Beruflich Dokumente
Kultur Dokumente
SHIPBUILDING AND REPAIR QUALITY STANDARD FOR HULL STRUCTURES DURING CONSTRUCTION
July 1998
ABS
Incorporated by Act of Legislature of the State of New York 1862
Copyright 1998 ABS American Bureau of Shipping Two World Trade Center, 106th Floor New York, NY 10048 U.S.A
Foreword
This guide contains information obtained from IACS Recommendation No. 47 . "Shipbuilding and Repair Quality Standards". In order to be consistent with ABS requirements, some specific standards have been modified from the original. The modified standards are indicated in the "Remarks" column of the tables, along with the rule reference.
1.0 Applicability This guide provides guidance on shipbuilding quality standards for the hull structure during construction. Whereas the standard generally applies to: conventional ship types hull structures constructed from normal and higher strength hull structural steel, the applicability of the standard is in each case to be agreed upon by the Bureau The standard generally does not apply to the new construction of special types of ships as e.g. gas tankers structures fabricated from stainless steel or other, special types or grades of steel Details relevant to structures or fabrication procedures not covered by this standard are to be approved on a case by case basis of procedure qualifications and/or recognized national standards. 2.0 Scope The standard covers typical construction methods and gives guidance on quality standards for the most important aspects of such construction. Unless explicitly stated elsewhere in the standard, the level of workmanship reflected herein will in principle be acceptable for primary and secondary structure of conventional designs. A more stringent standard may however be required for critical and highly stressed areas of the hull, and this is to be agreed with the Bureau in each case. It is intended that these standards provide guidance where established shipbuilding or national standards accepted by the Bureau do not exist. For use of this standard, fabrication fit-ups, deflections and similar quality attributes are intended to be uniformly distributed about the nominal values. The shipyard is to take corrective action to improve work processes that produce measurements where a skewed distribution is evident. Relying upon remedial steps that truncate a skewed distribution of the quality attribute is unacceptable. 3.0 General Requirements In general, the work is to be carried out in accordance with the Rules and under the survey of the classification representative. Provisions are to be made for proper accessibility, staging, lighting, and ventilation. Welding operations are to be carried out under shelter from rain, snow, and wind. Welding of hull structures is to be carried out by qualified welders, according to approved and qualified welding procedures and with welding consumables approved by the Bureau. Welding operations are to be carried out under proper supervision by the shipbuilder.
ABS Guide For Shipbuilding And Repair Quality Standard For Hull Structures During Construction
4.0 Qualification of Personnel and Procedures 4.1 Qualification of Welders Welders are to be qualified in accordance with 2/3 C .11of the ABS Rule Requirements for Materials and Welding. Subcontractors are to keep records of welders qualification and, when required, furnish valid approval test certificates. Welding operators using fully mechanized or fully automatic processes generally need not pass approval testing provided that the production welds made by the operators are of the required quality. However, operators are to receive adequate training in setting or programming and operating the equipment. Records of training and production test results shall be maintained on individual operators files and records, and be made available to the Bureau for inspection when requested. 4.2 Qualification of Welding Procedures Welding procedures are to be qualified in accordance with 2/3A.1.4 of the ABS Rule Requirements for Materials and Welding. The welding procedure should be supported by a welding procedure qualification record. The specification is to include the welding process, types of electrodes, weld shape, edge preparation, welding techniques and positions. 4.3 Qualifications of NDE Operators Personnel performing non-destructive examination for the purpose of assessing quality of welds in connection with new construction covered by this guide are to be qualified in accordance with the applicable Bureaus requirements or to a recognized national or international qualification scheme. Records of operators and their current certificates are to be kept and made available to the Surveyor for inspection. 5.0 Materials 5.1 Materials for Structural Members All Materials, including weld consumables, to be used for the structural members are to be in accordance with Bureau approved construction plans and with the ABS Rule Requirement for Materials and Welding. 5.2 Details, Standards and Tolerance Limits Details, standards and tolerance limits may be found in the following Tables Detail Fabrication And Fairness Flanged Longitudinals And Flanged Brackets Built-Up Sections Corrugated Bulkheads Pillars, Brackets And Stiffeners Maximum Heating Temperature On Surface For Line Heating Block Assembly Table #
ABS Guide For Shipbuilding And Repair Quality Standard For Hull Structures During Construction
Detail (Contd) Special Sub-Assembly Shape Fairness Of Plating Between Frames Fairness Of Plating With Frames Alignment
Table # (contd)
5.7 5.8 & 5.9 5.10 5.11 5.12, 5.13 and 5.14 TheBureau may require a closer construction tolerance in areas requiring special attention, as follows: -Regions exposed to high stress concentrations -fatigue prone area -detail design block erection joints -higher tensile steel regions 5.15 and 5.16 5.17 and 5.18 5.19 5.20 5.21 5.22 5.23 to 5.25 5.26 and 5.27 5.28 to 5.30 5.31 5.32 5.33 5.34 5.35
Welding Details Typical Butt Plate Edge Preparation (Manual Welding) Typical Fillet Weld Plate Edge Preparation (Manual Welding) Typical Butt And Fillet Weld Profile (Manual Welding) Lap, Plug And Slot Welding Distance Between Welds Automatic Welding Repair Typical Misalignment Repair Typical Butt Weld Plate Edge Preparation Repair (Manual Welding) Typical Fillet Weld Edge Preparation Repair (Manual Welding) Typical Fillet And Butt Weld Profile Repair (Manual Welding) Distance Between Welds Repair Erroneous Hole Repair Repair By Insert Plate Weld Surface Repair
ABS Guide For Shipbuilding And Repair Quality Standard For Hull Structures During Construction
Standard
Limit
Remarks
3 mm
5 mm
per 100 mm of a
10 mm
25 mm
ABS Guide For Shipbuilding And Repair Quality Standard For Hull Structures During Construction
Standard
Limit
Remarks
d 3 + a/100 mm
d 5 + a/100 mm
5 mm
8 mm
ABS Guide For Shipbuilding And Repair Quality Standard For Hull Structures During Construction
Standard
Limit
Remarks
Depth of corrugation
3 mm
6 mm
3 mm
6 mm
Breadth of corrugation
3 mm
6 mm
Pitch and depth of swedged corrugated bulkhead compared with correct value
h: 2.5 mm Where it is not aligned with other bulkheads P: 6 mm Where it is aligned with other bulkheads P: 2 mm
h: 5 mm Where it is not aligned with other bulkheads P: 9 mm Where it is aligned with other bulkheads P: 3 mm 6
ABS Guide For Shipbuilding And Repair Quality Standard For Hull Structures During Construction
Standard
Limit
Remarks
D/200 mm max. + 5 mm
Tripping bracket and small stiffener, distortion at the part of free edge
a t/2 mm
max. 8 mm
F = 15 mm
ABS Guide For Shipbuilding And Repair Quality Standard For Hull Structures During Construction
Table 5.5 Maximum Heating Temperature On Surface For Line Heating Item
Conventional Process AH32-EH32 & AH36-EH36 TCMP type AH32-EH32 & AH36-EH36 (Ceq.>0.38%) Water cooling just after heating
Standard
under 650C
Limit
Remarks
under 900C
Air cooling and subsequent water cooling after heating TMCP type AH32-DH32 & AH36-DH36 (Ceq. 0.38%) TMCP type EH32 & EH36 (Ceq. 0.38%) NOTE: Ceq = C + Mn 6 + Cr + Mo + V 5 + Water cooling just after heating or air cooling
under 1000C
under 900C
Ni + Cu 15
(% )
ABS Guide For Shipbuilding And Repair Quality Standard For Hull Structures During Construction
Standard
2.5 mm 10 mm 5 mm 5 mm
Limit
5 mm 20 mm 10 mm 10 mm
Remarks
2.5 mm 10 mm 10 mm 5 mm
5 mm 20 mm 15 mm 10 mm
2.5 mm 10 mm 10 mm 5 mm 10 mm 5 mm
5 mm 20 mm 10 mm 10 mm 20 mm 10 mm
2.5 mm 10 mm 10 mm 5 mm 15 mm 7 mm
5 mm 20 mm 15 mm 10 mm 25 mm 15 mm
ABS Guide For Shipbuilding And Repair Quality Standard For Hull Structures During Construction
Standard
5 mm
Limit
10 mm
Remarks
Distance between aft edge of boss and aft peak bulkhead Twist of sub -assembly of stern frame
5 mm
10 mm
5 mm
10 mm
4 mm 6 mm
8 mm 10 mm
Flatness of top plate of main engine bed Breadth and length of top plate of main engine bed
5 mm
10 mm
4 mm
6 mm
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Standard
Limit
Remarks
15 mm
30 mm
Cocking-up of aft-body
20 mm
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Standard
50 per 100 m
Limit
Remarks
Applied to ships of 100m length and above. For the convenience of the measurement the point where the keel is connected to the curve of the stern may be substituted for the fore perpendicular in the measurement of the length.
Length between aft edge of boss and main engine Molded breadth at midship
25 mm 15 mm Applied to ships of 15m breadth and above. Measured on the upper deck Applied to ships of 10 meter depth and above
10 mm
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Standard
4mm 5mm 4mm
Limit
Remarks
Tank Top plate Longitudinal bulkhead Bulkhead Transverse bulkhead Swash bulkhead
8mm
Parallel part Strength deck Fore and aft part Covered part
300<s<1000
Second deck
5mm
7mm
5mm
7mm
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Standard
2 /1000mm 3 /1000mm 3 /1000mm
Limit
3 /1000mm 4 /1000mm 4 /1000mm
Remarks
4 /1000mm 5 /1000mm
5 /1000mm 6 /1000mm
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Standard
Limit
Remarks
Strength and higher tensile: a t1/3 measured on the median a (5t1- 3t2)/6 measured on the heel line Other: a t1/2 measured on the median a (2t1- t2)/2 measured on the heel line
Strength and higher tensile: a t1/3 measured on the median Other: a t1/2 measured on the median
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Standard
a 0.04b strength
Limit
a = 8.0 mm
Remarks
3.0 mm
d L/50
a 2.0 mm
3 mm
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Standard
Limit
Remarks
Position of scallop
d 75 mm
s 2.0 mm
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Table 5.15 Typical Butt Plate Edge Preparation (Manual Welding) Detail
Square butt t 5 mm G = 3 mm see Note 1
Standard
Limit
Remarks
t > 5 mm G 3 mm R 3 mm = 50 - 70
see Note 1
t > 19 mm G 3 mm R 3 mm = 50 - 70
see Note 1
see Note 1
G 3 mm R 3 mm 6 h t/3 mm = 50 = 90
see Note 1
NOTE 1 Different plate edge preparation may be accepted or approved by the Bureau on the basis of an appropriate welding procedure specification. For welding procedures other than manual welding, see paragraph 4.2 Qualification of weld procedures
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Table 5.16 Typical Butt Plate Edge Preparation (Manual Welding) Detail
Single vee butt, one side welding with backing strip (temporary or permanent)
Standard
G = 3 - 9 mm = 30 -45
Limit
Remarks
see Note 1
G 3 mm = 30 - 70 R 3 mm
see Note 1
NOTE 1 Different plate edge preparation may be accepted or approved by the Bureau on the basis of an appropriate welding procedure specification. For welding procedures other than manual welding, see paragraph 4.2 Qualification of weld procedures
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Table 5.17 Typical Fillet Weld Plate Edge Preparation (Manual Welding) Detail
Tee Fillet G 2 mm
Standard
Limit
Remarks
see Note 1
= 50 -70 = 70 - 90 G 2 mm
see Note 1
G 4 - 6 mm = 30 - 45
G 3 mm R 3 mm = 50
see Note 1
NOTE 1 Different plate edge preparation may be accepted or approved by the Bureau on the basis of an appropriate welding procedure specification. For welding procedures other than manual welding, see paragraph 4.2 Qualification of weld procedures
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Table 5.18 Typical Fillet Weld Plate Edge Preparation (Manual Welding) Detail
Single J tee
Standard
G =2.5- 4 mm r = 12 -15 mm R = 3 mm 35
Limit
Remarks
see Note 1
t > 19 mm G 3 mm R 3 mm
see Note 1
G =2.5- 4 mm r = 12 -15 mm R 3 mm 35
see Note 1
NOTE 1 Different plate edge preparation may be accepted or approved by the Bureau on the basis of an appropriate welding procedure specification. For welding procedures other than manual welding, see paragraph 4.2 Qualification of weld procedures
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Table 5.19 Typical Butt And Fillet Weld Profile (Manual Welding) Detail
Butt weld toe angle
Standard
60 h 0.2R
Limit
maximum h = 6 mm
Remarks
D = 0 mm
0.5 mm
Fillet weld toe angle 90 In areas of stress concentration and fatigue, the Bureau may require a lesser angle
D = 0 mm
0.5 mm
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Standard
b = 2t2 + 25
Limit
Remarks
location of lap joint to be approved by the Bureau
b 2t2 + 25
Plug welding
when t 12 mm l = 60 mm R = 6 mm, 40-50 G = 12 mm L > 2l when 12< t 25 mm l = 80 mm R = 0.5t mm, 30 G = t mm L > 2l when t 12 mm l = 80 mm G = 20 mm L= 2l-3l max. 250mm when t > 12 mm l = 100 mm G = 2t L = 2l-3l max. 250 mm
Slot welding
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Standard
Limit
Remarks
r
d
d 0 mm
d 10 mm
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Standard
Limit
Remarks
NOTE 1 Different plate edge preparation may be accepted or approved by the Bureau on the basis of an appropriate welding procedure specification. For welding procedures other than manual welding, see paragraph 4.2 Qualification of weld procedures
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Repair Standard
Strength members a > 0.15t1 or a > 3 mm release and adjust Others a > 0.2t1 or a > 3 mm release and adjust
Remarks
Strength and Higher tensile steel t1/3 < a t1/2 generally increase weld throat by 10% a > t1/2-release and adjust over a minimum of 50a Other a > t1/2 release and adjust over a minimum of 30a
When 0.04b < a 0.08b, max 8 mm grind corners to smooth taper over a minimum distance L = 3a When a > 0.08b or 8 mm grind corners to smooth taper over a minimum distance L=50a
When 3 mm < a 6 mm building up by welding When a > 6 mm release and adjust over minimum L = 50a for primary structure and L = 30a elsewhere
2 mm < a 5 mm weld leg length to be increased by the same amount as increase in gap a > 5 mm members to be re-aligned
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Repair Standard
When 2mm < a 5mm weld leg length to be increased by increase in gap When 5mm < a 10mm chamfer 30 - 40 and build up with welding
Remarks
When a > 10mm increase gap to 50mm and fit collar plate
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Repair standard
When d < 75 mm, web plate to be cut between scallop and slot, and collar plate to be fitted
Remarks
When 2mm < s 5mm weld leg length to be increased as much as increase in gap opening over 2mm
When s > 10 mm cut off nib and fit collar plate with same height as nib
20 mm b 50mm
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Table 5.26 Typical Butt Weld Plate Edge Preparation Repair (Manual Welding) Detail
Square butt
Repair standard
When G 10 mm chamfer to 45 and build up by welding When G > 10 mm build up with backing strip; remove, back gouge and seal weld; or, insert plate, min. width 300mm
Remarks
When 3mm < G 3t/2 mm (maximum 25mm) build up gap with welding on one or both sides of preparation, with possible use of backing strip as necessary, to maximum t/2. Where a backing strip is used, the backing strip is to be removed, the weld back gouged, and a sealing weld made
When G > 25 mm or 3t/2 an insert plate, of minimum width 300mm, to be welded in place
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Table 5.27 Typical Butt Weld Plate Edge Preparation Repair (Manual Welding) Detail
Single vee butt, one side welding with backing strip
Repair Standard
When G 25mm or G t/2 build up edge preparation on one or both sides, grind edge preparation, weld with backing strip, remove backing strip, back gouge, and back weld
Remarks
Single vee butt, one side welding When 3 mm < G 3t/2 mm (maximum 25 mm) build up gap with welding on one or both sides of preparation, with possible use of backing strip as necessary, to maximum t/2. Where a backing strip is used, the backing strip is to be removed, the weld back gouged, and a sealing weld made
When G > 25 mm or t/2 an insert plate, of minimum width 300 mm, to be welded in place
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Table 5.28 Typical Fillet Weld Plate Edge Preparation Repair (Manual Welding) Detail
Tee Fillet
Repair Standard
2 mm < G 5mm leg length increased to Rule leg + (G-2) 5 mm < G 16 mm Chamfer to 30 to 45, build up with welding, on one side, with or without backing strip, grind and weld
Remarks
Liner treatment t2 t t1 G 2mm a = 5 mm + fillet leg length Not to be used in cargo area or areas of tensile stress perpendicular to liner
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Table 5.29 Typical Fillet Weld Plate Edge Preparation Repair (Manual Welding) Detail
Single bevel tee
Repair standard
3 mm < G 5mm build up weld 5 mm < G 16 mm - build up with welding, with or without backing strip, remove backing strip if used, back gouge and back weld
Remarks
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Table 5.30 Typical Fillet Weld Plate Edge Preparation Repair (Manual Welding) Detail
Single J tee
Repair standard
as single bevel tee
Remarks
When 3 mm < G 16 mm build up with welding using ceramic or other approved backing bar, remove, back gouge and back weld
Double bevel tee assymmetrical When G > 16 mm-insert plate of minimum height 300 mm to be fitted
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Table 5.31 Typical Fillet And Butt Weld Plate Edge Preparation Repair (Manual Welding) Detail
Fillet weld leg length Increase leg or throat by welding over
Standard
Remarks
Fillet weld toe angle > 90 grinding, and welding, where necessary, to make < 90
Butt weld toe angle > 90 grinding, and welding, where necessary, to make < 90
Butt weld undercut Where 0.5 < D 1 mm undercut to be ground smooth (localized only)
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Standard
Hole to be cut and ground smooth to obtain distance
Remarks
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Standard
Strength members open hole to minimum 75 mm dia. fit and weld spigot piece
Remarks
Fillet weld to be made after butt weld
OR open hole to over 300 mm and fit insert plate Other members open hole to over 300 mm and fit insert plate OR fit lap plate
The fitting of spigot pieces in areas of high stress concentration or fatigue is to be approved by the Bureau
L = 50 mm, min
Strength members open hole to over 300 mm and fit insert plate Other members open hole to over 300 mm and fit insertt plate OR fit lap plate
t1 = t2
L = 50 mm, min
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Repair standard
Remarks
L min 300 mm Welding sequence (1) (2) (3) (4) Web butt weld scallop to be filled during final pass (4)
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Repair standard
1. Remove spatter observed before blasting with scraper or chipping hammer etc. 2. For spatter observed after blasting: a) Remove with a chipping hammer, scraper, etc. b) For spatter not easily removed with a chipping hammer, scraper, etc., grind the sharp angle of spatter to make it obtuse
Remarks
In principal, no grinding is applied to weld surface
Irregularity of manual weld When the surface irregularity exceeds 3mm, apply grinding until the irregularity becomes less than 3mm
Arc Strike
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