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RULES FOR THE CLASSIFICATION AND CONSTRUCTION OF SEA-GOING SHIPS PART IX MATERIALS AND

RULES

FOR THE CLASSIFICATION AND CONSTRUCTION OF SEA-GOING SHIPS

PART IX

MATERIALS AND WELDING

2008

CLASSIFICATION AND CONSTRUCTION OF SEA-GOING SHIPS PART IX MATERIALS AND WELDING 2008 GDA Ń SK

GDAŃSK

RULES FOR CLASSIFICATION AND CONSTRUCTION OF SEA-GOING SHIPS prepared and edited by Polski Rejestr Statków S.A., hereinafter referred to as PRS, consist of the following Parts:

Part I Part II Part III Part IV Part V Part VI Part VII Part VIII Part IX

Classification Regulations

Hull Equipment Stability and Subdivision Fire Protection Machinery Installations and Refrigerating Plants Machinery, Boilers and Pressure Vessels Electrical Installations and Control Systems Materials and Welding

Hull

Part IX Materials and Welding 2008, was approved by PRS Executive Board on 1 April 2008 and enters into force on 1 May 2008. From the entry into force, the requirements of Part IX Materials and Welding apply, in full, to new ships. For existing ships, the requirements of Part IX Materials and Welding are applicable within the scope specified in Part I Classification Regulations. The requirements of Part IX Materials and Welding are extended by the following publications: Publication No. 3/P Principles for Examination of Welders, Publication No. 7/P Repair of Cast Copper Alloy Propellers, Publication No. 22/P Testing of Overweldable Shop Primers, Publication No. 23/P Pipelines Prefabrication, Publication No. 34/P Inspection of Underwater Welded Joints, Publication No. 40/P Non-metallic Materials, Publication No. 48/P Requirements Concerning Gas Tankers, Publication No. 56/P Procedural Requirements for Laboratories, Publication No. 70/P Non-destructive Testing of Hull and Machinery Steel Forgings, Publication No. 71/P Non-destructive Testing of Hull Marine Steel Castings, Publication No. 74/P Principles for Welding Procedure Qualification Tests, Publication No. 80/P Non-destructive Testing.

© Copyright by Polski Rejestr Statków S.A., 2008

PRS/HW, 04/2008

ISBN 978-83-60629-67-3

CONTENTS

 

Page

1

General

13

1.1 Application

13

1.2 Definitions, Explanations, Symbols, Abbreviations and Normative References

13

1.2.1 Definitions and Explanations

13

1.2.2 Explanations

15

1.2.3 Symbols and Abbreviations

16

1.2.4 Normative References

17

1.3 Scope of Survey

20

1.4 Technical Documentation

20

1.5 Approval of Materials’/Products’ Manufacturers

21

1.6 Approval of Welded Structures’ Manufacturers

21

1.7 Survey of Materials’/Products’ Manufacture

22

1.7.1 Direct Survey

22

1.7.2 Indirect Survey

22

1.8 Inspection Certificate

22

1.9 Marking

23

2

Testing

25

2.1 General Requirements

25

2.2 Testing Laboratories

25

2.3 Re-Tests

26

2.4 Chemical Analysis

27

2.5 Tensile Test

27

2.6 Impact Test

31

2.7 Bend test

33

2.8 Pellini Dropweight Test (DWT)

34

2.9 Hardness Testing

34

2.10 Macroscopic and Microscopic Examinations

34

2.11 Ductility Tests for Pipes and Tubes

35

2.11.1 Flattening Test

35

2.11.2 Drift Expanding Test

35

2.11.3 Ring Tensile Test

35

2.11.4 Flanging Test

36

2.11.5 Ring Expanding Test

36

2.12 Weldability Test

36

2.13 Non-Destructive Testing

37

2.14 Other Tests

37

MATERIALS

3

Normal and Higher Strength Hull Structural Steels

41

3.1 Scope of Application

41

3.2 Manufacturer Approval

41

3.3 Methods of Manufacture

42

3.4 Chemical Composition

44

3.5 Supply Condition

46

3.6 Mechanical Properties

48

3.7 Freedom from Defects

50

3.8 Inspection of Surface and Work Quality

51

3.8.1 Tolerances

51

3.8.2 Identification of Materials

52

3.8.3 Inspection and Testing

52

3.9 Test Material

53

3.10 Mechanical Test Specimens

54

3.11 Number of Test Specimens

55

3.11.1 Number of Tensile Test Specimens

55

3.11.2 Number of Impact Test Specimens (except E, EH32, EH36, EH40, FH32, FH36 and FH40 steel grades)

55

3.11.3 Number of Impact Test Specimens (E, EH32, EH36, EH40, FH32, FH36 and FH40 Steel Grades)

59

3.12 Retest Procedures

59

3.13 Marking

59

3.14 Inspection Certificate

59

Appendix A

Approval Procedure for Manufacturing Hull Structural Steels

60

1

Scope

60

2.

Approval Procedure

60

2.1 Documents to be Submitted

60

2.2 Documents to be Submitted for Changing the Approval Procedure

62

3.

Approval Tests

62

3.1 Extent of Approval Tests

62

3.2 Approval Test Programme

63

3.3 Approval Tests Supervision

63

3.4 Selection of the Test Product

63

3.5 Position of Test Samples

63

3.6 Parent Material Tests

64

3.6.1 Type of Tests

64

3.6.2 Test Specimens and Testing Procedure

65

3.6.3 Other Tests

66

3.7 Weldability Tests

66

3.7.1 Extent of Tests

66

3.7.2 Preparation and Welding of the Test Assemblies

66

3.7.3 Type of Tests

66

3.7.4 Other Tests

67

4

Results

67

5

Certification

67

5.1 Approval

67

5.2 List of Approved Manufacturers

67

6

Renewal of Approval

68

7

Reconsideration of the Approval

68

Appendix B Approval Procedure for Manufacturer of Hull Structural Steels Intended for Welding with High
Appendix B
Approval Procedure for Manufacturer of Hull Structural Steels
Intended for Welding with High Heat Input
69
1
69
2
Scope
Approval Procedure
Tests
3.1 Extent of Approval Tests
3.2 Weldabilty Test Programme
3.3 Test Plates
3.4 Test Assemblies
3.5 Examination and Tests of Test Assembly
Results
Certification
Grade Designation
69
3
69
69
70
70
70
71
4
72
5
72
6
73
4
High Strength Steels
4.1 Application
4.2 Approval
4.3 Manufacturing Methods
4.4 Chemical Composition
4.5 Supply Condition
4.6 Mechanical Properties
4.6.1 Tensile Test
4.6.2 Impact Test
4.6.3 Re-test Procedures
4.6.4 Through Thickness Tensile Test
4.7 Tolerances
4.8 Material Identification
4.9 Inspection of Surface and Work Quality
4.9.1 Facilities for Inspection
4.9.2 Freedom from Defects
4.9.3 Surface Inspection and Dimensions
4.9.4 Ultrasonic Testing
4.10 Marking
4.11 Inspection Certificate
74
74
74
74
75
75
75
75
77
77
78
78
78
78
78
78
78
78
79
79
5
Steel with Specified Through Thickness Properties (Steel “Z”)
5.1 General Requirements
5.2 Reduction of Area
5.3 Testing
5.4 Marking
5.5 Inspection Certificate
80
80
80
81
84
84
6
Steel for Boilers and Pressure Vessels
6.1 General Requirements
6.1.1 Application
6.1.2 Method of Manufacture
6.2 Steel Grades
6.3 Chemical Composition
85
85
85
85
85
85

 

6.4 Mechanical Properties

88

 

6.5 Supply Condition

90

6.6 Testing

91

6.6.1 General Requirements

91

 

6.6.2 Mandatory Testing

91

6.6.3 Additional Testing

91

6.6.4 Tensile Test at Ambient Temperature

92

6.6.5 Tensile Test at Elevated Temperature

92

6.6.6 Impact Test

92

6.6.7 Other Tests

92

6.7 Inspection of Surface and Work Quality

92

6.8 Marking

93

6.9 Inspection Certificate

93

7

Steel for Low Temperature Service

94

7.1 Steel for Hull Structures

94

 

7.2 Steels for Construction of Liquefied Gas Tankers

94

7.3 Steels for Other Structures

94

8

Stainless Steels

95

8.1 General Requirements

95

 

8.2 Chemical Composition

95

8.3 Mechanical Properties

95

8.4 Supply Condition

99

 

8.5 Testing

99

8.5.1 Chemical Analysis

99

 

8.5.2 Tensile Test

99

8.5.3 Impact Test

99

8.5.4 Intergranular Corrosion Resistance Test

99

8.5.5 Other Tests

100

8.6 Inspection of Surface and Work Quality

100

8.7 Marking

100

8.8 Inspection Certificate

100

9

Clad Steels

9.6

9.7

101

9.1 General Requirements

101

 

9.2 Chemical Composition

101

9.3 Mechanical Properties

101

9.4 Supply Condition

101

 

9.5 Testing

101

9.5.1 Testing Conditions

101

 

9.5.2 Tensile Test

102

9.5.3 Shear Test

102

9.5.4 Bend Test

103

9.5.5 Intergranular Corrosion Resistance Test

103

9.5.6 Impact Test

103

9.5.7 Non-destructive Testing Inspection of Surface and Work Quality Marking

103

103

104

9.8

Inspection Certificate

104

10 Steel Tubes

105

10.1 General Requirements

105

10.2 Manufacturing Techniques

105

 

10.3 Chemical Composition

105

10.4 Mechanical Properties

105

10.5 Supply Condition

112

10.6 Testing

112

10.7 Inspection of Surface and Work Quality

113

10.8 Marking

113

10.9 Inspection Certificate

113

11 Rolled Steels for Anchor Chain Cables

114

11.1 General Requirements

114

11.2 Manufacturing Procedures

114

11.3 Supply Condition

114

11.4 Chemical Composition

114

 

11.5 Mechanical Tests

115

11.6 Inspection of Surface and Work Quality

116

11.7 Freedom from Defects

116

 

11.8 Marking

116

11.9 Inspection Certificate

116

12 Steel Forgings

117

12.1 General Requirements

117

12.2 Manufacturing Procedure

117

 

12.3 Quality of Forgings

118

12.4 Chemical Composition

119

 

12.5 Supply Condition

120

12.6 Mechanical Tests

121

12.7 Mechanical Properties

126

12.8 Inspection of Surface and Work Quality

128

12.9 Rectification of Defective Forgings

129

12.10 Identification of Forgings

129

12.11 Marking

129

12.12 Inspection Certificate

130

13 Steel Castings

131

13.1 Carbon Steel Castings for Hull and Machinery Components

131

 

13.1.1 General Requirements

131

13.1.2 Manufacture

131

13.1.3 Quality of Castings

131

13.1.4 Chemical Composition

131

13.1.5 Supply Condition

132

13.1.6 Mechanical Tests

133

13.1.7 Mechanical Properties

134

 

13.1.8 Inspection of Surface and Work Quality

135

13.1.9 Rectification of Defective Castings

135

13.1.10 Marking

136

 

13.1.11 Inspection Certificate

136

 

13.2

Cast Stainless Steel Propellers

136

13.2.1 General Requirements

136

 

13.2.2 Chemical Composition

137

13.2.3 Heat Treatment

137

 

13.2.4 Mechanical Properties

137

 

13.2.5 Inspection of Surface and Work Quality

138

13.2.6 Non-destructive Testing

138

 

13.2.7 Repair

140

13.2.8 Marking

140

13.2.9 Inspection Certificate

140

 

14 Grey Iron Castings

141

 

14.2 Manufacture

14.1

General Requirements

141

141

 

14.3 Quality of Castings

141

 

14.4 Chemical Composition

141

14.5 Supply Condition

142

 

14.6 Mechanical Tests

142

14.7 Mechanical Properties

144

14.8 Inspection of Surface and Work Quality

145

14.9 Rectification of Defective Castings

146

14.10 Marking

146

 

14.11

Inspection Certificate

146

15 Nodular Iron Castings 15.1 General Requirements 15.2 Manufacture 15.3 Quality of Castings 15.4 Chemical Composition 15.5 Supply Condition 15.6 Mechanical Tests 15.7 Mechanical Properties 15.8 Inspection of Surface and Work Quality 15.9 Metallografic Examination

147 147 147 147 147 148 148 150 151 151

 

15.10 Rectification of Defective Castings

151

15.11 Marking

152

 

15.12 Inspection Certificate

152

16 Malleable Iron Castings

153

17 Copper Alloys

153

17.1 Copper and Copper Alloy Tubes

153

 

17.1.1 General Requirements

153

17.1.2 Manufacture 17.1.3 Chemical Composition 17.1.4 Supply Condition

153 153 154

 

17.1.5 Mechanical Properties

154

 

17.1.6 Testing

155

17.1.7 Inspection of Surface and Work Quality

155

17.1.8 Repair

155

17.1.9 Marking 17.1.10 Inspection Certificate 17.2 Copper Alloys Castings other than Castings for Propellers 17.2.1 General Requirements 17.2.2 Manufacture 17.2.3 Chemical Composition

155 155 155 155 156 156

17.2.4 Supply Condition

156

17.2.5 Mechanical Tests

157

17.2.6 Mechanical Properties

157

17.2.7 Inspection of Surface and Work Quality

158

17.2.8 Repair of Defective Castings

158

17.2.9 Marking

159

17.2.10 Inspection Certificate

159

17.3 Cast Copper Alloys for Propellers

159

17.3.1 General Requirements

159

17.3.2 Moulding and Casting

160

17.3.3 General Characteristics of Castings

160

17.3.4 Dimensions, Dimensional and Geometrical Tolerances

160

17.3.5 Chemical Composition and Structure Characteristics

161

17.3.6 Mechanical Properties

162

17.3.7 Testing and Inspection

163

17.3.8 Non-destructive Tests

164

17.3.9 Marking

164

17.3.10 Inspection Certificate

164

18 Aluminium Alloys 18.1 Wrought Aluminium Alloys 18.1.1 General Requirements 18.1.2 Approval of the Manufacturer 18.1.3 Aluminium Alloys and Their Temper Condition 18.1.4 Chemical Composition 18.1.5 Mechanical Properties 18.1.6 Freedom from Defects 18.1.7 Dimensional Tolerances 18.1.8 Testing and Inspection 18.1.9 Test Materials 18.1.10 Tensile Test Specimens 18.1.11 Number of Test Specimens 18.1.12 Re-tests 18.1.13 Marking 18.1.14 Inspection Certificate 18.2 Aluminium Alloy Castings 18.2.1 General Requirements 18.2.2 Chemical Composition and Mechanical Properties 18.2.3 Temper Condition 18.2.4 Tests 18.2.5 Inspection of Surface and Work Quality

166 166 166 166 166 167 169 170 170 171 173 173 173 174 174 175 175 175 175 176 176 177

18.2.6 Repair of Defective Castings

178

18.2.7 Marking

178

18.2.8 Inspection Certificate

178

19 Requirements for Manufacture of Anchors

179

19.1 General Requirements

179

19.1.1 Application

179

19.1.2 Anchor Types

179

19.2 Materials

179

19.2.1 Materials for Anchors

179

19.2.2 Materials for Super High Holding Power (SHHP) Anchors

180

19.3 Manufacture of Anchors

180

19.3.1 Tolerance

180

19.3.2 Welding of Anchors

181

19.3.3 Heat Treatment

181

19.3.4 Freedom from Defects

181

19.3.5 Repairs

181

19.3.6 Anchor Assembly

181

19.4 Testing and Certification

181

19.4.1 Proof Load Test

181

19.4.2 Product Tests

184

19.4.3 Mass and Dimensional Inspection

187

19.4.4 Re-tests

187

19.4.5 Marking

187

19.4.6 Inspection Certificate

187

19.4.7 Painting

187

20 Anchor Chain Cables and Accessories 20.1 General Requirements 20.1.1 Scope 20.1.2 Chain Cables Grades 20.1.3 Approval of Chain Manufacturer 20.2 Materials 20.2.1 Scope 20.2.2 Requirements for Material Manufacturer 20.2.3 Rolled Steel Bars 20.2.4 Steel Forgings 20.2.5 Steel Castings 20.2.6 Materials for Studs

188 188 188 188 188 188 188 188 189 189 189 189

20.3 Design and Manufacture of Chain Cables and Accessories

189

20.3.1

Design

20.3.2 Dimensions and Dimensional Tolerances 20.3.3 Manufacturing Process 20.3.4 The Welding of Studs 20.3.5 Supply Condition 20.3.6 Freedom from Defects 20.4 Testing and Inspection Certificate of Finished Chain Cables 20.4.1 Proof and Breaking Load Tests 20.4.2 Re-tests

189 191 192 192 193 193 194 194 194

20.4.3 Mechanical Tests of Grade 2 and 3 Chain Cables 20.4.4 Marking 20.4.5 Inspection Certificate 20.5 Testing and Inspection Certificate for Accessories 20.5.1 Proof Load Test 20.5.2 Breaking Load Test 20.5.3 Mechanical Properties 20.5.4 Marking 20.5.5 Inspection Certificate 20.6 Chafing Chain for ETA Equipment 20.6.1 Application 20.6.2 Approval of the Manufacturer 20.6.3 Materials 20.6.4 Design, Manufacture, Testing and Acceptance of Chafing Chain

195 196 196 197 197 197 197 197 198 198 198 198 198 198

21 Steel Wire Ropes

200

21.1 General Requirements

200

21.2 Manufacture

200

21.3 Tests

201

21.4 Inspection of Surface and Work Quality

203

21.5 Marking

203

21.6 Inspection Certificate

204

22 Fibre Ropes 22.1 General Requirements 22.2 Manufacture 22.3 Tests 22.4 Inspection of Surface and Work Quality 22.5 Marking 22.6 Inspection Certificate

205 205 205 205 207 208 208

WELDING

23 Welding

211

23.1 General

211

23.2 Welding of Ship Hull and its Equipment

212

23.3 Welding of Machinery

215

23.4 Welding of Boilers and Pressure Vessels

216

23.5 Welding of Pipelines

217

23.6 Welding of Stainless Steel

217

23.7 Welding of Stainless Steels with other Steels

217

23.8 Welding of Clad Steels with Austenitic Stainless Steels

217

23.9 Welding of Steel Forgings and Castings

218

23.10 Welding of Cast Iron

219

23.11 Welding of Copper and Copper Alloys

219

23.12 Welding of Wrought Aluminium Alloys

219

23.13 Hard Soldering

220

24 Welding Consumables

221

24.1 General Requirements

221

24.2 Approval Procedure

222

24.2.1 Technical Documentation 24.2.2 Works Inspection 24.2.3 Approval Tests 24.2.4 Annual Tests

24.3 Preparation and Testing of Welding Consumables Test Assemblies 24.4 Assessment of Results of Tests of Welding Consumables for Hull Structure Steels 24.5 Approval Tests of Covered Electrodes for Manual Arc Welding of Hull Structural Steels

24.5.2 Butt Weld Tests 24.5.3 Deposited Metal Hot Cracking Test 24.5.4 Determining Hydrogen Content in Deposited Metal 24.5.5 Approval Tests of Electrodes Intended for Fillet Welds 24.5.6 Approval Tests of Electrodes for Gravity Welding 24.5.7 Annual Tests

24.6 Approval Tests of Welding Consumables for Submerged Arc Welding of Hull Structural Steels

24.6.2 Butt Weld Tests for Multi-run Technique 24.6.3 Butt Weld Tests for Two-run Technique 24.6.4 Annual Tests 24.7 Approval Tests of Wires without and with Shielding Gas 24.7.1 Shielding Gases 24.7.2 Determining Hydrogen Content in Deposited Metal 24.7.3 Approval Tests of Wires for Semi-Automatic Welding 24.7.4 Approval Tests of Wires for Automatic Multi-run Welding 24.7.5 Approval Tests of Wires for Automatic Two-run Welding 24.7.6 Annual Tests 24.8 Approval Tests of Consumables for Use in Electroslag and Electrogas Welding 24.8.1 Test Assemblies’ Testing 24.8.2 Annual Tests 24.9 Approval Tests of Consumables for One Side Welding on Backing Strips 24.10 Approval Tests of Welding Consumables for High Strength Steels 24.11 Approval Tests of Welding Consumables for Boiler Steels 24.12 Approval Tests of Welding Consumables for Machinery, Equipment and Piping Steels 24.13 Approval Tests of Welding Consumables for Stainless and Clad