall thickness at the joints maynot exceed 30 mm.

2.3 In the chemical composition (melt analysis)of the base material and the weld metal, the followingcontents may not be exceeded:

– C 0,22 %, Si 0,50 %, Mn 1,40 %, Cr 0,30 %,Cu 0,30 %, Mo 0,50 %, Ni 0,30 %, V 0,20 %,

In this context, the following conditions shall also besatisfied:

– Cr + Ni ≤ 0,30 % und Mn + Mo + V ≤ 1,6 %.

These conditions may be relaxed in the case of steelswhich have been rendered resistant to brittle fractureand hardening by special metallurgical measures.Their suitability and properties shall be demonstratedto the Society after an adequate period of proving. Thesteels' resistance to brittle fracture, resistance to hard-ening and weldability must be equivalent to those ofsteels falling within the above analytical limits. Forthe weld metal, at a C content ≤ 0,10 % the Si contentshall be ≤ 0,75 %, the Mn content ≤ 2,0 % and thesum of the Mn, Mo and V contents ≤ 2,5 % if weldingconsumables are used which produce a weld metalwith a particularly high toughness, e.g. by usingwelding consumables with basic characteristics.

3. Post-weld heat treatment may be dispensedwith for butt welds located in the flue gas stream intubes made of 13CrMo44 steel with no lower limit forthe average wall temperature and in pipes made of10CrMo9 10 steel above an average wall temperatureof approx. 490 °C, provided that the outside tube di-ameter does not exceed 63,5 mm and the wall thick-ness does not exceed 10 mm. Butt welds between thetubes and tube nipples are included under this provi-sion, even if they are not located in the flue gasstream.

4. Components shall generally be heat-treated intheir entirety. In the case of stress relief heat treatmentand tempering heat treatment, an exception from sen-tence 1 may be made if

– in the case of cylindrical components, a suffi-ciently wide cylindrical section or

– in the case of longitudinal welds in open shellrings without a circumferential weld, the weldzone over a sufficient width

is heat-treated by (continuous) uniform heating, onboth sides if possible, provided that the Society's ex-pert raises no objection. In both cases, thermal stressesmust not be allowed to shift to parts subject to flexuralstresses (e.g. flanges or cut-outs).

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5. Welding of small parts into and onto thewalls of steam boilers shall generally be carried outprior to heat treatment. This especially applies if:

– the nominal wall thickness of the basic structureexceeds 30 mm (see para. 2.2),

– the contents specified in para. 2.3 are exceeded,

– cold forming takes place in conjunction withwelding.

When welding in individual small parts, heat treat-ment may be dispensed with if the properties of thematerials to be joined and the welding process enablethe making of a satisfactory welded joint which isappropriate to the conditions of service and the work-ing temperature.

6. Documentary proof of the heat treatmentsdescribed in para. 1.1 to 1.4 shall be provided bymeans of a works certificate to EN 10204 or ISO10474, as applicable (DIN 50049), which shall statethe method, temperature and duration of the heattreatment and the method of cooling. Any special heattreatment, e.g. temporary cooling after welding priorto tempering treatment, shall be recorded in the workscertificate.

I. Inspection of Welded Components

1. Where no production tests are carried out onwelded shell rings which have undergone hot bendingor heat treatment, for materials with a minimum ten-sile strength ≥ 440 N/mm2 2 and alloy steels 1 a testpiece taken from the plate used and stamped by theSociety's expert shall be subjected to the same treat-ment as the shell ring. A tensile test and a notched barimpact test (three test specimens) shall be performedon specimens from this test piece to establish the ulti-mate condition of the material of the drum or the shellring.

2. Fully welded drums for water-tube boilerswith upset or prewelded ends shall be subjected to thetests specified in para. 2.1 to 2.4.

2.1 The drums shall be subjected by the Society'sexpert to a hydraulic pressure test at 1,5 times theworking pressure, subject to the limitation that theresulting stress shall not exceed 0,9 times the yieldstrength at 20 °C, taking into account the positivediameter tolerance and the negative wall thicknesstolerance. The component shall exhibit no leaks dur-ing the hydraulic pressure test and no permanent de-

––––––––––––––2 The threshold may be raised to 470 N/mm2 if proof is fur-

nished that stress relief heat treatment is not liable to result inan unacceptable reduction in the yield stress.

formation afterwards. This test may be dispensed withif the complete longitudinal and circumferential weldshave been subjected to non-destructive testing byappropriate means with satisfactory results.

2.2 Where dished drums are fabricated from steel

with a minimum tensile strength ≥ 440 N/mm2 2 and aminimum yield strength at room temperature≥ 320 N/mm2 and the nominal wall thickness isgreater than 30 mm, following the final heat treatmentthree core samples shall be drilled out of the metal,one being taken from each end of the cylindrical partand one from the middle of the drum. The exact loca-tion of the sampling points, which shall be offset rela-tive to each other by approx. 120° if possible, shall beindicated to the drum manufacturer by the steamboiler manufacturer in good time. The core samplesshall be at least 60 mm in diameter to enable onespecimen for tensile testing and one set of threespecimens for notched bar impact testing to be pre-pared. The specimens shall be cut out transversely tothe direction of rolling of the plate; if possible, thetensile test specimen should be located 1/6 of the wallthickness below the surface. Of the three notched barimpact test specimens, one shall be taken from each ofthe extremities and one from the middle of the coresample.

2.3 Where cold-bent shell rings with a degree ofdeformation > 5 %, hot-bent shell rings or dishedhalf-drums are fabricated from steel with a minimumtensile strength ≥ 440 N/mm2

2 and a minimum yieldstrength at room temperature ≥ 320 N/mm2 and thenominal wall thickness is greater than 30 mm, fol-lowing heat treatment a sufficiently wide ring shall becut off, from which one specimen for tensile testingand one set of three specimens for notched bar impacttesting shall be taken transversely to the direction ofrolling of the plate. Alternatively, the procedure de-scribed in para. 2.2 may be followed.

2.4 If, in the situations described in para. 2.2 and2.3, the final heat treatment consists solely of stressrelief heat treatment or if working is carried out onlywithin the stress relief heat treatment range and is notliable to change the properties of the material substan-tially, the specimens prescribed in para. 2.2 and 2.3may be prepared beforehand and heat-treated in thesame manner. In this case, the temperature of thespecimens over their length and the extent of thevariation in temperature shall be measured and re-corded.

3. The requirements applicable to the mechani-cal and technological tests stated in para. 1. and 2. aregoverned by the provisions of Part 1, Metallic Materi-als, Chapter 2, Section 1, E. and Section 6, A.

In testing of the base material after heat treatment, anegative tolerance of 5 % applies in individual cases

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to the minimum yield strength and the minimum ten-sile strength if a load in the area of the high-temperature yield strength is applied.

The yield strength and tensile strength may be lessthan the minimum by more than 5 %, up to 10 %, ifproof is furnished that

– heat treatment has been satisfactorily carriedout,

– the requirements applicable to the elongation ofthe base material are met,

– the requirements applicable to the impact energyof the base material are met,

– the dimensional design based on the high-temperature yield strength established is stilladequate.

Where loads in the area of the creep strength are ap-plied, the yield strength and the tensile strength maybe less than the specified minimum by max. 10 %.

4. An internal and external inspection shall becarried out on the completed shell rings and drums,and especially of the welds and adjacent areas and thedished ends. For the inspection, the components shallhave a smooth external and internal surface corre-sponding to the condition as manufactured, to ensurethat significant surface defects can also be detected;the internal surface is to be descaled. At the sametime, measurements shall be carried out to determine:

4.1 External circumference

The measurements shall be spaced at approx. 1 mintervals over the entire length of the component. Themeasurements of the external circumference shall beused to determine the average outside diameter. Theoutside diameter of the shell rings and drums may notvary from the stipulated outside diameter by morethan ± 1,0 %.

4.2 Out-of-roundness

The measurements shall be spaced at approx. 1 mintervals over the entire length of the component.

The out-of-roundness

UD D

D Dm ax=

⋅ −+

⋅2

100max min

min%

� �

of the drums and shell rings following final heattreatment shall be:

– For non-heat-treated or stress relief heat-treateddrums and shell rings where the wall thicknessis > 1 % of the nominal diameter: 1 % max.

– For normalizing heat-treated, quenched andtempered or dished drums: 2 % max.

In calculating the out-of-roundness, the elastic defor-mations arising from the component's own weightshall be discounted. Isolated bulges and dents mustalso lie within the tolerances. In addition, the bulgesand dents must have a flat profile and their depth,measured as a deviation from the normal roundness orfrom the shell line, as applicable, must not exceed 1 %of the length or width of the dent or bulge.

The out-of-roundness need not be determined wherethe wall thickness is < 1 % of the nominal diameter.

4.3 Camber or flattening

The degree of camber or flattening in the area of thelongitudinal welds, measured as a deviation from thenormal roundness with a template length of 500 mm,may not exceed the dimension "a".

Depending on the ratio of the average diameter dm tothe wall thickness se of the drum or shell ring, thefollowing applies:

– a ≤ 10 mm for shell rings:d

sem < 40

– a ≤ 5 mm for shell rings:d

sem ≥ 40 .

4.4 Axial non-linearity

The degree of axial non-linearity may be:

– For shell rings: up to 0,3 % of the cylindricallength

– For drums: up to 0,5 % of the cylindrical length

4.5 Wall thickness of welds and adjoiningplate areas

The wall thickness in the plate must lie within thetolerance permitted for the plate.

5. If special conditions of fabrication apply tothe components stated in para. 1 and 2, i.e. wherelarge wall thicknesses or difficult-to-weld steels areused, non-destructive testing of the welds may also benecessary for an evaluation of up to V = 0,8. Weldedjoints in steels which, according to the report of theSociety's expert, are subject to a non-standard methodof heat treatment shall undergo the tests stipulated inthe report, especially hardness testing and ultrasonicinspection. Proof of the outcome of these tests shall beprovided by acceptance test certificate A or B to EN10204 or ISO 10474, as applicable (DIN 50049) inaccordance with the Society's report.

6. An acceptance test certificate A to EN 10204or ISO 10474, as applicable (DIN 50049) showing thatthe requirements stated in para. 3. and 4. are met shallbe furnished where one of the following limits is ex-ceeded:



I

– Overall length of cylindrical shell ring in excessof 2500 mm,

– Specified external diameter in excess of1200 mm,

– Acceptable working pressure in excess of16 bar,

– Weld factor higher than V = 0,8.

Below these limits, an acceptance test certificate B toEN 10204 or ISO 10474, as applicable (DIN 50049) issufficient.

7. An internal and external inspection of thecompleted smooth or corrugated furnaces, and espe-cially of the welds and adjoining areas, shall be car-ried out. During the inspection the following shall bemeasured:

7.1 Deviation from specified external circum-ference

The measurements shall be spaced at approx. 1 mintervals over the entire length of the components. Thepermitted deviations from the external circumferencespecified in the order in a measurement cross sectionare:

– For corrugated furnaces:

non-corrugated portion ± 15 mm

corrugated portion

– pull-through type + 0 mm– 75 mm

– other corrugated tubes + 15 mm– 60 mm

– For smooth furnaces:

at the ends of shell ringsover a distance of 250 mm ± 15 mm

in the remainder of the + 0 mmcylindrical shell rings – 75 mm

– For smooth furnaces withflanged ends:

cylindrical portion + 0 mm – 75 mm

7.2 For corrugated tubes, difference betweenmaximum outside diameter and associatedinside diameter

The measurements shall be spaced at approx. 1 mintervals over the entire length of the components. Forcorrugated tubes, the difference between the maxi-mum outside diameter and the inside diameter in thecorrugations shall equal the specified dimension witha maximum negative tolerance of 20 mm.


The measurements shall be spaced at approx. 1 mintervals over the entire length of the components. Thewall thickness shall invariably be measured at the endsof the shell rings and at any point where a decrease inwall thickness is significant.


UD D

D D

m ax=

⋅ −

+⋅

2100

min

max min%

� �

shall not exceed:

– For corrugated furnaces: 1,0 %

– For smooth furnaces: 1,5 % up to a maxi-mum of 15 mm.

7.4 Non-linearity

The non-linearity shall be measured by placing alength of cord against the wall. It may not exceed0,3 % of the cylindrical length of the shell rings.

7.5 Wall thickness of welds and adjoiningplate areas

The following tolerances apply to the wall thicknessof corrugated tubes: the average wall thickness must atleast equal the nominal wall thickness within the cor-rugation pitch. Localized deficiencies of up to 10 % inthe wall thickness within the corrugation pitch arepermitted. The reduction in wall thickness is to becompensated for when manufacturing the corrugatedtubes by means of an appropriate increase in the wallthickness of the original tube. The area A calculatedfrom the specified corrugation depth and the specifiedwall thickness must be attained. With a corrugationdepth w of 75 mm, a deficiency of 5 % in the area A isacceptable. In the flanged portion, a deficiency of upto 20 % in the wall thickness is permitted. In the as-sessment, defects which in the opinion of the Society'sexpert are clearly unimportant with regard to safetyshall be disregarded. Smooth furnaces are subject tothe tolerances applicable to plates.

8. Proof that the requirements stipulated in para.7. are met shall be furnished by means of an accep-tance test certificate A to EN 10204 or ISO 10474, asapplicable (DIN 50049). A hydraulic pressure test isnot required for furnaces.

9. The cut-out areas of headers certified ac-cording to quality grade I under DIN 17175 (cf. Part 1,Metallic Materials, Chapter 2, Section 2, C.) shall besubjected to appropriate non-destructive testing by theboiler manufacturer and the outcome of the testingshall be certified.

II - Part 3GL 2000


I

10. Repair welds

Exceptions to the foregoing rules may be made forrepair welds in justified special cases, provided thatthe Society's expert is informed of the nature andscope of the planned welds before work commencesand he has no objections to the planned exceptions.

11. Production test

The production test comprises non-destructive testingof the component and quality inspection of test pieces(mechanical and technological tests).


All longitudinal and circumferential welds shall besubjected to non-destructive testing over their entirelength. They shall also be examined for surface cracksif necessary. The tests shall be performed in accor-dance with Chapter 2, Section 4.

For circumferential welds where the wall thickness is< 30 mm, testing of 25 % of the length of the weld issufficient; however, all junctions with longitudinalwelds shall be tested.

The tests shall not be performed until the final heattreatment of the component has been carried out.

The non-destructive tests shall not reveal any majordefects in the weld. Such defects include cracks, lackof sidewall fusion and, in single-side welds, insuffi-cient root penetration. Other defects such as pores andslag shall be assessed in accordance with recognizedcodes, e.g. AD code HP 5/3 or the ASME Boiler andPressure Vessel Code, Section I.

The results of the non-destructive tests shall be docu-mented and presented to the Society's expert for as-sessment at the time of the structural inspection.

11.2 Quality testing of test pieces

The following tests shall be carried out on a test piecewelded at the same time as the component as an ex-tension of a longitudinal seam (cf. para. 11.3.6 and11.4):

a) Tensile test on two specimens, shape of speci-men according to EN 895 (DIN 50120, Fig. 1);however, test length = width of weld + at least80 mm.

b) Technological bend test to EN 910 (DIN 50121,Part 1, Fig. 2) on four transverse bending testspecimens (two specimens each with oppositesides of the weld in tension). On the side in ten-sion, after machining off the weld reinforcementthe original surface of the test piece shall be pre-served to the greatest possible extent. Sizeabledepressions such as undercuts and root notchesshall not be repaired.

c) Notched bar impact test on ISO V-notch speci-mens to EN 875 (EN 10045) on three specimenstaken from the centre of the weld metal with theposition of the notch vertical to the surface ofthe test piece.

The test temperature and requirements areshown in Table 2.2.

d) Structure examination of a specimen (mac-rographic specimen); for alloy

1 steels, a mi-

crographic specimen is also required.

e) A radiographic inspection to EN 1435(DIN 54111) shall be carried out prior to sec-tioning of the test piece.

Also, if the working temperature exceeds 350 °C:

f) Tensile test to EN 876 (DIN 50145) on a speci-men from the weld metal (cylindrical specimenwith L0 = 5 d to DIN 50125) for thicknesses

≥ 20 mm to determine the 0,2 % proof stress atthe working temperature

or

g) Analysis of the weld metal with regard to theconstituents which determine the mechanicalproperties at elevated temperature

as decided by the Society's expert.

For materials with a minimum tensile strength of≥ 440 N/mm2 and alloy 1 steels subjected to post-weld heat treatment, a tensile test and a notched barimpact test on specimens taken from the base materialtransversely to the direction of rolling shall also beperformed on the test piece.

11.3 Number, removal and dimensions of thetest pieces for quality testing

11.3.1 Procedure for the first six shell rings

If the higher evaluation is being made use of for thefirst time or is being extended through the inclusion ofnew types or grades of material, a test piece located atone end of each of the first six shell rings shall bewelded together with the shell ring and tested. Unlessotherwise stipulated, the specimens stated in para.11.4 shall be taken from this test piece. The test piecesrequired for these production tests shall be taken fromthe plates to be used for the component. Every meltshall be covered.

11.3.2 Procedure from the seventh shell ringonwards

The preparation and number of test pieces depends onwhether or not post-weld heat treatment is necessary;cf. para. H.2.



I

11.3.3 For components where heat treatment is un-necessary, the following applies, provided that theanalytical limits stated in para. H.2.3. are not ex-ceeded:

a) Preparation:

The test pieces may be taken from plates of thesame type and strength category and approxi-mately the same thickness as those used for theshell ring; a difference of ± 5 mm is acceptable.The characteristics of the plates must be verifiedin accordance with Part 1, Metallic Materials,Chapter 2.

b) Number of test pieces:

One test piece shall be welded as an extension ofone of the longitudinal seams of each compo-nent, irrespective of the number of shell rings.

11.3.4 For components where heat treatment is nec-essary, the following applies:

a) Preparation:

The test pieces shall be taken from plates to beused for the component in question.

b) Number of test pieces:

One test piece shall be welded as an extension ofone of the longitudinal seams of each compo-nent, irrespective of the number of shell rings. Ifthe component consists of material from severalmelts, one test piece shall be welded for eachmelt. If the analytical values differ only slightly,the Society's expert may reduce the number oftest pieces accordingly, even if a componentconsists of material from several melts.

11.3.5 The number and locations of the test piecesare shown in Table 2.3.

After at least 50 production tests per material cate-gory, relaxations may be agreed with the Society.

11.3.6 Size of test pieces

The size of each test piece shall be such that thespecimens prescribed in para. 11.4.2 and a sufficientnumber of retest specimens can be taken from it.

11.4 Welding of test pieces, number and re-moval of test specimens

11.4.1 Welding of test pieces

The seam of the test piece shall be welded in thecourse of fabrication together with the last 300 mm ofweld of the shell ring. The Society's expert has theright to be present while this weld is made. The testpieces shall undergo a heat treatment which is demon-strably similar to that applied to the component.

11.4.2 Number of test specimens

From every welded test piece, specimens for the testsprescribed in para. 11.2 shall be stamped by the Soci-ety's expert and removed. The specimens shall alter-nate with each other and lie adjacent to each other.

The remainder of the test piece is intended for retests.It shall also be stamped and marked in such a way thatits affiliation can be unequivocally established.

11.5 Requirements

11.5.1 Mechanical and technological tests

The mechanical and technological tests are governedby Table 2.2 in conjunction with para. I.3.

11.5.2 Retest specimens

If one of the tests listed in para. 11.2 fails to achievethe required result, each unsuccessful test shall berepeated by testing two more specimens of the sametype taken from the remainder of the test piece. Thetest conditions are met if the retest specimens meet therequirements.

11.6 Supplementary tests

Further tests, e.g. notched bar impact tests with thefracture section in the transition zone or radiographicinspections in various directions, shall be performed ifconsidered necessary by the competent expert in spe-cial cases for assessment of the weld.

II - Part 3GL 2000


I

Table 2.3 Number and locations of test pieces

Heat treatment

unnecessary necessary

1st to 6th shell ring One test piece per shell ring taken form the plates to be used for the com-ponent. Every melt is to be covered (see para. I.11.3.1)

From 7th shell ring and furthercomponents consisting of

on shell ring One test piece per shell ring (see para. I.11.3.2)

two or more shellrings

One test piece per component takenfrom plates of the same strengthcategory and approx. the samethickness (difference of ± 5 mmare acceptable).

One test piece per component;where different melts are usedhowever, one test piece for eachmelt from one of the plates to beused for the components.

After at least 50 production testsper material group

Relaxations by agreement with the Society (cf. TRD 201, Appendix 3,para.6)

II - Part 3GL 2000

Section 3 Welding of Pressure Vessels Chapter 3Page 3–1

B

Section 3

Welding of Pressure Vessels

Preliminary remark:

The following rules relating to the welding of pres-sure vessels comply with or incorporate the AD codesof practice. Subject to the approval of the Society,other codes of practice such as the ASME Boiler andPressure Vessel Code, Section VIII may also beadopted for the fabrication and testing of weldedpressure vessels (the following rules being applicablein analogous manner). Cf. also Chapter 1, Section 1,B.1.4.

A. General

1. Scope

1.1 These Rules apply to the fabrication andtesting of the following welded steel tanks, vesselsand process equipment which are designed to with-stand an internal working pressure:

1.1.1 Tanks, vessels and process equipment fabri-cated from unalloyed and alloyed ferritic steels withnominal yield strengths up to 380 N/mm2.

1.1.2 Tanks, vessels and process equipment fabri-cated from austenitic stainless steels.

1.1.3 Cargo tanks 1 and process vessels fabricatedfrom steels tough at subzero temperatures for thecarriage of cooled liquefied gases.

1.2 Tanks, vessels and process equipment fabri-cated from other materials not mentioned in para. 1.1may be manufactured and tested in accordance withtechnical codes recognized by the Society. Examplesof recognized technical codes are the more compre-hensive requirements set out in the AD Codes ofSeries HP published by the "Arbeitsgemeinschaft fürDruckbehälter" (Pressure Vessel Manufacturing As-sociation).

1.3 The design and testing of tanks, vessels andprocess equipment joined by other processes (e.g.brazed or bonded) shall be subject to agreement be-tween the manufacturer and the Society’s head officein each individual case (cf. also Chapter 1, Section 1,A.1.1).

––––––––––––––1 Independent "Type C" tanks.

2. Other relevant rules

2.1 The provisions of the Rules for ConstructionI, Part 1, Chapter 2, Section 8 shall also be compliedwith in the design and dimensioning of pressure ves-sels and process equipment.

2.2 Cargo tanks designed to carry chemicals arealso subject to the provisions of the rules for Con-struction I, Chapter 7 - Chemical Tankers, Section 1.

2.3 Cargo tanks and process vessels designed tocarry cooled liquefied gases are also subject to theprovisions of the Rules for Construction I, Part 1,Chapter 6 - LPG Tankers.

3. Assessment of welds

3.1 Tensionally stressed longitudinal welds inpressure vessels and process equipment, except forsuch welds in cargo tanks for carriage of liquefiedgases, may generally be evaluated according to aweld factor up to v = 0,85, provided that they meetthe requirements specified in Chapter 1, Section 1and 2, and in Sections D, E, G and H.

A higher evaluation up to v = 1,0 may be applied if aproduction test and non-destructive testing in accor-dance with I.4. have been successfully performed onthe finished component.

3.2 Cargo tanks for liquefied gases shall be soconstructed that their longitudinal welds can beevaluated according to a weld factor of at leastv = 0,95. A further condition is successful perform-ance of the production tests and non-destructive testsspecified in I.4.

A higher evaluation up to v = 1,0 may be applied ifthe characteristics of the material, the type of thewelded joints, the welding process and the type ofloading so permit and the Society has approved thehigher evaluation.

B. Approval of Welding Shops, WeldingPersonnel

1. All welding shops intending to performwelding work within the scope of these rules mustsatisfy the requirements applicable to welding shopsand personnel set out in Chapter 1, Section 2 and

Chapter 3Page 3–2

Section 3 Welding of Pressure Vessels II - Part 3GL 2000

D

must have been approved by the Society. Applica-tions for approval shall be submitted by the weldingshops in good time before starting the welding work,enclosing the information and documentation pre-scribed in Chapter 1, Section 2, A.3.

2. The welding personnel (welders and weldingsupervisors) and, where applicable, inspectors andinspection supervisors must satisfy the requirementsset out in Chapter 1, Section 2, B.2., B.3. and B.4.and be recognized by the Society. For the welder’squalification tests, see Chapter 1, Section 3.


1. The manufacturer shall submit to the Soci-ety, for inspection, drawings and other relevantdocuments containing at least the following informa-tion:

– The materials and welding consumables to beused,

– The welding process and the location and shapeof the weld,



– The calculated temperature or, in the case ofvessels fabricated from steels tough at sub-zerotemperatures, the minimum design temperature,



– The weld factor used as a basis for calculation,


– The nature and scope of the production tests.

2. If the quality or good working order of acomponent cannot be guaranteed or is in doubt due toinadequate or missing information in the manufac-turing documents (e.g. production drawings), theSociety may demand appropriate improvements.

3. The welding shops shall ensure by means ofregular in-house quality inspections during fabrica-tion and on completion of the welding work that thiswork has been performed competently and satisfacto-rily (cf. Chapter 1, Section 1, F.). For the duties andresponsibilities of the welding supervisor, see alsoEN 719/ISO 14731.

4. The welding shops are responsible for en-suring that the welding work conforms to theseRules, the approved manufacturing documents, anyconditions stipulated in the approval documents and

the latest state of welding practice. The inspectionsand checks to be performed by the Society’s Sur-veyor do not relieve the welding shops of this respon-sibility.


6. The scope of the required quality inspectionsdepends on the construction project in question. It isessential to ensure, however, that the intended mate-rials, welding consumables and auxiliary materialsare used and that the weld preparation, assembly,execution of the tack and final welds and the dimen-sional accuracy and completeness of the weldedjoints meets the requirements stated in para. 3. Fornon-destructive testing of the welded joints and pro-duction tests have to be performed, see I.

7. Following internal inspection and, if neces-sary, repair by the welding shop, the componentsshall be presented to the Society's Surveyor forchecking at suitable stages of fabrication. For thispurpose they shall be readily accessible and shallnormally be uncoated. Where the previous inspectionhas been inadequate, the Surveyor may reject compo-nents and require that they be presented again aftersatisfactory workshop inspection and any necessaryrepair work has been performed.

8. The Society is not responsible for guaran-teeing that all the components and welded jointsinspected to the prescribed extent (generally on arandom basis) by its surveyors have been fabricatedin accordance with the conditions and meet the re-quirements in every respect. Components or weldedjoints which subsequently turn out to be defectivemay be rejected or their repair may be demandedeven if acceptance testing has already been carriedout.


1. The materials selected must be appropriatefor the intended purpose, with allowance made formechanical and thermal stresses. The characteristicsof materials subjected to further processing shall besuch that they are able to withstand the operatingloads.

2. Welded structures may only be fabricatedusing base materials of proven weldability. The in-tended materials must comply with the requirements

II - Part 3GL 2000


F

set out in the relevant sections of Part 1, MetallicMaterials, Chapter 2. Other comparable materialsmay only be used after the Society has given its ap-proval in each individual case.

3. Materials for cargo tanks and process vesselsfor liquefied gases must also meet the impact energyrequirements at the stipulated test temperature; cf.Table 3.3.

E. Welding Consumables and AuxiliaryMaterials

1. The welding consumables and auxiliarymaterials must enable a welded joint to be madewhich is appropriate to the base material, the operat-ing temperature and the conditions of service. Thesuitability of the welding consumables must alsohave been verified under the conditions prevailing infurther processing and heat treatment.

2. All the welding consumables and auxiliarymaterials used (e.g. covered electrodes, wire-gascombinations, wire-flux combinations, etc.) musthave been approved by the Society in accordancewith Chapter 1, Section 5. They may also, however,be approved if tested at the same time as the weldingprocedure and restricted to the user’s works (cf.Chapter 1, Section 4, B.3.2 and Section 5, A.1.4).

3. Welding consumables for steels tough atsubzero temperatures must also meet the impact en-ergy requirements for the weld metal at the stipulatedtest temperatures; cf. Table 3.3.

4. If it is necessary, in special cases, to usewelding consumables of dissimilar material where thestrength of the resulting weld metal is lower than thatof the base materials, e.g. when welding 9 % nickelsteel with austenitic consumables, appropriate allow-ance shall be made in the design calculations for thevessels.

5. Welding consumables and auxiliary materi-als specified in a procedure approval document with amaker’s or brand name (cf. F.3.5) may only be re-placed by equivalent consumables approved by theSociety with an appropriate quality grade if this isexplicitly stated in the respective approval document.Failing this, the Society's agreement shall be ob-tained.

6. The welding consumables and auxiliarymaterials may only be used in the approved weldingpositions. The manufacturers' recommendations andinstructions for welding (e.g. type of current andpolarity) shall be followed.

7. The welding consumables and auxiliarymaterials (especially hydrogen-controlled, basic-covered electrodes and basic welding fluxes) shall bere-dried before use in accordance with the manufac-turer's instructions (observe maximum drying time!)and stored in a dry place (in heated containers or thelike) at the workplace.

Note:

The DVS guideline 0504 "Handling, storage and re-drying of covered electrodes" and the DVS regula-tions 0914 "Use and storage of welding fluxes forsubmerged-arc and electro-slag welding" issued bythe German Welding Society (Deutscher Verband fürSchweißtechnik e.V) contain detailed instructions onthis subject.


Preliminary remark:

In contrast to earlier issues of these Rules, weldingprocedure tests shall be performed in accordancewith EN 288 or ISO 9956, as applicable. This para-graph essentially covers requirements applicable tothe welding of pressure vessels over and above thoseset out in EN 288-3 and ISO 9956-3.

1. General

Only those welding procedures shall be employedwhose satisfactory operational handling and adequatequality properties have been verified as part of awelding procedure test under production conditions atthe user’s works. The general requirements set out inChapter 1, Section 4 shall be observed. The weldingprocedures must have been approved by the Societyfor the particular welding shop in question.


2.1 A preliminary "manufacturer’s" weldingprocedure specification (pWPS) setting out all themajor parameters shall be produced by the weldingshop for the welding of test pieces in accordance withEN 288-2 or ISO 9956-2, as applicable (see Chapter1, Annex D).


2.3 The test pieces shall be made from materialswhose properties are proven in accordance with therequirements specified in Part 1, Metallic Materials,Chapter 2. Pre-treatment and after-treatment of thetest pieces by preheating, heat treatment and the like

Chapter 3Page 3–4


F

is only permitted if stipulated for these materialsduring actual fabrication.


2.5 The shape and dimensions of the test piecesare specified in EN 288-3/ISO 9956-3 or, whereapplicable, stipulated in para. 2.6 and 2.7.

2.6 The plate test pieces for cargo tanks de-signed to carry liquefied gases shall be executed asshown in Fig. 3.1.

2.7 For making fillet welds on tanks for thecarriage of liquefied gases, the following shall bemade:

– One fillet-welded test piece approx. 300 mmlong for each welding position (see Fig. 3.2)

– One Y test piece approx. 300 mm long from thejoint between the central longitudinal bulkheadand the tank walls for each welding position(see Fig. 3.3) (where applicable, e.g. for bilobetanks).


The qualification of the welding procedure shall beascertained in accordance with EN 288/ISO 9956Part 1, para. 5.1.1 by means of welding procedurequalification tests, for steel in accordance with EN288/ISO 9956 Part 3.

The test is valid within the limits described in para.3.1 to 3.7.

The scope of the welding procedure test is specifiedby the Society in writing. Any exceptions require theperformance of a supplementary test, the scope ofwhich shall be decided by the Society. Productiontests may be recognized as supplementary tests.

3.1 Material groups



b) A welding procedure qualification performedon group 1 killed steel does not apply tounkilled steels unless they were welded usingbasic covered electrodes or wire-flux combina-tions with basic flux.

c) Approval is also granted for the following fur-ther material combinations in addition to thosestipulated in EN 288/ISO 9956 Part 3, Table 4but under the following conditions (see Table3.1).

d) Deviating from EN 288/ISO 9956 Part 3, Table4, a welding procedure test available for thecombination group 9 welded to group 2 doesnot incorporate the combination group 9welded to group 3.

� � � ��

��

��

��

��

Fig. 3.1 Test piece for cargo tanks

II - Part 3GL 2000


F

��

��

��

��

Fig. 3.2 Fillet-welded test piece

��

��

��

��

Fig. 3.3 Y test piece

e) Depending on material composition and/or thetype of post-weld treatment required, the Soci-ety may also limit the scope to the base mate-rial used in the welding procedure test.

f) For the materials used in the fabrication ofcargo tanks and process vessels for liquefiedgases, the test applies only to the grade of steelinspected.

3.2 Welding process


3.3 Gas welding

In gas welding a test performed on the wall thicknesst shall apply to the wall thickness range 0,75 t to1,25 t.



3.5 Welding consumables and auxiliary mate-rials

The requirements of EN 288/ISO 9956 Part 3, para.8.4.5 do not apply if the filler metal used is of thesame type and has been approved by GL to be underthe scope of the welding procedure qualification (cf.E.5.).

Table 3.1

Welding procedure qualification availablefor a steel group of combination joints Suitable for the following combination joints

5 (10CrMo9-10) welded with 4

4 welded with 5 (13CrMo4-5)

4 welded with 1

4 welded with 2 (Re < 430 N/mm2)

55 welded with 1

5 welded with 2

6 welded with 46 welded with 5

6 welded with 2

6 welded with 1

Chapter 3Page 3–6


F

3.6 Heat treatment

The welding procedure test applies to the heat treatedcondition existing at the time of the test. Heat treat-ment of the test piece shall be performed so that aheat treated condition is achieved which is compara-ble to that of the component.

3.7 Special cases

For special cases, for example projection welds,welding of clad steels, stud welds and difficult repairsto be performed in the course of fabrication on steelswhich are susceptible to cracking due to hardening ofthe heat affected zone, welding procedure tests arenecessary which are geared to these particular cases.The tests required and their scope are specified by theSociety in each individual case.



Deviating from EN 288/ISO 9956 Part 3, para. 7.1and Table 1, the following specimens shall also betaken from the test pieces:

a) One all-weld metal tensile test specimen with adiameter of 10 mm and L0 = 5 d shall also betaken in the case of test pieces more than 20mm thick in materials where the weld metalmay be significantly affected by the weldedjoints.

This applies to steels in material groups 2 (hightemperature steels only), 4 and 6. This testshall also be performed on group 7 materialswhere post-weld heat treatment is stipulated.

b) Notched bar impact test specimens shall alwaysbe taken from the centre of the weld metal foreach welding position in the case of wall thick-nesses greater than 5 mm

c) Notched bar impact test specimens shall also betaken from the weld boundary for each weldingposition in the case of material groups 2, 4, 5,6, 7 and 9 (proportion of delta ferrite in theweld metal ≤ 3 %) and wall thicknesses≥ 10 mm.

d) Micrographic specimen for alloy steels 2. Thestructure shall be described and verified bymeans of photographs.

e) Analysis of the weld metal for alloy steels 2.

f) Contrary to the provisions of para. b) and c), 3notched bar impact test specimens with thenotch perpendicular to the surface of the plateshall each be taken from the centre of the weldmetal (KM), the weld boundary (fusion line KS)and also 1, 3 and 5 mm away from the fusion

line in the heat affected zone (KS+1, KS+3, KS+52)for plate test pieces for cargo tanks for the car-riage of liquefied gases; cf. Fig. 3.1.


The irregularities in the test piece must fall within thelimits specified for quality level B in accordance withEN 25817/ISO 5817, exceptions being: excessiveweld reinforcement (butt and fillet welds), excessiveroot reinforcement and excessive throat thickness(fillet welds) which fall into quality level C.

For the mechanical and technological tests, Table 3.2applies. The impact energy requirements for cargotanks and process vessels designed to carry liquefiedgases are given in Table 3.3.


The tested specimens and the remaining portions ofthe test pieces shall be stored until the report on thewelding procedure test has been issued (cf. alsoChapter 1, Section 4, C.3.).


The validity of a welding procedure test is generally1 year provided that the preconditions under which itwas granted have not significantly changed. It maybe continued by means of regular production tests(see para. I.4.).

In addition to production tests and tests performed onwelded components (cf. para. I.) non-destructive testsmay, given certain preconditions, also be recognizedby the Society for continuing the validity.

The welding procedure test shall be repeated if thereis a break in the fabrication of pressure vessels orpressure vessel components lasting longer than oneyear.

––––––––––––––2 For the classification of steels (unalloyed and alloyed), see

EN 10020.

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Table 3.2 Test requirements applicable to welded joints in steel



Tensile strength as stipulated for the base material or in the assessment of suitability for thewelding consumable

Tensile test on a specimenof the weld metal

Yield strength or 0,2 % proof stress, tensile strength and elongation as stipulated for the basematerial or in the assessment of suitability for the welding consumable

Where temperature of medium 1 is – 10 °C or above:

As stipulated for the base material in transverse direction. Test temperature as in testing of thebase material, but not lower than – 10 °C. When using ferritic-austenitic, austenitic and nickel-base welding consumables ≥ 40 JNotched bar impact test

on ISO V-notch specimentaken from centre of weld Where temperature of medium 1 is lower than – 10 °C:

At minimum working temperature, ≥ 27 J 2 when using ferritic welding consumables, ≥ 32 J 2

when using ferritic-austenitic, austenitic and nickel-base alloy welding consumables

Where temperature of medium 1 is – 10 °C or above:

≥ 27 J 2 ; test temperature as in testing of the base material, but not lower than – 10 °CNotched bar impact teston ISO V-notched

specimen taken fromweld transition zone

Where temperature of medium 1 is lower than – 10 °C:

≥ 16 J 2; at minimum working temperature

Bendingangle,

DegreesStrength category 3

Bendingmandrel

dia.

180 4

Ferritic steels with:

min. tensile strength < 430 N/mm2

min. tensile strength ≥ 430 to 460 N/mm2

2 × a

2,5 × a

180 4

Austenitic stainless steels and austenitic steels tough atsubzero temperatures,

high-temperature austenitic steels,

ferritic steels, with a minimum tensilestrength ≥ 460 N/mm2

2 × a

3

× a

3 × a

If a bending angle of 180 degrees is not attained, the following applies:

≥ 90 Elongation (L00 = width of weld + wall thickness, symmetrical to weld)

≥ minimum elongation A5 of base materials

Technologicalbend test

or < 90 Elongation over width of weld > 30 % 5 and faultless appearance of fracture

Metallographicexamination

The macrographic specimen of the welded joint must reveal a satisfactory weld build-up and fullpenetration of the weld.

The micrographic section is to be examined for cracks. Only hot cracks are acceptable, and thenonly if they are few in number and widely scattered and agreement has been reached with theSurveyor as to their acceptability with regard to the material and the range of application.

Hardness testingThe hardness in the heat-affected zones shall not exceed 350 HV 10. Hardness peaks in excess ofthis figure in narrow transition zones shall not give rise to complaints if the outcome of thetechnological tests meets the requirements.

1 Cargo tanks and process vessels for liquefied gases are subject to the impact energy requirements at the relevant test temperatures asshown in Table 3.3.

2 Only one impact energy value may be lower than the minimum mean value, and only by max. 30 %.3 The tensile strength value applies to the area of least thickness.4 The 180-degree requirement is deemed to have been met if the bend test was performed according to EN 910/ISO 5173 (DIN 50121) and

pressure was applied by the supports without cracks appearing.5 For steels welded with dissimilar consumables, e.g. X8Ni9, different values may be agreed with the Society.

Chapter 3Page 3–8


G

Table 3.3 Impact energy requirements for cargo tanks and process vessels for liquefied gases

Notched bar impact test on ISO V specimen

Type of steel

Minimumdesign

temperature[°C]

Thicknesst

[mm] Test temperatureKV(J)

min.

Carbon-manganesesteels

0 t ≤ 20

20 < t ≥ 40

0 °C

– 20 °C

Carbon-manga-nese steelincl. 0,5 %nickel steel

– 55

t ≤ 25

25 < t ≤ 30

30 < t ≤ 35

35 < t ≤ 40

5 K below minimum

10 K design temperature 1,

15 K but not exceeding

20 K – 20 °C

Nickel alloysteels containing

1,5 % Nickel

2,25 % Nickel

3,5 % Nickel

5 % Nickel

– 60

– 65

– 90

– 105

t ≤ 25

25 < t ≤ 30

30 < t ≤ 35

35 < t ≤ 40

5 K below (– 65 °C)10 K minimum (– 70 °C)15 K design tem- (– 95 °C)20 K perature 2 (– 110 °C)

Nickel alloysteels containing

5 % Nickel

9 % Nickel

Austenitic steels

– 165 3

– 165

– 165

t ≤ 25 4

t ≤ 25 4

t ≤ 25 4

– 196 °C– 196 °C– 196 °C

Centre of weld:

for ferritic consum-ables ≥ 27, for aus-tenitic and nickel-base alloy consum-ables ≥ 32

Weld boundary andfusion line:

≥ 27

1 For components subjected to stress relief heat treatment after welding, a test temperature of 5 K below the minimum design tem-perature or – 20 °C, whichever is lower, may be adequate.

2 The test temperature shall not exceed the figures stated in brackets.3 The steel type 5 Ni may only be used for design temperatures down to – 165 °C after a special test of product suitability.4 For thicknesses > 25 mm, the requirements shall be agreed with the Society.


1. Welds must exhibit full penetration overtheir entire cross section and must not have anycracks or lack of fusion defects. Wherever possible,the root shall be grooved and capped.

If backing rings are used when making circumferen-tial welds, they must be removed after welding. Thismay be dispensed with in the case of small vessels,the inside of which is no longer accessible.

2. When welding plates of the same thickness,the edge misalignment shall not exceed the followingvalues:

– Seams welded on both sides:

0,15 × plate thickness (mm), subject to amaximum of 3 mm

– Seams welded on one side only:

0,10 × plate thickness (mm), subject to amaximum of 2 mm.

For vessels fabricated from clad plates, a smalleredge misalignment tolerance may be necessary de-pending on the thickness of the cladding.

3. When welding plates whose thicknessesdiffer by more than 20 % or more than 3 mm, thethicker plate shall be bevelled to the thickness of thethinner plate at a maximum angle of 30°.

4. In the case of shells consisting of severalrings, the longitudinal seams shall be staggered. As aguide, the amount of stagger should be 4 times theplate thickness, but at least 100 mm.

5. Lapped joints with fillet welds between shellrings, bottoms and tubes are only acceptable in indi-vidual cases as circumferential welds with a wallthickness of 8 mm, provided that both sides of the lapare welded. Such joints may not be used in cargotanks and process vessels for liquefied gases.

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H

6. Corner welds and similar welded jointswhich are subjected to considerable flexural stressesunder adverse conditions of fabrication or service areonly acceptable if the Society raises no objection tothe method of execution.

7. Holes and cut-outs in or immediately adja-cent to welds, especially longitudinal welds, shall beavoided wherever possible.

8. Butt-welded joints in walls under pressureshall not be intersected by fillet welds of fitments. Ifintersection of fitments with vessel welds cannot beavoided, sufficiently large cut-outs shall be made inthe fitments in the area of the butt welds in the vessel.

9. Weld preparation for welds between thevessel wall and domes and between the domes andthe corresponding nozzles shall be carried out inaccordance with recognized standards.

All welds on nozzles, domes and other componentswhich penetrate the pressure vessel and all weldsbetween flanges and vessel or nozzle must be weldedwith full penetration over the entire wall thickness ofthe vessel or the nozzle.

As an exception, other joints without full penetrationmay, with the Society's consent, be used for small-diameter nozzles in the dome.

10. Bearings, tank mountings and other fitmentswhich may induce stresses in the walls of the vesselshall be joined to the vessel wall with adequatelydimensioned doubling plates or transition pieces.

11. Fillet welds of sockets, tank stiffeners andfitments which may induce stresses in the walls of thevessel shall be laid down in more than one pass.

12. Doubling plates, flanges, mountings, liftinglugs and other welded fitments must be adapted to thecontour of the vessel. All parts must be welded priorto any heat treatment and before pressure testing. Anexception to this rule may be allowed in the case ofparts subsequently attached to doubling plates ortransition pieces.

13. Welding of components from ferritic steelsin cold-formed areas where the outer fibres have beenstretched by more than 5 % (Dm < 20 ⋅ s for cylindri-cal shell rings) is only allowed if the effects of cold-forming have been cured by means of appropriateheat treatment.

This shall generally be accomplished by normalizingheat treatment or quenching and tempering. Thisrequirement may be waived if proof is furnished that

the properties of the material are no more than insig-nificantly impaired with regard to the intended use.

14. Every weld in a pressure vessel componentshall be marked in such a way that its location re-mains recognizable and the welder concerned can beidentified at any time. Both of these may be evi-denced either by stamping the weld accordingly or bymaking entries in drawings, welding schedules orother records.


1. Welded components must be heat-treatedafter welding in accordance with the stipulations ofthe relevant standards or the Society's approvaldocument.

1.1 The post-weld heat treatment shall normallyconsist of stress relief heat treatment.

1.2 Components fabricated from steels whichhave undergone normalizing heat treatment shall besubjected to normalizing heat treatment if:

– the required properties of the welded joint canonly be established by normalizing heat treat-ment

or

– the component has undergone hot-forming afterwelding, unless hot-forming was completedwithin a temperature range equivalent to nor-malizing heat treatment.

1.3 Components fabricated from quenched andtempered steels shall be subjected to quenching andtempering if:

– the required properties of the welded joint canonly be established by quenching and temper-ing

or

– the component has undergone hot-forming afterwelding.

If, in the case of air-hardened and tempered steels,the hot-forming of the component was on the wholeperformed under the conditions applicable to nor-malizing heat treatment, tempering alone is sufficient.

1.4 Cargo tanks for liquefied gases fabricatedfrom carbon- manganese steels or 0,5 % nickel steelsand designed for service at temperatures below- 10 °C shall be subjected to stress relief heat treat-ment, unless para. 2.4 applies.



I

1.5 For high-alloy steels with a ferritic or aus-tenitic structure and nickel alloy steels tough at sub-zero temperatures with the exception of 0,5 % nickelsteel, the need for and method of heat treatment shallbe determined separately (see also Chapter 2, Section3, para. E.).

2. Except in the case of the tanks described inpara. 1.4, post-weld heat treatment may be dispensedwith if the following conditions are met:

2.1 Prior to welding, the materials must be in theheat- treated condition specified in the relevant stan-dards or in the Society's approval document. Thiscondition is also deemed to be met if the requiredheat-treated condition is only attained during subse-quent fabrication.

2.2 The nominal wall thickness at the joints maynot exceed 30 mm.

2.3 In the chemical composition (melt analysis)of the base material and the weld metal, the followingcontents may not be exceeded:

C 0,22 %, Si 0,50 %, Mn 1,40 %,Cr 0,30 %, Cu 0,30 %, Mo 0,50 %,Ni 0,30 %, V 0,20 %;

In this context, the following conditions shall also besatisfied:

Cr + Ni ≤ 0,30 % and Mn + Mo + V ≤ 1,6 %.

These conditions may be relaxed in the case of steelswhich have been rendered resistant to brittle fractureand hardening by special metallurgical measures.Their suitability and properties shall be demonstratedto the Society after an adequate period of proving.The steels' resistance to brittle fracture, resistance tohardening and weldability must be equivalent tothose of steels falling within the above analyticallimits. For the weld metal, at a C content ≤ 0,10 %the Si content shall be ≤ 0,75 %, the Mn content≤ 2,0 % and the sum of the Mn, Mo and V contents≤ 2,5 % if welding consumables are used which pro-duce a weld metal with a particularly high toughness,e.g. by using welding consumables with basic char-acteristics.

2.4 If, in the case of cargo tanks for liquefiedgases fabricated from carbon-manganese steels or0,5 % nickel steels and designed for service at tem-peratures below minus 10 °C, heat treatment is on thewhole not possible due to the dimensions of the tank,mechanical destressing shall be carried out afterwelding.

For this purpose, individual components of complexdesign, e.g. domes, sumps, rings and other compo-nents which penetrate the casing of the tank, mustfirst be welded to the adjoining shell or bottom plates

and subjected with them to stress relief heat treatmentbefore being attached to the tank structure.

3. If carbon-manganese or nickel alloy steelsare welded with austenitic consumables, they shallnot be heat-treated after welding.

4. Documentary proof of the heat treatmentsdescribed in para. 1.1 to 1.4 shall be provided bymeans of a works certificate to EN 10204 or ISO10474, as applicable (DIN 50049) which shall statethe method, temperature and duration of the heattreatment and the method of cooling. Any specialheat treatment, e.g. temporary cooling after weldingprior to tempering treatment, shall be recorded in theworks certificate.


1. All tanks, vessels and process equipmentshall be subjected to a hydraulic pressure test at 1,5times the working pressure in the presence of theSurveyor, subject to the limitation that the resultingstress shall not exceed 0,9 times the yield strength at20 °C, taking into account the positive diameter tol-erance and the negative wall thickness tolerance. Thisdoes not apply to cargo tanks of the type described inpara. H.2.4. The component shall exhibit no leaksduring the hydraulic pressure test and no permanentdeformation afterwards.

2. An internal and external inspection shall becarried out on the completed vessels and processequipment, and especially of the welds and adjoiningareas. The components shall have a smooth externaland internal surface corresponding to the condition asmanufactured, to enable significant surface defects tobe detected. Vessels fabricated from austenitic steelsmust be pickled on the inside. At the same time,measurements shall be carried out to determine:

2.1 External circumference

The measurements shall be spaced at approx. 1 – 2 mintervals over the entire length of the component,depending on the length of the vessel. The measure-ments of the external circumference shall be used todetermine the average outside diameter. The outsidediameter of the shell rings and vessels may not varyfrom the stipulated outside diameter by more than± 1,5 %.


The measurements shall be spaced at approx. 1 – 2 mintervals over the entire length of the component.

II - Part 3GL 2000


I


UD D

D D=

⋅ −+

⋅2

100max min

max min%

� �

shall not exceed the following values:

Table 3.4

Ratio of wall thicknessto diameter

Maximum acceptableout-of-roundness

s/D ≤ 0,01

0,01 < s/D ≤ 0,1

s/D > 0,1

2,0 %

1,5 %

1,0 %

In calculating the out-of-roundness, the elastic de-formations arising from the component's own weightshall be discounted. Isolated bulges and dents mustalso lie within the tolerances. In addition, the bulgesand dents must have a flat profile and their depth,measured as a deviation from the normal roundnessor from the shell line, as applicable, must not exceed1 % of the length or width of the dent or bulge.

2.3 Axial non-linearity

The axial non-linearity shall not exceed 0,5 % of thecylindrical length.

2.4 Camber or flattening

The degree of camber or flattening in the area of thelongitudinal welds, measured as a deviation from thenormal roundness with a template length of 500 mm,may not exceed the dimension "a".

Depending on the ratio of the average diameter dm to

the wall thickness se of the vessel or shell ring, thefollowing applies:

a mm for sh

a mm for sh

≤ <

≤ ≥

10 40

5 40

ell ringsd

s

ell ringsd

s

m

e

m

e

,

.

2.5 Wall thickness of the welds and the ad-joining plate areas

The wall thickness in the plate must lie within thetolerance permitted for the plate.

3. To show that the requirements stated inparas. 1 and 2 are met, the manufacturer shall issuean acceptance test certificate 3.1B to EN 10204 orISO 10474, as applicable (DIN 50049 3.1B) andpresent it to the Surveyor at the final acceptancetesting of the vessels.

4. Production tests

The production test comprises non-destructive testingof the component and quality testing of test pieces(mechanical and technological tests).


The performance of the tests is subject to the provi-sions of Chapter 2, Section 4.

4.1.1 Non-destructive testing of cargo tanks forthe carriage of liquefied gases

4.1.1.1 The following welds shall be tested:

a) All butt welds in the pressure structure (shells,ends, domes, sumps) shall be subjected to X-ray radiographic inspection over their entirelength. In addition, at least 10 % of the weldlength shall be tested for surface cracks.

b) Fillet welds at the joint between the centrallongitudinal bulkhead and the tank casing oftwin tanks or similar structures shall be sub-jected to ultrasonic or, where this is not possi-ble, X-ray radiographic inspection over theirentire length. In addition, at least 10 % of theweld length shall be tested for surface cracks.

c) 10 % of the butt-welded joints of supportingrings in tanks shall be subjected to X-ray radio-graphic inspection. In the case of fillet weldsbetween the web and the tank wall and betweenthe web and the girder plate, at least 10 % ofthe weld length shall be tested for surfacecracks.

d) All butt and fillet welds of nozzles weldments,e.g. sockets, domes, sumps, rings, and of rein-forcing plates around cutouts shall be tested forsurface cracks over their whole length.

e) Fillet welds of fitments welded to the tankwhich may induce stresses in the tank wall, e.g.lifting lugs, feet, brackets, shall be tested forsurface cracks over their whole length.

f) Full root penetration nozzle connections in thepressure structure shall undergo ultrasonic orradiographic inspection if the attachment wallthickness at the pressure structure is > 15 mmand the inside diameter of the nozzle is≥ 120 mm.

g) If cargo tanks are to be mechanically de-stressed, all points with geometry-related stressconcentrations, such as the seams of socketweldments or fitments, shall afterwards betested for cracks by the magnetic particle ordye penetrant method.

4.1.1.2 If radiographic inspection is to be partlyreplaced by ultrasonic inspection, the method andscope must be authorized by the Society beforehand.



I

4.1.1.3 Notwithstanding para. 4.1.1.2, the Societymay require radiographic inspection to be supple-mented by ultrasonic testing and vice versa if consid-ered necessary in special cases.

4.1.1.4 Isotopes (Ir 192) may only be used if the useof an X-ray tube is impossible for technical reasons.

4.1.2 Non-destructive testing of pressureequipment with a weld factor v > 0,85

4.1.2.1 The following welds shall be inspected:

a) Longitudinal welds shall be subjected to radio-graphic inspection over their entire length andcircumferential welds over 25 % of theirlength. In addition, at least 10 % of the weldlength shall be tested for surface cracks.

b) All butt and fillet welds of weld-in componentsand reinforcing plates around cut-outs shall betested for surface cracks over their entirelength. The same applies to fitments if they arecapable of inducing stresses in the wall of thevessel.

c) The attachment welds of nozzles with an insidediameter ≥ 120 mm and a thickness of the at-tachment cross section > 15 mm shall undergoradiographic or ultrasonic inspection.

4.1.2.2 Where the radiographic inspection is to bereplaced by ultrasonic inspection, the process andscope of the test must be authorized by the Societybeforehand. The Society may prescribe an ultrasonicinspection to supplement the radiographic inspectionwhere there are doubts in interpretation of radio-graphic exposures.

4.1.3 Non-destructive testing of pressureequipment with a weld factor v ≤≤≤≤ 0,85

The manufacturer shall test the components at ran-dom in the course of his quality assurance proceduresand shall present the results to the Surveyor at thevessel inspection. For this purpose, around 2 % (10 %in the case of wall thicknesses over 15 mm) of thelongitudinal welds shall undergo radiographic orultrasonic inspection, which shall include the junc-tions between longitudinal and circumferential welds.

4.1.4 Inspection criteria

The non-destructive testing shall not reveal any majordeficiencies in the weld. These include: cracks, lackof sidewall fusion and, in the case of single-sidewelds, inadequate root penetration.

Other defects, e.g. pores and slag, shall be assessed inaccordance with recognized codes of practice, e.g.AD Code HP 5/3 or the ASME Boiler and PressureVessel Code, Section VIII.

4.2 Quality inspection of test pieces

4.2.1 Quality inspection of cargo tanks for thecarriage of liquefied gases

4.2.1.1 On all tanks for the carriage of liquefiedgases, one test piece as shown in Fig. 3.4 shall bewelded on to every 50 m of butt weld (longitudinaland circumferential welds). The location of the testpieces shall be such that every welding position iscovered. Wherever possible, they shall be made asextensions of the vessel seams and shall be weldedtogether with the vessel seam in the same operation.If this is not feasible in exceptional cases, the testpieces shall be attached beside the relevant tank weldand welded immediately on completion of the associ-ated section of the weld under the same conditions aswere used for the actual weld. The test pieces shall bestamped by the Society's expert before being re-moved from the tank. The positions and numbers ofthe test pieces shall be marked on the tank and indi-cated in the inspection schedule.

��

��!��"#��!

��

��

Fig. 3.4 Test piece for production tests

4.2.1.2 The test pieces shall be subjected to thefollowing tests (for shapes of specimens, see alsoChapter 2, Section 5):

a) Tensile test on one specimen (Z), shape ofspecimen according to EN 895 (DIN 50120,Fig. 1); however, test length = width of weld +at least 80 mm.

b) Technological bend test (B) to EN 910(DIN 50121, Part 1, Fig. 2) on two specimens(one specimen each with opposite sides of theweld in tension). On the side in tension, aftermachining off the weld reinforcement theoriginal surface of the test piece shall be pre-served to the greatest possible extent. Sizeabledepressions such as undercuts and root notchesshall not be repaired.

c) Notched bar impact tests on ISO V-notchspecimens in accordance with EN 875

II - Part 3GL 2000


I

(DIN 50115), taking from each test piece oneset of specimens with the notch in the centre ofthe weld metal (KM) and one set located at apoint in the heat-affected zone (KÜ) at whichthe lowest impact energy values were measuredin the welding procedure test.

d) Structure examination (G) of one specimen(macrographic specimen).

e) Hardness testing of the structure examinationspecimen according to d).

f) A radiographic inspection in accordance withEN 1435 (DIN 54111) shall be performed priorto sectioning of the test pieces.

4.2.2 Quality inspection of pressure equipmentwith a weld factor v > 0,85

4.2.2.1 In the fabrication of all vessels, a test pieceas shown in Fig. 3.4 is to be welded at the same time,regardless of the number of melts used for the plates.Two test pieces are required if there are more thanfive rings per pressure vessel.

4.2.2.2 The test pieces shall be subjected to thescope of testing described in para. 4.2.1.2; however,the notched bar impact test specimens shall be pre-pared as follows:

a) One set of notched bar impact test specimenswith the notch in the centre of the weld (KM)shall be taken from each test piece.

b) In addition, one set of notched bar impact testspecimens shall be taken from the transitionzone (KÜ) for:

– all process pressure vessels with a designtemperature below 0 °C

– all alloy steels

– all unalloyed steels where the wall thicknessin the area of the weld is over 30 mm.

4.2.3 Quality inspection of pressure equipmentwith a weld factor v ≤≤≤≤ 0,85

The manufacturer shall perform random quality in-spections on his components as part of his qualityassurance procedures in accordance with para. 4.2.2.These inspections shall cover 2 % of the components,but shall be performed at least one test piece a yearfor each material group and welding process. Theresults of the quality inspections shall be presented tothe Society's expert at the acceptance testing of pres-sure vessels.

4.2.4 Requirements

The requirements stated in Table 3.2 and, for cargotanks and process vessels for liquefied gases, alsothose stated in Table 3.3 shall be met in the qualityinspection. Failing this, the associated section of weldmust be machined out and rewelded and its charac-teristics must be verified by testing of a new testpiece.

II - Part 3GL 2000

Section 4 Welding of Pipelines Chapter 3Page 4–1

B

Section 4

Welding of Pipelines

A. General

1. Scope

1.1 These Rules apply to the fabrication andtesting of welded pipelines made of

– unalloyed steels

– high-temperature steels

– steels tough at subzero temperatures

– stainless steels.

1.2 Welded pipelines fabricated from other mate-rials not listed in para. 1.1 (e.g. copper-nickel wroughtalloys) may be manufactured and tested to other rulesor regulations issued by the Society for specific uses orother engineering regulations recognized by the Soci-ety.

1.3 The design and testing of pipelines joined byother processes (e.g. brazed or bonded) are subject toagreement between the manufacturer and the Society’shead office in each individual case (cf. Chapter 1,Section 1, A.1.1).

2. Other relevant standards

2.1 The provisions of the Rules for ConstructionI, Part 1, Chapter 2, Section 11 shall also be compliedwith in the design and dimensioning of pipelines sub-ject to pressure.

2.2 Cargo lines on ships designed for the bulkcarriage of chemicals are also subject to the provisionsof the rules for Construction I, Chapter 7 "ChemicalTankers", Section 1.

2.3 Cargo and process lines on ships designed tocarry cooled liquefied gases are also subject to theprovisions of the Rules for Construction I, Part 1,Chapter 6 "LPG Tankers".

3. Pipe classes

Depending upon the nature of the pipe and its content(medium) and also the design pressure and designtemperature, pipelines are classified into three pipeclasses, see Rules for Construction I, Part 1, Chapter 2,Section 11, Table 11.1. The type of pipe connections,welding requirements, the need for post-weld heattreatment and the scope of the non-destructive tests are

stipulated in the following paragraphs or in other rele-vant rules, as applicable, in relation to the particularpipe class.


1. All welding shops intending to performwelding work within the scope of these rules mustsatisfy the requirements applicable to welding shopsand personnel set out in Chapter 1, Section 2 and musthave been approved by the Society. Applications forapproval shall be submitted by the welding shops ingood time before starting the welding work, enclosingthe information and documentation prescribed inChapter 1, Section 2, A.3.

2. The welding personnel (welders and weldingsupervisors) and, where applicable, inspectors andinspection supervisors must satisfy the requirementsset out in Chapter 1, Section 2, B.2., B.3. and B.4. andbe recognized by the Society. For the welder’s qualifi-cation tests, see Chapter 1, Section 3.

3. The scope of the approval is determined bythe capabilities of the welding shop and by the in-tended range of application (pipe class, materials,welding processes, welding positions, etc.). The in-tended range of application shall be specified in theapplication for approval; cf. the form "Description ofWelding Shop" enclosed at Chapter 1, Annex B. Forthe period of validity of the approval, see Chapter 1,Section 2, A.4. and A.5.


4.1 For the welding of class III pipelines, as ageneral rule (basic) approval is granted first of all onthe basis of a works inspection and, if necessary,welder’s qualification tests in accordance with Chapter1, Section 3 normally for the manual arc welding(welding process 111), tungsten inert gas welding(welding process 141), gas welding (welding process311) and/or semi-mechanized metal-arc active gaswelding using solid and flux-cored wire (weldingprocesses 135 and 136) of unalloyed tubular steels inthe strength category 360 and 410 (cf. Part 1, MetallicMaterials, Chapter 2) and also comparable cast and

Chapter 3Page 4–2

Section 4 Welding of Pipelines II - Part 3GL 2000

D

forged steels. The range of wall thicknesses for theseis determined by the scope of the valid welder’s quali-fication tests.

4.2 This does not apply to welding in the verticaldown position using these processes, for which weld-ing procedure tests shall be performed in every case.Cf. F.

4.3 A basic approval may be extended to includeany welding procedure approvals on the basis of thewelding procedure tests in accordance with Chapter 1,Section 4, (cf. also F.); in exceptional cases, however,a limited approval may also be granted, in conjunctionwith a welding shop inspection, for one specific mate-rial and/or one specific welding process only.

C. Quality inspection responsibility

1. The manufacturer shall submit to the Society,for inspection, drawings and other relevant documentscontaining at least the following information:

– The type of pipeline/medium

– The pipe grades and welding consumables to beused,

– The welding process, welding position andshape of the weld,



– The design temperature or, in the case of cargoand process pipelines for gas tankers, the mini-mum design temperature,




2. If the quality or good working order of acomponent cannot be guaranteed or is in doubt due toinadequate or missing information in the manufactur-ing documents (e.g. production drawings), the Societymay demand appropriate improvements.

3. Welding shops shall ensure by means ofregular in-house quality inspections during fabricationand on completion of the welding work that this workhas been performed competently and satisfactorily (cf.Chapter 1, Section 1, F.). For the duties and responsi-bilities of the welding supervisor, see also EN 719/ISO14731.

4. The welding shops are responsible for ensur-ing that the welding work conforms to these Rules, theapproved manufacturing documents, any conditionsstipulated in the approval documents and the lateststate of welding practice. The inspections and checksto be performed by the Society’s Surveyor do notrelieve the welding shops of this responsibility.


6. The scope of the required quality inspectionsdepends on the construction project in question. It isessential to ensure, however, that the intended materi-als, welding consumables and auxiliary materials areused and that the weld preparation, assembly, execu-tion of the tack and final welds and the dimensionalaccuracy and completeness of the welded joints meetsthe requirements stated in para. 3. For non-destructivetesting of the welded joints, see I.

7. Following internal inspection and, if neces-sary, repair by the welding shop, the components shallbe presented to the Society's Surveyor for checking atsuitable stages of fabrication. For this purpose theyshall be readily accessible and shall normally be un-coated. Where the previous inspection has been inade-quate, the Surveyor may reject components and re-quire that they be presented again after satisfactoryworkshop inspection and any necessary repair workhas been performed.



1. The materials selected must be appropriatefor the intended purpose, with allowance made formechanical and thermal stresses. The characteristics ofmaterials subjected to further processing shall be suchthat they are able to withstand the operating loads.

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F

2. Welded structures may only be fabricatedusing base materials of proven weldability. Materialsfor pipelines (pipes, flanges, adapting pieces, fittings)must comply with the requirements set out in the rele-vant sections of Part 1, Metallic Materials, Chapter 2.Other comparable materials may only be used after theSociety has given its approval in each individual case.

3. Pipeline materials for cargo and process linesfor liquefied gases must also meet the impact energyrequirements at the stipulated test temperature; cf.Tables 4.1 to 4.3.


1. The welding consumables and auxiliary mate-rials must enable a welded joint to be made which isappropriate to the pipeline material, the operatingtemperature and the conditions of service. The suit-ability of the welding consumables must also havebeen verified under the conditions prevailing in anypotential heat treatment.

2. All the welding consumables and auxiliarymaterials used (e.g. covered electrodes, wire-gas com-binations, wire-flux combinations, etc.) must havebeen approved by the Society in accordance withChapter 1, Section 5. They may also, however, beapproved if tested at the same time as the weldingprocess and restricted to the user’s works (cf. Chapter1, Section 4, B.3.2 and Section 5, A.1.4).

3. Welding consumables for steels tough atsubzero temperatures must also meet the impact en-ergy requirements for the weld metal at the stipulatedtest temperatures; cf. Table 4.2.

4. Welding consumables and auxiliary materialsspecified in a procedure approval document with amaker’s or brand name (cf. F.3.5) may only be re-placed by equivalent consumables approved by theSociety with an appropriate quality grade if this isexplicitly stated in the respective approval document.Failing this, the Society's agreement shall be obtained.

5. The welding consumables and auxiliary mate-rials may only be used in the approved welding posi-tions. The manufacturers' recommendations and in-structions for welding (e.g. type of current and polar-ity) shall be followed.

6. The welding consumables and auxiliary mate-rials (especially hydrogen-controlled, basic-coveredelectrodes and basic welding fluxes) shall be re-driedbefore use in accordance with the manufacturer's in-structions (observe maximum drying time!) and stored

in a dry place (in heated containers or the like) at theworkplace.

Note:

The DVS guideline 0504 "Handling, storage and re-drying of covered electrodes" and the DVS regula-tions 0914 "Use and storage of welding fluxes forsubmerged-arc and electro-slag welding" issued by theGerman Welding Society (Deutscher Verband fürSchweißtechnik e.V) contain detailed instructions onthis subject.


Preliminary remark:

In contrast to earlier issues of these Rules, weldingprocedure tests shall be performed in accordance withEN 288 or ISO 9956, as applicable. This paragraphessentially covers requirements applicable to thewelding of pipelines over and above those set out inEN 288-3 and ISO 9956-3.

1. General

Only those welding procedures whose suitability forthe application in question is evident from generalexperience or has been verified by means of a weldingprocedure test in accordance with Chapter 1, Section 4and the following provisions may be used. Table 4.1 inChapter 1, Section 4 gives a list of necessary verifica-tions. The welding procedures must have been ap-proved by the Society for the particular welding shopin question as part of the welding shop approval (cf.also B.).


2.1 A preliminary "manufacturer’s" weldingprocedure specification (pWPS) setting out all themajor parameters shall be produced by the weldingshop for the welding of test pieces in accordance withEN 288-2 or ISO 9956-2, as applicable (see Chapter 1,Annex D).


2.3 The test pieces shall be made from materialswhose properties are proven in accordance with therequirements specified in Part 1, Metallic Materials,Chapter 2. Pre-treatment and after-treatment of the testpieces by preheating, heat treatment and the like isonly permitted if stipulated for these materials duringactual fabrication.

Chapter 3Page 4–4


F


2.5 The shape and dimensions of the test piecesare specified in EN 288-3/ISO 9956-3.


Except in the case of basic approvals for pipe class III(see B.4.1 and Table 4.1 in Chapter 1, Section 4), thequalification of the welding procedure shall be ascer-tained in accordance with EN 288/ISO 9956 Part 1,para. 5.1.1 by means of welding procedure qualifica-tion tests, for steel in accordance with EN 288/ISO9956 Part 3.

The test is valid within the limits described in paras.3.1 to 3.7.

The scope of the welding procedure test is specified bythe Society in writing. Any exceptions require theperformance of a supplementary test, the scope ofwhich shall be decided by the Society.

3.1 Base materials, material groups



b) A welding procedure qualification performed ongroup 1 killed steel does not apply to unkilledsteels unless they were welded using basic cov-ered electrodes.

c) Depending on material composition and/or thetype of post-weld treatment required, the Societymay also limit the scope to the base materialused in the welding procedure test.

d) For cargo and process pipelines designed tocarry liquefied gases, the test applies only to thegrade of steel inspected.

3.2 Welding process


3.3 Gas welding

In gas welding a test performed on the wall thickness tshall apply to the wall thickness range 0,75 t to 1,25 t.



3.5 Welding consumables and auxiliary mate-rials

The requirements of EN 288/ISO 9956 Part 3, para.8.4.5 do not apply if the filler metal used is of thesame type and has been approved by the Society to beunder the scope of the welding procedure qualification(cf. E.4).

3.6 Heat treatment

The welding procedure test applies to the heat treatedcondition existing at the time of the test. Heat treat-ment of the test piece shall be performed so that a heattreated condition is achieved which is comparable tothat of the component.

3.7 Special cases

For special cases, for example difficult repairs to beperformed in the course of fabrication on steels whichare susceptible to cracking due to hardening of theheat affected zone, welding procedure tests are neces-sary which are geared to these particular cases. Thetests required and their scope are specified by theSociety in each individual case.



Deviating from EN 288/ISO 9956 Part 3, para. 7.1 andTable 1, the following specimens shall also be takenfrom the test pieces:

a) Notched bar impact test on ISO V-notch speci-mens to EN 875 (DIN 50115) taken from thecentre of the weld metal (KM) (one set of speci-

mens per welding position) as follows:

– For cargo and process lines for gas tankerswhere the wall thickness is ≥ 4 mm1

– For other alloy steels and fine-grainedstructural steels where the wall thickness is≥ 6 mm.

b) Notched bar impact test on ISO V-notch speci-mens as above, but with the notch in the transi-tion zone (KÜ) where the wall thickness is

≥ 6 mm.

For austenitic pipe steels, the test is only re-quired for wall thicknesses ≥ 10 mm.

c) Macro- and micrographic specimens are re-quired for alloy steels. In particular, mi-crographic specimens shall be examined for mi-

––––––––––––––1 Size of specimen and requirements for wall thickness < 6 mm

must be separate agreed.

II - Part 3GL 2000


G

crocracks. The metallographic structure is to bedescribed or verified by means of photographs.

d) An analysis of the weld metal, except for unal-loyed steels.


The irregularities in the test piece must fall within thelimits specified for quality level B in accordance withEN 25817/ISO 5817, exceptions being: excessiveconvexity and excessive throat thickness (fillet welds)which fall into quality level C.

For the mechanical and technological tests, Table 4.1applies in conjunction with Table 4.2 which indicatesthe impact energy requirements for cargo and processlines for gas tankers.


The tested specimens and the remaining portions ofthe test pieces shall be stored until the report on thewelding procedure test has been issued (cf. alsoChapter 1, Section 4, C.3.).


The validity of a welding procedure test is generally 1year provided that the preconditions under which itwas granted have not significantly changed. It may becontinued by means of regular verifications of quality,e.g. the results of non-destructive tests or productiontests.

The welding procedure test shall be repeated if there isa break in the fabrication of pipelines or pipeline com-ponents lasting longer than one year.


1. Welds must exhibit full penetration over theirentire cross section and must not have any cracks orlack of fusion defects. The welds shall be made in theworkshop as far as possible.

2. Permanent backing rings shall be of such ashape that they can neither impede the flow nor causecorrosion. Backing rings shall be made of pipe steels

of the same composition as the base metal; with unal-loyed and low-alloy pipe grades, they may also, whereappropriate, be made of low-carbon steels(C ≤ 0,10 %).

3. In the case of pipelines fabricated from aus-tenitic steels and all other pipelines with working pres-sures in excess of 10 bar and design temperatures of- 10°C and below, permanent backing rings may not beused on principle.

4. For butt-welded joints in lines with designtemperatures below – 10°C and for all stainless pipesteels, the root passes shall as a rule be laid down bytungsten inert gas welding with gas shielding on boththe inside and the outside of the pipe.

5. Wherever possible, adequately dimensionedpipe fittings shall be used for branches. Where out-ward flanged pipeline connections are used, the insidediameter ratio shall not exceed 0,8. Outward flangesshall be made by established methods.

6. The preparation of welds must conform torecognized standards.

Wherever possible, welding edges shall be preparedby machining or with a mechanically guided cuttingtorch. Slag, scale, drag lines and other irregularitiesshall be removed. Where necessary, the same appliesto the heat-affected boundary zone in the case of aus-tenitic steels. The welding edges of steel forgings andcastings must be machined.

7. Tack welds may only be made with consum-ables which are also compatible with the pipe material.Where tack welds are to be left in place, they must beof the same quality as the root welds. The rules forpreheating shall also apply to tack welding.

8. Flange-pipe joints shall be chosen in accor-dance with the GL Rules I, Part 1, Chapter 2, Section11, in relation to the pipe class.

9. Pipeline sections to be welded must be axiallyaligned. The internal misalignment of the pipe endsmay not exceed the values stated in Table 4.4.

Chapter 3Page 4–6


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Table 4.1 Requirements as per para. 5 for testing of welded joints in pipelines

Type of Test Requirements


Tensile strength as stipulated for the base material or in the assessment of suitability forthe welding consumable

All pipelines exceptthose indicated below

As stipulated for the base material, at least ≥ 27 J. Test tem-perature as for testing of base material. When using ferritic-austenitic, austenitic and nickel-base alloy welding consum-ables, ≥ 40 J.


on ISO V-notchspecimens takenfrom the centre

of the weld metal Cargo and process linesof gas tankers

Test temperature as shown in Table 4.2. When using ferriticwelding consumables, ≥ 27 J 2; when using ferritic-austeni-tic, austenitic and nickel-base alloy welding consumables,≥ 34 J 2.

All pipelines exceptthose indicated below

≥ 27 J 2 test temperature as for testing of base materialNotched bar impact test 1

on ISO V-notch specimenstaken from the weld

transition zone

Cargo and process linesof gas tankers

Test temperature as shown in Table 4.2. ≥ 27 J for carbon-manganese steels, ≥ 34 J for nickel alloy steels, ≥ 41 J foraustenitic steels.

Bendingangle,

degreesStrength category

Bendingmandreldiameter

180 3

Ferritic steels with

minimum tensile strength < 430 N/mm2

minimum tensile strength ≥ 430 to < 460 N/mm2

2 × a

2,5 × a

180 3

Austenitic stainless steels and austenitic steels toughat subzero temperatures

High-temperature austenitic steels

Ferritic steels with a minimum tensile strength≥ 460 N/mm2

2 × a

3 × a

3 × a


≥ 90 Elongation (L0 = width of weld + wall thickness, simetrically to weld)

≥ minimum elongation A5 of base material


or < 90 Elongation over width of weld > 30 % and faultless appearance offracture

Metallographicexamination

The macrographic specimen of the welded joint must reveal a satisfactory weld build-up and full penetration of the weld.

Micrographic specimens are to be examined for cracks. Only hot cracks are acceptable,and then only if they are few in number and widely scattered and agreement has beenreached with the expert as to their acceptability with regard to the material and therange of application.

Hardness testing

The hardness in the heat-affected zones shall not exceed 350 HV 10. Hardness peaks inexcess of this figure in narrow transition zones shall not give rise to complaints if theoutcome of the technological tests meets the requirements.

1 For the requirements applicable to specimens with a depth of less than 10 mm, see Table 4.3.2 Only one impact energy value may be lower than the minimum mean value, and only by max. 30 %.3 The 180-degree requirement is deemed to have been met if the bend test was performed according to EN 910/ISO 5173

(DIN 50121) and pressure was applied by the supports without cracks appearing.

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Table 4.2 Test temperatures for notched bar impact testing of pipe steels tough at subzero temperatures

Type of steelStandard

Designation Standard

Minimum designtemperature

[°C]

Testtemperature

[°C]

Carbon and carbon-manganese steels

TT St 35 NTT St 35 V

– 40– 50

5 K below mini-mum design tem-perature, but notexceeding – 20 °C

Nickel alloy steelscontaining

0,5 % Nickel

3,5 % Nickel

5 % Nickel

9 % Nickel

13MnNi63

10Ni14

12Ni19

X8Ni9

DIN 17173

– 55

– 90

–105

–165

– 60

– 95

–110

–196

Austenitic steels 1, 2

(AISI 304 L)

(AISI 316 L)

(AISI 321)

(AISI 347)

X2CrNi19-11

X2CrNiMo18-14-3

X6CrNiTi18-10

X6CrNiNb18-10

DIN 17457

DIN 17458

–165 –196

1 The designations in brackets are comparable pipe steels to AISI standards.2 Where austenitic pipe steels are used for design temperatures not less than – 55 °C, a test temperature 5 K below the minimum

design temperature but not exceeding – 20 °C may be agreed upon.

Table 4.3 Impact energy requirements for specimens of reduced size

Required impact energy KVfor standard specimens 1

Required impact energy KVfor specimen sizes 1

10 ×××× 10 mm 7,5 ×××× 10 mm 5 ×××× 10 mm

[J] [J] [J]

27 (19)

34 (24)

41 (27)

22 (16)

28 (20)

34 (24)

18 (13)

23 (16)

27 (22)

1 Figures in brackets are for the minimum individual value.

Chapter 3Page 4–8


H

10. Weld reinforcements shall lie within the fol-lowing tolerances (cf.Fig. 4.1):

Cover pass reinforcement:

Ü B mmD ≤ +1 0 1,

Root pass reinforcement:

Ü b mmW ≤ +1 0 3,

(cf. also EN 25817/ISO 5817, quality level B)

B

bÜW

ÜD

Fig. 4.1 Weld reinforcements

11. Welding of pipeline components made offerritic steels in areas subjected to cold forming wherethe outer fibres have been stretched by more than 5 %(e.g. where pipe bending is carried out with a radiusrm < 10 � Da) is only allowed if the effects of cold-

forming have been eliminated by means of appropriateheat treatment. This shall generally be accomplishedby normalizing heat treatment or quenching and tem-pering.

This requirement may be waived if proof is furnishedthat the properties of the material are no more thaninsignificantly impaired with regard to the intendeduse or if the conditions specified in para. H.1. or H.2.,as applicable, are met.

H. Heat treatments after cold or hot workingand welding

1. Ferritic steel pipes

1.1 Heat treatment after cold forming

1.1.1 Pipes or pipelines shall normally be subjectedto heat treatment (normalizing heat treatment orquenching and tempering) following cold forming witha degree of deformation ≥ 5 % (rm ≤ 10 × Da) in ac-

cordance with the material specification.

1.1.2 Post-forming heat treatment may be dis-pensed with in the case of unalloyed steel or fine-grained structural steel pipes with an outside diameterDa ≤ 133 mm which are subjected to cold-bending

with a bending radius rm ≤ 1,3 × Da.

An exception applies to pipes fabricated from steelstough at subzero temperatures with wall thicknesses> 2,5 mm or pipes to which stressed components arewelded outside the neutral fibres.

1.2 Heat treatment after hot forming

1.2.1 Pipes and pipeline components shall be sub-jected to heat treatment after hot forming in accor-dance with the material specification.

If the hot forming operation is begun and ended withinthe temperature range stated in the material specifica-tion, normalizing heat treatment may be dispensedwith for normalized steels. Subsequent tempering isrequired in the case of air-hardened and temperedsteels.

1.2.2 If the pipe only undergoes localized heatingin certain areas during bending, the provisions of para.1.2.1 still apply; however, the entire pipe must be inthe prescribed heat- treated condition.

Table 4.4 Tolerances on internal misalignment of pipe ends

Type of joint

Inside diameterDi

[mm]

Wall thicknesst

[mm]

Tolerances on internalmisalignment

with permanent backingrings any any max. 0,5 mm

without backing rings

Di < 150150 ≤ Di < 300

300 ≤ Di

any

t ≤ 6

t ≤ 9,5

any

t > 9,5

t/4 max. 1 mmt/4 max. 1,5 mm

t/4 max. 2,0 mm

t/4 max. 2,0 mm

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2. Austenitic steel pipes

2.1 Heat treatment after cold forming

Heat treatment of pipes subjected to cold bending witha bending radius ≥ 1,3 × Da is normally not required.

2.2 Heat treatment after hot forming

Renewed heat treatment (solution heat treatment andquenching or stabilization heat treatment) in accor-dance with the material specification is normally re-quired after hot forming. If the heat treatment is car-ried out at initial forming temperatures between1000 °C and 1150 °C and if the forming operation iscompleted at a temperature > 750 °C in the case ofstabilized steels or steels with a carbon content≤ 0,03 % and > 875 °C in the case of other steels,follow-up heat treatment may be dispensed with. Acondition of this is that the material must be rapidlycooled down from the forming temperature.

2.3 Where more exacting corrosion resistancerequirements apply, e.g. to pipelines for chemicaltankers, the procedures described in para. 2.12 or 2.2,as applicable, may only be followed if the pipelinefabricator has proved by means of corrosion tests thatthe required resistance is present after forming. Failingthis, renewed heat treatment after cold or hot formingis required.

3. Heat treatment of pipe fittings

The provisions of Part 1, Chapter 2, Section 6, B.,Pipe Fittings, apply.

4. Post-weld heat treatment

4.1 Heat treatment shall be applied in accordancewith Chapter 2, Section 3. Welded joints in pipelinesfabricated from ferritic steels shall be heat-treated afterwelding in accordance with the stipulations of therelevant standards or the Society's approval documentwhere the conditions stated in para. 4.1.1 and 4.1.2apply. Unless otherwise stipulated, the post-weld heattreatment shall consist of stress relief heat treatment.

4.1.1 Electrically fusion-welded pipe joints shallundergo stress relief heat treatment if the limit wallthicknesses shown in Table 4.5 in relation to the typeof pipe steel are exceeded.

4.1.2 Gas fusion-welded joints shall undergo nor-malizing heat treatment or quenching and tempering,depending on the type of material, if the wall thicknessof the pipe exceeds 3,2 mm or the outside diameterexceeds 88,9 mm.

4.1.3 For pipes made of nickel alloy steels tough atsubzero temperatures, the need for post-weld heattreatment and the limit wall thicknesses will be deter-mined during the welding procedure test.

Table 4.5 Limit wall thicknesses for stress relief heat treatment of ferritic steel pipelines

SteelWall thickness of

the thicker element[mm]

Heat treatment temperature[°C]

Carbon and carbon-manganesestells containing

CMn+ ≤6

0 40, ≥ 20 1

CMn+ >6

0 40, ≥ 10

0,3 Mo ≥ 15

1 Cr 0,5 Mo ≥ 8

2,25 Cr 1 Mo all thicknessses 2

The provisions of Chapter 2,

Section 3 apply

1 The limit wall thickness for heat treatment may be raised if the welding procedure test has proved that the welds of untreated testpieces possess the required mechanical properties.

2 Stress relief heat treatment may be dispensed with where the operating temperature is at least 450 °C and where the outside diameterand the wall thickness do not exceed 100 mm and 6 mm respectively.



I

4.2 For pipelines fabricated from austenitic andaustenitic- ferritic steels, post-weld heat treatment isgenerally unnecessary if the pipeline materials are inthe proper heat-treated condition prior to welding.

I. Inspection of Welded Pipelines

The inspection shall consist of an internal hydraulicpressure test and non-destructive tests. The non-destructive tests shall be performed in accordancewith Chapter 2, Section 4.

1. Completed pipeline sections shall be sub-jected to a hydraulic pressure test at 1,5 times theworking pressure in the presence of the Surveyor. Thepipeline section may not exhibit any leaks during thehydraulic pressure test or any permanent deformationafterwards.

2. An external and, wherever possible, also aninternal inspection of the completed pipeline sectionsand especially of the welds shall be performed. Forthe inspections, the sections shall have a smooth ex-ternal and internal surface corresponding to the as-fabricated condition which enables major surfacedefects to be detected, and pipelines fabricated fromaustenitic and austenitic-ferritic steels must be freefrom harmful temper colours.

3. The misalignment of pipe ends, the externalweld reinforcements and - where accessible - theinternal weld reinforcements shall be checked. Theymust lie within the tolerances specified in para. G.9.and G.10.

4. The butt-welded joints of the followingpipelines shall be subjected to radiographic inspec-tion as follows:

a) All pipelines in pipe class I: 100%.

A reduction in the scope of the test may beagreed on application for pipelines with an in-side diameter ≤ 75 mm, provided that proof is

furnished that the results are consistently goodand that the percentage of repairs is relativelylow.

b) All cargo and process lines of gas tankers witha service temperature below – 10°C: 100 %.

A reduction in the scope of the test may beagreed on application for pipelines with an in-side diameter ≤ 75 mm or wall thicknesses ≤ 10mm provided that proof is furnished that theresults are consistently good and that the per-centage of repairs is relatively low.

c) All pipelines in pipe class II: 10 %.

A reduction in the scope of the test may beagreed on application for pipelines with an in-side diameter ≤ 100 mm provided that proof isfurnished that the results are consistently goodand that the percentage of repairs is relativelylow.

d) Where the execution of welding operationsgives rise to doubts as to the quality of thewelded joints, the Society may also call for arandom radiographic test to be carried out onthe butt welds of pipe class III.

The radiographic inspection shall as a rule be per-formed with an X-ray tube. With the Society's con-sent, radiographic inspection may be replaced byultrasonic inspection for ferritic steel pipes with wallthicknesses ≥ 20 mm.

5. Fillet welds of flanges, sockets and nipplesof pipelines in class I, including cargo and processlines of gas tankers, shall be 100 % tested for surfacecracks.

For pipelines in pipe class II and III, random testingcovering 10 % of the welds is required.

Note:

The scope of the tests to be applied to series-manufactured pipe fittings is specified separately; cf.Part 1, Metallic Materials, Chapter 2, Section 6, B.

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Section 5 Welding of Machinery Components Chapter 3Page 5–1

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Section 5

Welding of Machinery Components

A. General

1. Scope

1.1 These Rules apply to all welding work per-formed during the fabrication and repair of machinerycomponents such as bedplates, frames, housings fordiesel engines, gear boxes, wheel bodies, steeringengine housings, quadrants and similar components ofa corresponding nature.

Note:

Since the machinery components listed above aremostly "steel components" which are not significantlydifferent from hull structures in their materials, weld-ing processes and welding works (cf. also Table 4.1 inChapter 1, Section 4), the specifications set out inSection 1 of this Chapter applicable to the welding ofhull structures may also be applied here where nospecial provisions are prescribed in the followingparagraphs.

1.2 They also apply to welding work performedon machinery components such as axles or shafts,pistons, propellers, hubs, machinery tanks, hydrauliccylinders, valve housings, valves etc. where the Soci-ety has approved welding work to be carried out oncomponents of this kind either as a general approval orin an individual case. They apply to welding workperformed in the course of new fabrications and alsoto repair welds on machinery components.

1.3 For the use of welding as a production proc-ess during the course of the manufacture of materialsand/or semi-finished products, such as the "fabricationwelding" of the forgings or castings used in machinerycomponents (e.g. propellers), see also the Rules forMetallic Materials and the Iron and Steel MaterialSpecification (Stahl-Eisen-Werkstoffblatt) SEW 110,welding procedure tests for production welds made oncast steel.

2. Other relevant rules and regulations

The design and dimensions of welded joints and alsothe welding technique are subject to the provisions ofthe Rules for Construction I, Part 1, Chapter 2 andother rules or regulations issued by the Society forspecific ranges of application. For other relevant stan-

dards, etc., see Chapter 1, Section 1, B. of these Rulesfor Welding.


1. Works and works divisions

1.1 In the following paragraphs, the term "weld-ing shop" refers to the welding fabrication shop whichmay be considered an independent unit with regard toits physical and organizational situation.

1.2 Branches and subcontractors are thus gener-ally deemed to be "independent" welding shops whichhave to satisfy the requirements prescribed below. Inparticular, every welding shop must have a weldingsupervisor who is a permanent member of the weldingshop staff (cf. Chapter 1, Section 2).

1.3 Outside firms working in welding shops maybe granted approval as independent welding shops. Onthis and on temporary workers, see also C.3. andChapter 1, Section 1, F.

2. Requirements, scope of approval

2.1 All welding shops intending to performwelding work covered by these rules must satisfy therequirements relating to the welding shop and its per-sonnel set out in Chapter 1, Section 2 and must havebeen approved for this work by the Society. Applica-tions for approval shall be submitted by the shipyardsand welding shops in good time before starting thewelding work, enclosing the information and docu-mentation prescribed in Chapter 1, Section 2, A.3.

2.2 Welding personnel (welders, operators andsupervisory staff) and where applicable inspectors andtest supervisors must meet the requirements set out inChapter 1, Section 2, B.2., B.3. and B.4. and be rec-ognized by the Society. For welder’s qualificationtests, see Chapter 1, Section 3.

2.3 The scope of the approval is determined bythe capabilities of the welding shop and by the in-tended range of application (components, materials,welding processes, welding positions, etc.). The in-

Chapter 3Page 5–2

Section 5 Welding of Machinery Components II - Part 3GL 2000

C

tended range of application shall be specified in theapplication for approval; cf. the form "Description ofWelding Shop" attached at Chapter 1, Annex B. Forthe period of validity of the approvals, see Chapter 1,Section 2, A.4. and A.5.


3.1 For welding machinery components, as ageneral rule (basic) approval is granted first of all onthe basis of a works inspection and, if necessary,welder's qualification tests in accordance with Chapter1, Section 3 (see also 4.) normally for manual arcwelding (welding process 111) and/or for semi-mechanized metal-arc active gas welding using solidand flux-cored wire electrodes (welding processes 135and 136) of normal-strength structural steels and othercomparable grades of forged and cast steel. The thick-ness range is in this case determined by the scope ofthe valid welder’s qualification tests.

3.2 Welding procedure tests shall be performedfor other components, materials and/or welding proc-esses, cf. F. Single-wire submerged arc welding(welding process 121) may also be covered in thebasic approval described in 3.1 on the basis of docu-mentary proof of satisfactory operational handling (cf.F.1.3) (for the normal welding in one run on each side[two-run technique] on plates 4 to 25 mm thick and formulti-pass welding up to 40 mm).

3.3 Basic approval may be extended to includeany welding process approvals on the basis of weldingprocedure tests as set out in Chapter 1, Section 4 (seealso F.); in exceptional cases, however, limited ap-proval may also only be granted (in conjunction with aworks inspection) for a specific material and/or weld-ing process.

4. Welding staff (welders and supervisors) mustmeet the requirements set out in Chapter 1, Section 2,B.2. and B.3. and be recognized by the Society. Forwelder’s qualification tests see Chapter 1, Section 3.


1. Welding shops shall ensure by means ofregular in-house quality inspections during fabricationand on completion of the welding work that this workhas been performed competently and satisfactorily (cf.Chapter 1, Section 1, F.). For the duties and responsi-bilities of the welding supervisor, see also EN 719/ISO14731 (DIN 8563 Part 2).

2. The welding shops are responsible for ensur-ing that the welding work conforms to these Rules, theapproved manufacturing documents, any conditionsstipulated in the approval documents, good machinerybuilding practice and the latest state of welding prac-tice. The inspections and checks to be performed bythe Society’s Surveyor do not relieve the weldingshops of this responsibility.

3. With regard to quality inspections and theresponsibilities involved in awarding subcontracts toindependent branches or suppliers or to approved ornon-approved outside firms working in the weldingshop (subcontractors), see Chapter 1, Section 1, F.; the"prime contractor" shall ensure that "subcontractors"also meet the conditions specified in para. 1.

4. Where non-approved outside firms and tem-porary staff are employed in the welding shop, thewelding shop is responsible for carrying out qualityinspections and for compliance with the conditionsstated in para. 1. Subcontracting of work or the em-ployment of temporary staff shall be notified to theSociety.

5. The scope of the required quality inspectionsdepends on the construction project in question. It isessential to ensure, however, that the intended materi-als, welding consumables and auxiliary materials areused and that the weld preparation, assembly, execu-tion of welding work and the dimensional accuracyand completeness of the welded joints meets the re-quirements stated in para. 2. For non-destructive test-ing of the welded joints, see I.

6. Following inspection and, if necessary, repairby the welding shop, the components shall be pre-sented to the Society's Surveyor for checking at suit-able stages of fabrication. For this purpose they shallbe readily accessible and shall normally be uncoated.Where the previous inspection has been inadequate,the Surveyor may reject components and require thatthey be presented again after satisfactory workshopinspection and any necessary repair work has beenperformed.

7. If the quality or good working order of acomponent cannot be guaranteed or is in doubt due toinadequate or missing information in the manufactur-ing documents (e.g. production drawings), the Societymay demand appropriate improvements. This appliesin analogous manner to supplementary or additionalmeasures, even if these measures were not stipulatedwhen the drawings were scrutinized or could not bestipulated due to insufficiently detailed representationin the production documents.

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8. Responsibility for the proper performance ofquality inspections and compliance with the conditionsstated above lies with the welding shop. The inspec-tions and checks to be performed by the Society’sSurveyor do not relieve the welding shops from thisresponsibility.



1. Welded structures may only be fabricatedusing base materials of proven weldability. Materialsmust comply with the Society’s Rules for Materials.Other comparable materials (e.g. structural steels con-forming to the standards) may only be used after theSociety has given its approval in each individual case.

2. Any conditions relating to working andwelding imposed by the approval certificate and therecommendations of the material producer shall becomplied with. For the selection of materials for theship's hull, see the Rules for Construction I, Part 1,Chapter 2 and in other rules and regulations issued bythe Society for specific ranges of application.

3. Steel castings and forgings shall comply withthe Rules for Materials and shall have been tested bythe Society. The carbon content of components madefrom carbon and carbon-manganese steels or caststeels for welded structures shall not exceed 0,23 % Cat ladle analysis (check analysis: max. 0,25 % C).


1. All the welding consumables and auxiliarymaterials used (e.g. covered electrodes, wire-gas com-binations, wire-flux combinations, etc.) must havebeen approved by the Society in accordance withChapter 1, Section 5. The quality grade required de-pends on the base materials to be welded and is shownin the relevant tables in Chapter 1, Section 5.

2. The welding consumables must enable awelded joint to be made which is appropriate to thebase material and the type of stress to which it is sub-jected and also enable trouble-free further processing.For joints between dissimilar materials (with the ex-ception of high-alloy, austenitic steels), the weldingconsumable should, wherever possible, be geared tothe lower alloyed material or the material with thelower strength.

3. For welding very thick-walled, rigid compo-nents (approx. 30 mm and over) and welding of forg-ings and castings, hydrogen-controlled welding con-sumables and auxiliary materials shall be used wher-ever possible, e.g. those of quality grade … H15(H) orlower or …Y.. H10 (HH) or lower for higher-strengthstructural steels.

4. Hydrogen-controlled welding consumablesand auxiliary materials should also be used for com-ponents which are subjected to full load immediatelyafter welding (e.g. lifting lugs or as a result of pressuretests) or where allowance has to be made for a highdegree of residual stress due to the rigidity of thestructure and, where applicable, a high yield strengthor strength of a structure.


1. General

1.1 Only welding procedures whose suitability forthe application in question is evident from generalexperience or has been verified by means of a weldingprocedure test in accordance with Chapter 1, Section 4and the following provisions may be used. Table 4.1 inChapter 1, Section 4 gives a list of the requisite verifi-cations. The welding procedure must have been ap-proved by the Society for the welding shop in questionas part of the welding shop approval (cf. also B.).

1.2 Welding procedure tests supervised by theSociety for verification of satisfactory operationalhandling and a trouble-free execution of the procedure,and also adequate quality properties for the weldedjoints made under production conditions at the user'sworks are in general required for all materials andwelding processes other than those covered by the(basic) approval as described in B.3.1.

1.3 For conventional single-wire submerged-arcbutt welding processes using solid wire electrodes forwelding normal-strength structural steels, comparableforged steels and cast steels from both sides, proofprior to initial use of the reliability and technical suit-ability of the method by means of trial welds and non-

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destructive (e.g. radiographic) tests as directed by theSurveyor is sufficient. The welding consumables andauxiliary materials used must have been approved bythe Society.

1.4 The Society may additionally require weldingprocedure tests for specific (difficult) componentshapes or combinations of materials, particular weldshapes, process variants or combinations, and also forparticular welding consumables and auxiliary materi-als. The same applies in analogous manner to otherjoining processes or (surface) finishing operationssuch as thermal cutting or flame straightening.

1.5 The information in the preceding and fol-lowing paragraphs, especially the information on testpieces, specimen shapes, tests and requirements, ap-plies to the normal materials, welding processes andweld shapes in current use in ship-machine building,the behaviour of which under service conditions hasbeen verified by experience and/or test results. Incases of doubt, the Society may call for additionaland/or different test pieces, specimen shapes or tests toverify satisfactory suitability for use.

1.6 In the case of welding processes whose char-acteristics result in weld shapes other than those veri-fied by experience and/or test results (e.g. those with aconsiderable notch effect), the influence of the weldshape on the fatigue strength behaviour of the weldedjoints may be investigated in addition to carrying outthe prescribed tests. The same applies in analogousmanner to other characteristics of the welded joints,e.g. corrosion resistance.

2. Scope of tests, test schedule, limits of appli-cation

2.1 Test schedule, test details

2.1.1 The scope of the welding procedure tests(materials, test pieces, heat treatment, specimens, tests,etc.) shall be laid down in a test schedule to be sub-mitted for approval in good time prior to testing, inaccordance with Chapter 1, Section 4, B.1. Dependingon the nature and application of a welding process, theprocess details stipulated in Chapter 1, Section 4,B.1.1 shall be specified and taken into account in thetests.

2.1.2 Where no further details on the welding pro-cedure tests are given in the following paragraphs, theprovisions of Chapter 1, Section 4 shall apply. Thestandards of the series EN 288/ISO 9956 may be ap-plied, however the Society reserve the right to setsupplementary or different requirements above andbeyond the provisions stated in the following para-graphs, e.g. for the scope of application (materials,weld types, welding positions, cf. 2.1.3).

2.1.3 For welding procedure tests for the weldingof (steel) machinery components, the provisions setout in Section 1, F. relating to the welding proceduretests for (hull) structural steels shall apply in analo-gous manner. This shall also particularly apply withregard to weld types and welding positions. Accord-ingly, both butt and fillet welds (or other particularweld forms) are also covered in the welding proceduretests, as are all the welding positions encountered.

2.1.4 Welding procedure tests for the (repair)welding of propellers shall be performed in accor-dance with the provisions applicable to "productionwelds" in the Rules for Materials issued by the Soci-ety. These must also be complied with for the weldingconsumables and heat treatment recommended andalso the areas where welding is not permitted.

2.1.5 For special welding processes, such as flashbutt welding, friction welding, electron-beam or laserwelding and also for special applications such asbuild-up welding on shafts, pistons or valves, the typeand scope (form and dimensions of the test pieces) ofthe welding procedure tests and their scope in accor-dance with the foregoing provisions are specifiedseparately in each individual case.

3. Test pieces, fabrication (welding), (post-weld) heat treatment

3.1 For (steel) machinery components weldingshall be performed on butt and fillet weld test pieces(where these are encountered in the production proc-ess) in analogous manner to Section 1, F.3. or, byagreement with the Society, in accordance with thestandards of the series EN 288/ISO 9956. Test piecesfor other components, particular welding processes orapplications shall be agreed with the Society in eachindividual case.

3.2 The direction of rolling of butt and fillet weldtest pieces shall generally be parallel to the directionof the weld. The weld shapes shall correspond to thoseused in the fabrication process.

3.3 For welding, the test pieces shall be madefrom materials whose properties may be unequivocallyproved in accordance with the requirements specifiedin the Rules for Materials or approved material speci-fications by the submission of certificates and bymarking the material (stamping). In cases of doubt, theSociety may call for appropriate material examinationsto be carried out. Cf. Chapter 1, Section 4, B.3.

3.4 The welding parameters stipulated in thepreliminary welding procedure specification (pWPS)shall be complied with (see Annex D in Chapter 1) andit is necessary to record the parameters used in the

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tests and specify these in the final welding procedurespecification. Cf. Chapter 1, Section 4, B.5.

3.5 Pre-treatment and after-treatment of the testpieces by preheating, heat treatment or the like is onlypermitted if stipulated for these materials during actualfabrication. This treatment shall also be recorded andspecified in the final welding procedure specification.Cf. Chapter 1, Section 4, B.6.


Prior to sectioning, the test pieces shall undergo com-prehensive non-destructive tests to detect weldingdefects or defects in the welding procedure. The testmethod or methods (a combination) to be applied aredetermined by the nature of the test piece or weld andshall be agreed with the Society and stipulated in thetest schedule. Cf. Chapter 1, Section 4, B.7.

5. Sectioning of test pieces, type and numberof specimens

5.1 The sectioning of test pieces and the prepara-tion of specimens is subject to the provisions ofChapter 1, Section 4, B.8.

5.2 Unless otherwise agreed in a particular case,one set of butt weld specimens shall comprise thefollowing specimens. The specimen shapes and dimen-sions shall conform to the provisions of the standardsor Chapter 2, Section 5 as applicable:

– 2 transverse tensile test specimens in accor-dance with EN 895/ISO 4136 (for larger platethicknesses a correspondingly greater number ofspecimens shall be provided to cover the fullcross-section),

– 1 round tensile test specimen by analogy to theprovisions of Chapter 1, Section 5, B.2.3 (Fig.5.1 and 5.2) taken lengthwise from the weldmetal if welding consumables and auxiliary ma-terials not approved by the Society are to beused (cf. Chapter 1, Section 4, B.3.2), if differ-ent materials are to be joined, if welds are madeusing dissimilar welding consumables or if thecharacteristics of the welding process suggestthat the weld metal itself is likely to be consid-erably affected.

A round tensile test specimen is to be preparedin every case (except for aluminium alloys)where the mechanical properties of the weldmetal are inferior to those of the base material(e.g. when welding high-strength steels). The di-ameter "d0" of the specimen shall be as large as

possible (but not more than 10 mm) and thegauge length "L0" shall be 5 × d0. The provi-

sions of Chapter 1, Section 5, B.2. are to be ap-

plied in analogous manner. For plate thicknesses≤ 20 mm the Society may dispense with theround tensile specimen.

– 4 transverse bend test specimens, in accor-dance with EN 910/(ISO 5173) half to be bentwith the final pass in tension (FBB) and halfwith the root pass in tension (RBB),

or

– 2 transverse bend test specimens (1FBB and1RBB) as before and

2 side bend test specimens taken at right anglesto the butt weld (SBB) in accordance with EN910/(ISO 5173) in the case of test pieces over12 mm thick, or

– 4 side bend test specimens (SBB) in the case oftest pieces more than 20 mm thick and weldingprocesses liable to give rise to segregations, so-lidification cracking, lack of fusion or similardefects inside the weld (e.g. single-side and ver-tical-down welding)

Note:

In the case of pairs of materials which differ instrength, it may be advisable to use butt-weldedlongitudinal bend test specimens (FBB andRBB) in accordance with EN 910/ISO 5173 withthe weld seam in the centre of the specimen in-stead of butt-welded transverse bend test speci-mens. See also Chapter 2, Section 5. The detailsof this test and the requirements (as a rule aqualitative assessment of the bending behav-iour) shall be agreed on a case-by-case basis.

– 3 notched bar impact test specimens each(Charpy V-notch specimens with the notch per-pendicular to the surface of the plate) in accor-dance with EN 875/ISO 9016, from the centre ofthe weld (VWT 0/1), from the fusion bound-ary/transition zone (VHT 0/1) and from the heat-affected zone (VHT 2/1), taken from the lastside welded. Where plate and castings are to beunited, the notched bar impact test specimensshall be taken from the fusion bound-ary/transition zone and heat affected zone ofboth materials. With very large plate thick-nesses, notched bar impact test specimens shallbe taken from the surface and back of the weldand in the case of welding processes liable tocause segregation in the central zone, an addi-tional 3 notched bar impact test specimens ofeach type shall be taken from the same areas inmiddle of the plate thickness.

The dimension "a" (cf. EN 875/ISO 9016) shallbe such that the point of intersection of the cen-tre line of the specimen and the middle of thenotch lies in the coarse-grained area of the heat-

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affected zone. This dimension may be generallytaken as 2 mm. Where welding procedure testsare performed on steels tough at subzero tem-peratures, test specimens with notches located ata = 1 mm, a = 3 mm and a = 5 mm shall be pre-pared, unless otherwise specified in an individ-ual case.

Depending on the base material and weldingprocess concerned, further notched bar impacttest specimens from other areas may be stipu-lated. Notched bar impact test specimens may bepartly or wholly dispensed with where the resultsof these tests in connection with the use of aparticular welding process are of minor signifi-cance for certain materials, e.g. austenitic stain-less steels or aluminium alloys (except for low-temperature applications).

– 2 macrographic specimens for evaluating thegrain structure and if necessary (e.g. for alloysteels) micrographic specimens.

– Hardness tests (Vickers HV5 or HV10) in ac-cordance with EN 1043-1 (EN 1043-2 in thecase of laser welding) shall be carried out where,having regard to the base material and thewelding process, the possibility cannot be dis-counted that preheating and/or the heat flowduring welding may affect the hardness values insuch a way as to impair the toughness or strengthcharacteristics of the weld. Hardness measure-ments shall always be performed on higher-strength structural steels and on high-strength(quenched and tempered) fine-grained structuralsteels with minimum yield strengths of morethan 355 N/mm2.

– Weld metal analysis, if necessary and if agreedwith the Society.

5.3 Two or more macrographic specimens, asapplicable depending on the length of the test piece,shall be taken from the simplified (T-jointed) fillet-welded test pieces in accordance with EN 288/ISO9956 to evaluate the penetration conditions, any ir-regularities in the welded joints and the grain structure.If necessary, hardness measurements as described inEN 1043-1 and -2 shall be performed (cf. 5.2) and (inthe case of alloy steels) micrographic specimenstaken. The remainder of the test pieces is to be dividedinto convenient portions which, after removal of oneof the welds, are to be broken open on alternate sidesfor evaluation of the fracture (cf. EN 1320).

5.4 A set of double T-joint (cruciform) filletweld test specimens according to Fig. 5.1 shall com-prise the following specimens. The specimen shapesand dimensions shall conform to the provisions ofChapter 2, Section 5:

– 3 cruciform tensile test specimens (Z) asshown in Fig. 5.2 for determining the tensile-shear strength of the weld metal

– 2 macrographic specimens (M) for evaluatingthe penetration conditions, any irregularities inthe welded joints and the grain structure. If nec-essary, hardness measurements (cf. 5.2) shallbe performed in accordance with EN 1043-1 and-2. Where necessary (e.g. in the case of alloysteels), micrographic specimens.

The remainder of the test pieces is to be divided intoconvenient portions which, after removal of one of thewelds, are to be broken open on alternate sides forevaluation of the fracture (cf. EN 1320).

� � �

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Fig. 5.1 Set of double T-joint (cruciform) speci-mens

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Fig. 5.2 Cruciform tensile test specimen, weldcross-section

5.5 The specimens and tests for particular com-ponents, materials, welding processes and/or their uses(cf. 2.1.5) will be specified separately in accordancewith the foregoing provisions in each individual case.

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Table 5.1 Requirements applicable to the testing of welded joints 1



Tensile strength as stipulated for the base material or in the assessment of suitability for thewelding consumable

Tensile test on a specimenof the weld metal

Yield strength or 0,2 % proof stress. Tensile strength and elongation as for the base materialor as specified in the assessment of suitability for the welding consumable.

Notched bar impact teston ISO-V-notch

specimens taken fromthe centre of the weld

As specified for the base material in transverse direction or as specified in the assessment ofsuitability for the welding consumable. When using ferritic-austenitic, austenitic and nickel-base alloy welding consumables, ≥ 40 J 2

Notched bar impact teston ISO-V-notch

specimens taken fromthe weld transition zone

70 % of the required value for the base material in transverse direction, but at least 20 J 2

Bending angleDegrees Strength category

Bendingmandrel dia.

180 3

Ferritic steels with

min. tensile strength < 430 N/mm2

min. tensile strength ≥ 430 to 460 N/mm2

2 × a

2,5 × a

180 3

Austenitic stainless steels and austenitic steels toughat subzero temperatures

Ferritic steels with a minimum tensile strength≥ 460 N/mm2

2 × a

3 × a


≥ 90 Elongation (L0 = width of weld + wall thickness, symmetrical to weld)

≥ minimum elongation A5 of base material


or < 90 Elongation over width of weld > 30 % 4 and faultless appearance of fracture

Metallographicexamintation

The macrographic specimen of the welded joint must reveal a satisfactory weld build-up andfull penetration of the weld.

Micrographic specimens are to be examined for cracks. Only hot cracks are acceptable, andthen only if they are few in number and widely scattered and agreement has been reachedwith the Surveyor as to their acceptability with regard to the materials and the range ofapplication

Hardness testingThe hardness in the heat-affected zones shall not exceed 350 HV 10. Hardness peaks inexcess of this figure in narrow transition zones shall not give rise to complaints if theoutcome of the technological test meets the requirements

1 Where special welding precesses are used as described in para. 2.1.5, the values shall be agreed with the Society.2 Only one impact energy value may be lower than the minimum mean value, and only by max. 30 %.3 The 180-degree requirement is deemed to have been met if the bend test was performed according to EN 910/ISO 5173 (DIN 50121)

and pressure was applied by the supports without cracks appearing.4 For steels welded with dissimilar consumables, different values may be agreed with the Society.

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6. Mechanical and technological tests, re-quirements

6.1 The mechanical and technological tests shallbe performed according to the provisions of Chapter 2,Section 5 or to the standards stipulated therein. Forretests, see Chapter 1, Section 4, C.2.

6.2 The results of the mechanical and technologi-cal tests must satisfy the requirements stated in Table5.1. The Society may stipulate different or supple-mentary requirements especially for the specimens andtests described in para. 2.1.5 and 5.5.

G. Design, Welding Technique

1. The general design principles described inChapter 2, Section 1 shall be observed. With regard todesign and dimensioning (particularly that of (steel)machinery components in accordance with A.1.1), theSociety may call for application, in analogous manner,of the provisions Section 1, G. of this Chapter.

2. Butt welds which are critical to the strengthof the component must be executed as full-penetrationwelds. This category includes, for example, the buttwelds joining the web and flange plates of enginebedplates and the butt welds uniting bearing bracketsand connecting plates.

3. The fillet welds of load-bearing members, e.g.the neck seams of plate girders for uniting flange andweb plates, must be capable of being welded without abreak. For this purpose, the stiffeners or web plates areeither to be added on close to the neck seams at a laterdate or adequate welding apertures are to be provided.

4. Components shall be designed so as to avoidseam intersections wherever possible. Individual com-ponents of complicated shape which, if welded, wouldresult in a clustering of weld seams, e.g. bearingbrackets, should either be cast in steel or, if welded,should undergo stress relief heat treatment. Cf. H.

5. All parts to be joined by welding have to becarefully aligned and mounted and tacked in such away that welding can be carried out with a minimumof distortion and residual stress. Wherever possible,welding should be performed in the downhand posi-tion.

6. Wherever possible, stiffening plates and webplates which are open at the ends are to be cut off atthe ends as shown in Fig. 5.3 (corresponding to the

thickness of the weld) at an angle of 90° to themounting plane and welded round at the ends.

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Fig. 5.3 Welding round of stiffening plates orweb plates

7. Castings and forgings that are to be joined tothin-walled components shall be provided with weld-ing flanges which have been cast or forged on. Beforewelding, the welding edges of castings and forgingsmust be metallically clean and bright and must havebeen inspected for material defects using a suitableprocess.

8. Tack welds which are to be left in place aspart of the seam are subject to the same qualitativerequirements as root passes. Defective tack welds maynot be welded over. They are to be removed.

9. If the thickness of flange plates or web plateschanges at butt joints, to give a better transition to thethicker section the edges which stand proud by morethan 10 mm shall be bevelled off with a gradient of 1:1or shallower, as shown in Fig. 5.4. Differences inthickness less than 10 mm may be compensated for inthe weld.

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Fig. 5.4 Butt-welded joints in plates of differentthickness

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Where the loading transversely to the weld is pre-dominantly dynamic, the transitions are to be madeshallower and in this case the provisions of Section 1,G.3. of this Chapter shall be applied in analogousmanner.

10. Welding may be performed in areas of com-ponents where cold forming has been carried out,including the adjoining surfaces over a width of 5times the plate thickness t, provided that the conditions(bending radii) specified in Section 1, G.8. of thisChapter are met. Where components subjected to coldforming undergo normalizing heat treatment prior towelding, these conditions need not be adhered to.

11. Where approved by the Society allowing forthe relevant load conditions, build-up welds on ma-chinery components subject to dynamic loads (e.g.shafts) shall be executed in a circumferential directionusing a fully-mechanized welding process. The provi-sions of Section 1, G.9. of this Chapter shall apply inanalogous manner.


1. Thick-walled, rigid components or those ofcomplicated design which exhibit high levels of resid-ual stress after joining must be heat-treated afterwelding in accordance with the relevant standards orthe Society's approval document. Examples are bed-plates for diesel engines, gear boxes and welded gearwheels. Cf. also G.4.

Note:

Post-weld heat treatment (stress-relief heat treatment)may be advisable whenever components have, subse-quently, to undergo machining and where thereforethere is a risk of stresses being produced during themachining process leading to distortion of the compo-nents.

2. The heat treatment generally takes the form ofstress relief heat treatment. Depending on the material,however, annealing heat treatment or quenching andtempering may also be advisable or necessary. "Blackto white" joints between unalloyed steels and austeni-tic stainless steels may not be subjected to a post-weld

heat treatment. For the type and performance of theheat treatment, see Chapter 2, Section 3.


1. The manufacturer shall present the compo-nents for the required intermediate and final inspec-tions, (cf. also Chapter 1, Section 1, F.1. and G.) inwhich the following shall be demonstrated to the Soci-ety’s Surveyor:

– Proper weld preparation and execution of weld-ing work,

– The satisfactory external condition of the com-ponents and especially of the welds,

– Use of the prescribed materials and dimensionsby presentation of the documents relating tomaterials,

– The existence of relevant, valid welder's qualifi-cation and welding procedure tests covering therange of application,

– The proper performance of heat treatments bypresentation of the relevant records and/or cer-tificates,

– Compliance with the specified dimensions andtolerances by presentation of the records of di-mensional data.

2. The following components shall be subjectedto non-destructive testing in every case. The Society’sSurveyor may also demand additional tests, as follows:

– Welded wheel bodies:

Ultrasonic and/or radiographic inspections to-gether with surface crack inspections of thescope specified when the drawing was approved.

– Engine bedplates:

Surface crack inspection and random ultrasonictests applied to the transverse girder welds, es-pecially those of the bearing brackets.

– Other components:

Testing of the scope specified when the draw-ings were approved or when individual approvalwas granted.