Fabrication and Testing of Structures: Ships / High Speed, Light Craft and Naval Surface Craft

RULES FOR
CLASSIFICATION OF
SHIPS / HIGH SPEED, LIGHT CRAFT AND

NAVAL SURFACE CRAFT
NEWBUILDING
MATERIALS AND WELDING
PART 2 CHAPTER 3
FABRICATION AND TESTING OF

STRUCTURES
JANUARY 2005
This booklet includes the relevant amendments and corrections
shown in the July 2008 version of Pt.0 Ch.1 Sec.3.
CONTENTS PAGE
Sec. 1 General Requirements ................................................................................................................ 5
Sec. 2 Requirements for Builders of Ship Structures............................................................................ 7
Sec. 3 Qualification of Welders ............................................................................................................ 8
Sec. 4 Welding Consumables................................................................................................................ 9
Sec. 5 Welding Procedures ................................................................................................................. 12
Sec. 6 Fabrication and Tolerances....................................................................................................... 25
Sec. 7 Non Destructive Testing of Welds ........................................................................................... 27
Sec. 8 Structural and Tightness Testing .............................................................................................. 29
DET NORSKE VERITAS

Veritasveien 1, NO-1322 Høvik, Norway Tel.: +47 67 57 99 00 Fax: +47 67 57 99 11
CHANGES IN THE RULES
General Main changes adopted January 2004
The present edition of the rules includes additions and amendments
decided by the Board on 29 November 2004, and supersedes the Jan- Coming into force 1 July 2005
uary 2003 edition of the same chapter.
• General
The rule changes come into force as indicated below.
Until now, rules for fabrication of ship structures have been found in
This chapter is valid until superseded by a revised chapter. Supple- different parts of the rules (e.g. Pt.2, Pt.3 and Pt.5). Further, bench-
ments will not be issued except for an updated list of minor amend- marking has uncovered a need to align the rules with the latest devel-
ments and corrections presented in Pt.0 Ch.1 Sec.3. Pt.0 Ch.1 is opment and with industry standards. With this in mind, this booklet is
normally revised in January and July each year. issued as a new and consolidated version under the title “Fabrication
Revised chapters will be forwarded to all subscribers to the rules. and Testing of Ship Structures”. The main goals of the upgrading are:
Buyers of reprints are advised to check the updated list of rule chap- — Include, as far possible, all requirements for fabrication and fab-
ters printed Pt.0 Ch.1 Sec.1 to ensure that the chapter is current. rication testing in one booklet.
— Update the requirements to align with other international stand-
ards for welding, assembly and testing of steel structures.
— Provide a rule structure suited for optimising quantitative re-
Significant editorial changes adopted July 2008 quirements based on FSA (Formal Safety Assessment).
Among others, important changes are:
Taking effect immediately
• Sec.1 General Requirements
• Sec.8 Structural and Tightness Testing
— Project specific NDT procedures and test plan is required submit-
— Under B301, the minimum test pressure specified in Table B1 for ted for approval.
tanks containing liquids has been reduced for FRP tanks.
— In Table B1, tablenote 2) has been amended to align the require- • Sec.2 Requirements for Builders of Ship Structures
ment to structural testing of subsequent vessels with other IACS — Requirements for builder and subcontractor have been clearly
members. defined.
• Sec.5 Welding Procedures
Main changes adopted July 2006 — Different alternatives for approval of welding procedures have
been included. Validity of a welding procedure has been adjusted
and the range of qualification has been updated to align with
Coming into force 1 July 2006 common international standards.
• Sec.8 Structural and Tightness Testing • Sec.7 Non Destructive Testing of Welds
— The first sentence of item B302 has been replaced. — Extent of NDT has been given as a percentage of total welded
length and importance of the welded structure. It should be noted
that this section replaces the old text in Pt.3 Ch.1 Sec.11 "All
weld crossings in the bottom and deck plating within 0.4 L amid-
Main changes adopted January 2006 ships are to be examined".
Coming into force 1 January 2006

Corrections and Clarifications
• Sec.8 Structural and Tightness Testing
In addition to the above stated rule requirements, a number of correc-
— In Table B1, the footnote 2) has been replaced. tions and clarifications have been made in the existing rule text.
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Amended, Rules for Ships / High Speed, Light Craft and Naval Surface Craft, January 2005
see Pt.0 Ch.1 Sec.3, July 2008 Pt.2 Ch.3 Contents – Page 3
CONTENTS
SEC. 1 GENERAL REQUIREMENTS .......................... 5 Systems ............................................................................... 19

G 100 Welds in plates and pipes................................................19
A. General...................................................................................5 G 200 Test requirements............................................................19
A 100 Application........................................................................5 G 300 Weld production test requirements .................................19
A 200 Basic requirements............................................................5
A 300 Builders and subcontractors ..............................................5 H. Additional Requirements WPQT for
Ferritic-Austenitic Stainless Steel .................................... 20
B. Definitions ..............................................................................5 H 100 Welds in plates and pipes................................................20
B 100 Terms ................................................................................5 H 200 Test requirements............................................................20
H 300 Validity of a qualified welding procedure ......................20
C. Documentation ......................................................................5
C 100 Plans and particulars .........................................................5 I. Additional Requirements WPQT for Austenitic
Stainless Steel ..................................................................... 20
SEC. 2 REQUIREMENTS FOR BUILDERS OF SHIP I 100 Welds in plates and pipes................................................20
STRUCTURES...................................................... 7 I 200 Test requirements............................................................20
A. General...................................................................................7 J. Welding procedures for aluminium ................................ 20
A 100 Application........................................................................7 J 100 General............................................................................20
A 200 Basic requirements............................................................7 J 200 Butt welds in plates.........................................................20
J 300 Butt welds in pipes..........................................................21
B. Survey Arrangement.............................................................7 J 400 Branch connections.........................................................21
B 100 Quality management system .............................................7 J 500 Fillet welds......................................................................21
J 600 Non destructive testing of test assemblies ......................21
C. Workmanship and Supervision ...........................................7 J 700 Destructive testing .........................................................21
C 100 General ..............................................................................7 J 800 Range of qualification.....................................................22
J 900 Retesting .........................................................................23
SEC. 3 QUALIFICATION OF WELDERS ................... 8
K. Testing ................................................................................. 23
A. General...................................................................................8 K 100 General............................................................................23
A 100 Application........................................................................8 K 200 Tensile testing at ambient temperature ...........................23
A 200 Requirements ....................................................................8 K 300 Bend testing ....................................................................24
B. Qualification testing and certification.................................8 SEC. 6 FABRICATION AND TOLERANCES........... 25
B 100 General ..............................................................................8
B 200 Certification .....................................................................8 A. General ................................................................................ 25
SEC. 4 WELDING CONSUMABLES ............................ 9 A 100 Application......................................................................25
A. General...................................................................................9 B. Material Identification....................................................... 25

A 100 Application........................................................................9 B 100 General............................................................................25
A 200 Basic groups and grades....................................................9 C. Approval of Shop Primers................................................. 25
SEC. 5 WELDING PROCEDURES.............................. 12 C 100 General............................................................................25
A. General.................................................................................12 D. Welding Environment........................................................ 25

A 100 Application......................................................................12 D 100 General............................................................................25
A 200 Welding processes...........................................................12 E. Cutting, Forming, Assembly and Welding ...................... 25
B. Welding Procedure Specification ......................................12 E 100 Cutting.............................................................................25
B 100 General ............................................................................12 E 200 Forming...........................................................................25
B 200 Approved welding procedure specification ....................12 E 300 Assembly and Welding ..................................................25
C. Welding Procedure Test Assembly and Sampling of F. Repairs ................................................................................ 26

Test Pieces............................................................................12 F 100 General............................................................................26
C 100 Butt welds in plates .........................................................12 F 200 Repair welding ................................................................26
C 200 Butt welds in pipes..........................................................14 F 300 Flame straightening ........................................................26
C 300 Full penetration T-, Y-, and K- joints .............................14
C 400 Branch connection...........................................................14 G. Inspection and Tolerances................................................. 26
C 500 Fillet welds......................................................................15 G 100 General............................................................................26
G 200 Alignment and straightness.............................................26
D. Non Destructive Testing of Test Assemblies.....................15 G 300 Special building tolerances .............................................26
D 100 Butt welds and full penetration T-joints .........................15 G 400 Weld production test requirements .................................26
D 200 Fillet welds and partial penetration welds.......................15
SEC. 7 NON DESTRUCTIVE TESTING OF
E. Destructive Testing .............................................................15 WELDS................................................................ 27
E 100 Transverse tensile test ....................................................15
E 200 Bend test..........................................................................15 A. General ................................................................................ 27
E 300 Macrosection and hardness testing .................................15 A 100 Application......................................................................27
E 400 Impact testing..................................................................15 A 200 Basic requirements..........................................................27
E 500 Welds between different material grades........................16
E 600 Retesting .........................................................................16 B. NDT Procedures ................................................................. 27
B 100 General............................................................................27
F. Validity of Approved Welding Procedures.......................16 B 200 Visual testing ..................................................................27
F 100 General ............................................................................16 B 300 Magnetic particle testing.................................................27
F 200 Range of qualification.....................................................16 B 400 Radiographic testing .......................................................27
B 500 Ultrasonic testing ............................................................27
G. Additional Requirements WPQT for Liquefied Gas B 600 Penetrant testing..............................................................27
DET NORSKE VERITAS

Rules for Ships / High Speed, Light Craft and Naval Surface Craft, January 2005 Amended,
Pt.2 Ch.3 Contents – Page 4 see Pt.0 Ch.1 Sec.3, July 2008
C. Personnel Qualifications .................................................... 27 SEC. 8 STRUCTURAL AND TIGHTNESS

C 100 General ............................................................................27 TESTING ............................................................ 29
D. Extent of NDT ..................................................................... 27 A. General................................................................................. 29
D 100 General ............................................................................27 A 100 Application......................................................................29
B. Testing..................................................................................29
E. Acceptance Criteria for NDT ............................................ 28 B 100 Definitions.......................................................................29
E 100 General ............................................................................28 B 200 General requirements ......................................................29
E 200 Non-conforming weldments ..........................................28 B 300 Specific requirements for extent and type of testing.......29
DET NORSKE VERITAS

see Pt.0 Ch.1 Sec.3, July 2008 Pt.2 Ch.3 Sec.1 – Page 5
SECTION 1
GENERAL REQUIREMENTS
A. General
Builder Yard involved in fabrication planning, building,
A 100 Application assembly and testing of ship structures for pur-
101 This section provides general requirements for fabrica- pose of classification.
tion of welded structures involving parts and units described in Subcontractor Independent unit performing work under super-
Pt.3. vision by the builder. The subcontractor may be
required to be approved by the Society.
102 Basic requirements are given in Pt.1 Ch.1 Sec.1 B300 Quality Manage- Quality Management System worked out in ac-
(ship rules). ment System cordance with a reputable quality standard, such
103 Additional fabrication requirements for ship hull struc- as ISO 9001:2000 or equivalent. The Quality
tures relating to special service and type are given in Pt.5. Management System may be required to be cer-
tified by an accredited certification body, see
104 Fabrication and welding of piping and boilers/pressure Pt.1 Ch.1 Sec.4 B500.
vessels are dealt with in Pt.4 Ch.6 Sec.7 (ship rules) and Pt.4 New Building Agreement between the builder and the Society
Ch.7 Sec.8, respectively. Survey defining responsibility and authority of person-
Arrangement nel and items to be controlled with acceptance
A 200 Basic requirements (NSA) criteria, quality control functions. The activities
201 Welding of important structures like: through this agreement are complementary to
the Society’s own inspection scheme.
— hull, superstructure taking part in the overall strength pWPS Preliminary welding procedure specification: A
— hull equipment, stern frames, rudders, rudder stocks and tentative welding procedure specification,
rudder horn which is assumed adequate by the builder as ba-
sis for approval by the Society.
shall be carried out by certified welders, with approved weld- WPS Welding procedure specification: A specifica-
ing procedures and welding consumables, and at builders and tion of material, detailed methods, practices and
subcontractors recognized by the Society. parameters employed in the welding of a partic-
ular joint, and which have been approved by the
202 Welders and welding procedures approved for the type Society.
of connection and parent material in question as given in Sec.3
WPQR Welding procedure qualification record: The
and Sec.5, respectively, shall be used. record of the actual parameters employed during
203 Welding consumables shall be type approved. Sec.4 welding of the qualification test piece, and re-
specifies basic groups and grades, application of the various sults from non-destructive testing and mechani-
grades and grouping of shielding gases. cal testing.
WPQT Welding procedure qualification test: A test car-
A 300 Builders and subcontractors ried out in order to demonstrate that the weld
carried out according to the pWPS meets the
301 Builders and subcontractors will have to prove their specified requirements.
abilities for the welding operations in question.
WPT Weld production test: A test carried out to dem-
302 It is assumed that the builders and subcontractors make onstrate that actual production welding meets
use of the necessary equipment for carrying out inspection of the specified requirements.
the welding operations in a satisfactory manner. NDT Non-destructive testing: Visual inspection, radi-
303 Important welding operations shall be carried out under ographic testing, ultrasonic testing, magnetic
daily supervision of an inspector, who has the experience and particle testing, penetrant testing and other non-
destructive methods for revealing defects and ir-
qualifications which enable him to judge this type of work. The regularities.
work of each welder shall be regularly examined.
Manual welding Welding where the electrode holder, welding
304 Builders and subcontractors shall keep a card index or hand gun, torch or blowpipe are manipulated by
register of all certified welders. The register shall give infor- hand.
mation on training of the welders and date and results of qual- Partly mecha- Manual welding where the wire feed is mecha-
ification tests. Information about the base metal, type of nised welding nized.
welding consumable, joint design and welding positions shall Fully mechanised Welding where all main operations (excluding
be stated in the event of re-qualification tests. The surveyor welding the handling of the workpiece) are mechanized.
shall be allowed to examine the register at any time. Fully automatic Welding where all operations are mechanized.
processes
B. Definitions
B 100 Terms C. Documentation
101 The following terms are used in connection with fabri- C 100 Plans and particulars
cation of ship structures:
101 The following documentation shall be submitted for ap-
proval:
— WPS, including WPQR, if applicable
— project specific NDT procedures
— NDT test plan.
DET NORSKE VERITAS

Pt.2 Ch.3 Sec.1 – Page 6 see Pt.0 Ch.1 Sec.3, July 2008
102 The following documentation to be sent for information: — inspection of preparatory work (assembly, fit-up form
work, reinforcements, preheating, etc.)
— erection and inspection plan — erection sequence
— tank testing plan. — inspection of fabrication work for compliance with speci-
103 For builders, unknown to the Society, documentation fications and procedures
describing the following activities shall be submitted for infor- — witnessing NDT, control and testing
mation: — repairs and inspection of repairs
— welding inspection
— qualification and acceptance of fabrication procedures and — ensure functionality of examination, testing equipment
personnel and of recording and/or measuring devices vital for correct
— correct identification and documentation and use of mate- functioning of equipment and machinery used in fabrica-
rials tion.
DET NORSKE VERITAS

SECTION 2
REQUIREMENTS FOR BUILDERS OF SHIP STRUCTURES
A. General hull structures shall possess a documented and implemented

quality management system. The extent of the quality manage-
A 100 Application ment system shall be dependent on the size and type of the or-
101 This section specifies general requirements to builders ganisation, complexity and interaction of the processes and
of ship structures, hereafter called “builders”, involved in competence of personnel.
building activities of structures intended for classification by 102 This section shall also apply to subcontractors of build-
the Society. ers, when performing fabrication work defined under the Soci-
ety’s classification scope for the project.
A 200 Basic requirements
201 Prior to commencement, builders unknown to the Soci-
ety shall demonstrate their capability to carry out fabrication in
line with the overall requirements of this section. C. Workmanship and Supervision
Guidance note: C 100 General
Upon successful conformity with this section, the Society may
grant a Newbuilding Survey Arrangement (NSA), which entitles 101 Builders shall ensure that works are skilfully and com-
builders to carry out fabrication within an actual scope of work, petently executed in accordance with fabrication procedures
and further, indicates that the builder’s quality management sys- and work instructions, inspection and test plans
tem has been adopted as complementary to the Society’s classi- 102 Builders shall ensure that all works are effectively and
fication surveys.
systematically controlled at all stages.
---e-n-d---of---G-u-i-d-a-n-c-e---n-o-t-e--- Guidance note:
Quality requirements for welding may be based on EN 729-se-
ries.
---e-n-d---of---G-u-i-d-a-n-c-e---n-o-t-e---
B. Survey Arrangement
103 Builders shall be in control of work performed at the lo-
B 100 Quality management system cation of subcontractors and/or of subcontractors performing
101 Unless otherwise agreed with the Society, builders of work at the builder.
DET NORSKE VERITAS

SECTION 3
QUALIFICATION OF WELDERS
A. General the Society, e.g. EN 287, ISO 9606, ASME Section IX, ANSI/
AWS D1.1.
A 100 Application
102 Recognition of other standards is subject to acceptance
101 These requirements shall apply to the Society’s accept- by the Society.
ance of welders for fusion welding of steel and non-ferrous
metals. B 200 Certification
A 200 Requirements 201 Welding and testing of weld assemblies shall be per-
201 Welding operators using fully mechanized or fully auto- formed in the presence of the Society’s representative. Upon
matic processes shall be required to have records of proficien- successful completion, and on client’s request, the Society will
cy, which provide evidence that the operators are receiving certify that the welder has passed the approval testing.
adequate regularly training in setting, programming and oper-
ating the equipment. 202 Where certification is performed by other IACS mem-
bers or independent organisations e.g. accredited or nationally
approved certification bodies, recognition of such certification
will be evaluated on a case by case basis. The Society reserves
B. Qualification testing and certification the right, however, to require verification of welders’ qualifi-
cations when deemed necessary. Such verification may in-
B 100 General clude testing prior to production, extra NDT and/or welding
101 Welders shall be qualified to a standard recognised by production tests.
DET NORSKE VERITAS

SECTION 4
WELDING CONSUMABLES
A. General A 200 Basic groups and grades

201 Welding consumables are divided into groups, depend-
A 100 Application ing on the strength of the filler metal and further divided into
101 This section specifies basic groups and grades for type grades depending on the impact test temperature and the chem-
approved welding consumables, application of the various ical composition of the filler metal.
grades and grouping of the shielding gases. The grades of welding consumables are specified in Table A1.
Table A1 Grades of welding consumables

Normal strength steels High strength steels Extra high strength steels Austenitic stainless steels
1 2Y 3/4/5 Y42 308 /308Mo/ 308L
2 3Y 309 /309L/ 309Nb/
3 4Y 3/4/5 Y46 309 Mo/309Mo L
5 5Y 310/310 Nb/310Mo
3/4/5 Y50 312
I 2/3/4 Y40 316/ 316 L
Grade of welding II 3/4/5 Y55 317/317 L
consumables III IY 318
V II Y 3/4/5 Y62 330
III Y 347
IV Y 3/4/5 Y69 349
VY
II/III/IV Y40
202 Welding consumables which have satisfied the require- lower strength steel.
ments for a higher toughness grade, are also considered as When welding high strength steels of grade E, it is recom-
complying with the requirements for a lower toughness grade mended that the applied welding consumable have been tested
of the same group. at -40°C (grade 4 or IV).
203 The following tables (Table A2 - Table A7) show which 204 Where applicable, the composition of the shielding gas
welding consumables that can be applied for various steel shall be reported. The approval of a wire ion combination with
grades. any particular gas can be applied to or transferred to any com-
When two different steel grades shall be joined, the welding bination of the same wire and any gas in the same numbered
consumable shall have a yield strength not below that of the group as defined in Table A8.
Table A2
Hull Structural Grade of welding consumables
steel grade 1 (DP) 2 2 Y 1) 2 Y40 1) 3 3 Y 1) 3 Y40 1) 4 Y 1) 4 Y40 1) 5 Y 1)
NV A X X X (X) X X (X) X (X) X
NV B X X (X) X X (X) X (X) X
NV D X X (X) X X (X) X (X) X
NV E X X (X) X (X) X
NV A27S X X X X X X X
NV D27S X X X X X X X
NV E27S X X X X X
NV A32/36 X X X X X X X
NV D32/36 X X X X X X X
NV E32/36 X X X X X
NV F32/36 X X X
NV A40 X X X
NV D40 X X X
NV E40 X X
NV F40 X
1) To have Hydrogen mark H15, H10 or H5, (x) may be used, but should preferably be avoided.
DET NORSKE VERITAS

Table A3
Hull Structur- Grade of welding consumables
al steel grade 1 IY II II Y II Y40 III III Y III Y40 IV Y IV Y40 VY
NV A X X X X (X) X X (X) X (X) X
NV B X X (X) X X (X) X (X) X
NV D X X (X) X X (X) X (X) X
NV E X X (X) X (X) X
NV A27S X X X X X X X X
NV D27S X X X X X X X
NV E27S X X X X X
NV A32/36 X X X X X X X X
NV D32/36 X X X X X X X
NV E32/36 X X X X X
NV F32/36 X X X
NV A40 X X X
NV D40 X X X
NV E40 X X
NV F40 X
(X) May be used, but should preferably be avoided.
Table A4
For welding of Grade of welding consumables
steel grade 1(DP) 2 2Y 1) 2Y 40 1) 3 3Y 1) 3Y40 1) 4Y 1) 4Y40 1) 5 5Y 1)
NV 360-ON X X X (X) X X (X) X (X) X X
NV 360-1FN X X (X) X X (X) X (X) X X
NV 360-2FN (X) X X (X) X (X) X X
NV 410-ON X X X (X) X (X) X
NV 410-1FN X X X X X X X
NV 460-ON X X X X X X X
NV 460-1FN X X X X X X
NV 490-ON X X X X X X X
NV 510-1FN X X X X
NV 2-2 X X X X X X X
NV 2-3 X X X X
NV 2-4 (L) X 2) X 2)
NV 4-2 X X X X X
NV 4-3 X X X
NV 4-4 (L) X 2)
1) To have Hydrogen mark H15, H10 or H5, (x) may be used, but should preferably be avoided.
2) To be specially approved for low temperature application.
Table A5
For welding of Grade of welding consumables
steel grade 1 IY II II Y II Y40 III III Y III Y40 IV Y IV Y40 VY
NV 360.ON X X X X (X) X X (X) X (X) X
NV 360-1FN X X (X) X X (X) X (X) X
NV 360-2FN (X) X X (X) X (X) X
NV 410-ON X X X X (X) X (X) X
NV 460-ON X X X X X X X X
NV 460-1FN X X X X X X
NV 490-ON X X X X X X X X
NV 510-1FN X X X X
NV 2-2 X X X X X X
NV 2-3 X X X
NV 2-4 (L) X 1)
NV 4-2 X X X X X
NV 4-3 X X X
NV 4-4 (L) X 1)
1) To be specially approved for low temperature application.
DET NORSKE VERITAS

Table A6
For welding of Grade of welding consumable
steel grade Y42H10 1) Y46H10 1) Y50H10 1) Y55H5 Y62H5 Y69H5
NV D420 3/III, 4/IV, 5/V 3/III, 4/IV, 5/V 3/III, 4/IV, 5/V
NV E420 4/IV, 5/V 4/IV, 5/V 4/IV, 5/V
NV F420 5/V 5/V 5/V
NV D460 3/III, 4/IV, 5/V 3/III, 4/IV, 5/V
NV E460 4/IV, 5/V 4/IV, 5/V
NV F460 5/V 5/V
NV E500 4/IV, 5/V 4/IV, 5/V
NV F500 5/V 5/V
NV E550 4/IV, 5/V 4/IV, 5/V
NV F550 5/V 5/V
NV E620 4/IV, 5/V 4/IV, 5/V
NV F620 5/V 5/V
NV D690 3/III, 4/IV, 5/V
NV E690 4/IV, 5/V
NV F690 5/V
1) May have hydrogen mark H5
Table A7 Selection of suitable consumables for combinations of aluminium alloys

NV-5052, NV-5754 NV-5083 NV-6060, NV-6061
Base metal alloy NV-5154, NV-5454 NV-5383 NV-6063, NV-6005A
NV-5086 NV-5059 NV-6082
NV-5052, NV-5754
NV-5154, NV-5454 5356, 5556, 5183 5356, 5556, 5183 5356, 5556, 5183
NV-5086
NV-5083, NV-5383 5356, 5556, 5183 5183 1) 5356, 5556, 5183
NV-5059
NV-6060, NV6061
NV-6063, NV-6005A 5356, 5556, 5183 5356, 5556, 5183 5356, 5556, 5183
NV-6082
Note: All consumables are covered by the AWS specification. The prefix "ER" is committed.
1) Other consumables may be use if allowable stresses are reduced.
Table A8 Grouping of shielding gases, 1)

Gas composition (Vol.%)
Group
CO2 O2 H2 He Ar
I1 100
I2 100
I3 > 0-95 Rest
M 11 >0-5 >0-5 Rest 2)
M 12 >0-5 Rest 2)
M 13 >0-3 Rest 2)
M 14 >0-5 >0-3 Rest 2)
M 21 > 5 - 25 Rest 2)
M 22 > 3 - 10 Rest 2)
M 23 > 5 - 25 >0-8 Rest 2)
M 31 > 25 - 50 Rest 2)
M 32 > 10 - 15 Rest 2)
M 33 > 5 - 50 > 8 - 15 Rest 2)
C1 100
C2 Rest > 0 - 30
1) The compositions of shielding gasses in group I are in accordance with EN 439, while group M and C gasses are in accordance with IACS W17:1993.
2) Argon may be partly substituted by Helium up to 95% of the Argon content.
DET NORSKE VERITAS

SECTION 5
WELDING PROCEDURES
A. General cation in question. The welding procedure test on which

the WPQR is based shall be witnessed by the Society or by
A 100 Application a party recognised by the Society.
101 This section specifies requirements for welding proce- b) Review and verification of documentation showing suc-
dure specifications and welding procedure qualification tests cessful application of the welding procedure specification
for C-Mn and low alloy steels, aluminium, austenitic stainless over a prolonged period of time.
steel and feritic-austenic (duplex) stainless steels. C-Mn and
low alloy steels are in this context referred to as “steels”. c) The welding procedure specification is compiled on basis
of other approved welding procedures.
A 200 Welding processes
203 For the following type of services the approval of weld-
201 Welding may be performed with the following processes ing procedure specifications shall be based on alternative 202
unless otherwise specified: a):
— manual metal arc welding (metal arc welding with covered — butt welds used in cargo tanks, process pressure vessels
electrode) and/or piping systems for liquefied gases
— self-shielded tubular-cored arc welding — all welds in aluminium
— submerged arc welding with one wire electrode (SAW)
— submerged arc welding with strip electrode — butt welds and essential fillet welds used in cargo tanks,
— metal inert gas welding, (MIG) welding hull structure, process pressure vessels and/or piping sys-
— metal active gas welding, (MAG) welding tems in ferritic-austenitic stainless steels
— tubular-cored metal arc welding with active gas shield — butt welds in plate thickness above 50 mm
— tubular-cored metal arc welding with inert gas shield — butt welds of material grade E and F single-side buttwelds
— tungsten inert gas arc welding, (TIG) welding with and without backing in the vertical down positions,
— plasma arc welding. welded connections between castings/forgings and rolled
material, such as e.g. stern frames, rudder, rudder horns
202 Other processes shall be specially approved. and struts. welding of highly stressed butt welds and cru-
ciform joints located at large hatch openings
— when welding consumables are not type approved.
B. Welding Procedure Specification 204 When a welding procedure qualification test (WPQT) is
required, the tests must be performed in the environment appli-
B 100 General cable to the actual production and meet the specified minimum
101 A welding procedure specification shall as a minimum requirements.
contain the following information as relevant for the welding
operation:
— material: standard, grade and modification C. Welding Procedure Test Assembly and Sam-
— nominal thickness or diameter range (dimensions) pling of Test Pieces
— welding process
— joint or groove design with tolerances C 100 Butt welds in plates
— welding position(s) and direction of progression
— welding consumables: trade name, electrode or wire diam- 101 The test assembly consists of two plates welded togeth-
eter, shielding gas, flux and recognised classification er. As far as possible the plates shall have a size which can
— welding sequence: number and order of passes or layers simulate the heat transfer during the production welding. For
— electrical parameters: voltage range, current range, polari- manual or semiautomatic welding, a test assembly according
ty to Fig.1 shall be carried out with:
— travel speed- and heat input ranges
— preheat and interpass temperatures lmin = 300 mm
— post weld heat treatment parameters Lmin = 350 mm
— details on cleaning processes employed and restrictions if
any. For automatic welding, the dimensions shall be:
B 200 Approved welding procedure specification lmin = 400 mm

Lmin = 1 000 mm
201 Welding procedure specifications shall be approved by
the Society prior to welding. Edge preparation and fit-up shall be as detailed in the pWPS.
202 A welding procedure specification may be approved The plates shall be joined and held by tack welds to provide the
based on one of the following alternatives: correct gap for the edge preparation used. 50 mm of each end
of the test piece shall be discarded. The test assemblies shall
a) Review of a welding procedure qualification test record normally be so prepared that the principal direction of rolling
(WPQR) corresponding to the welding procedure specifi- is parallel to the direction of welding.
DET NORSKE VERITAS

50 Discard Discard 50 mm
Macro / hardness test
Flat tensile test
Plate rolling
}
direction Face bend test or 2
side bend
( Steel plates Root bend test tests
KV T-tested )
Round tensile test

L
}
Weld metal
Fusion line Charpy

V-notch
HAZ + 2 mm tests
HAZ + 5 mm
50 Discard
Flat tensile test

l/2 l/2
l
Discard 50 mm
Fig. 1
Test assembly for butt welds in plates
t
102 The following mechanical tests are required from each

Fig. 2
assembly (see Fig.2): Sampling of test specimens in plates
— 2 tensile test (flat specimen transverse to the weld)
— 1 root and 1 face bend tests when t ≤ 20 mm and 2 side
bend tests when t > 20 mm 104 When required the round tensile specimen shall be ma-
— when the welding consumable is not approved, 1 extra ten- chined to the dimensions shown in K200, type A, care being
sile test (round specimen from the weld metal) taken that the longitudinal axis coincides with the intersection
— 12 Charpy V-notch tests with the notch location as given between the midplane of the weld, and the midplane of the
in 107 plates. If the section area of the weld metal is too small to allow
— 1 macrosection test (metallographic examination + hard- sampling of the round specimen, an all-weld-metal tensile test
ness measurements). shall be carried out.
105 Transverse side bend, root bend and face bend speci-
103 Specimens for transverse tensile testing shall be in ac- mens shall be machined to the dimensions shown in K300. For
cordance with K200, type B. a mixed or heterogeneous butt joint, longitudinal bend test
specimens may replace transverse bend test specimens.
106 The macrosection shall include about 10 mm of unaf-
fected base material and shall be prepared and etched on one
side to clearly reveal the fusion line and the HAZ
107 The Charpy V-notch specimens shall be machined in ac-
cordance with the requirements given in Ch.1 Sec.2 (ISO148).
The specimens shall be sampled 2 mm below the surface of the
parent material and transverse to the weld.
12 Charpy V-notch specimens shall be localized in the welded
joint as follows:
— 3 specimens with the notch along the weld metal cen-
treline
— 3 specimens with the notch in the fusion line
— 3 specimens with the notch in the HAZ, 2 mm from the fu-
sion line
— 3 specimens with the notch in the HAZ, 5 mm from the fu-
sion line.
108 HAZ impact test specimens are normally not required
for grade NVA steels, aluminium and austenitic stainless steels
with service temperature above -105 degrees Celsius. For ma-
terial thicknesses below 6 mm impact testing is not required
unless specifically required by the Society. The V-notch shall
DET NORSKE VERITAS

be perpendicular to the plate surface. For plate thicknesses >50

mm, two additional sets of specimens shall be taken from the
root area: one with the notch in the centre of the weld and one
with the notch in the fusion line.
C 200 Butt welds in pipes
201 The test assembly shall be in accordance with Fig.3.
Edge preparation and fit-up as detailed in the pWPS
b
a
D
a a
a = minimum value 150 mm

D = outside diameter. a = 3 t; minimum value 150 mm
b = 6 t; minimum value 350 mm
Fig. 3
Test assembly for butt welds in pipes Fig. 5
Test assembly for full penetration T-joints

assembly (see Fig.4): 302 The following mechanical tests are required from each
assembly (see Fig.6):
— 2 tensile test (flat specimen transverse to the weld)
— 1 root and 1 face bend tests when t ≤ 20 mm and 2 side — 12 Charpy V-notch tests with the notch location as given
bend tests when t > 20 mm in 107
— 12 Charpy V-notch tests with the notch location as given — 1 macrosection test (metallographic examination + hard-
in 107 ness measurements).
— 1 macrosection test (metallographic examination + hard-
ness measurements).
WELD METAL
FUSION LINE CHARPY
TENSILE TEST V-NOTCH
HAZ + 2 mm TESTS
HAZ + 5 mm
WELD METAL HARDNESS MACRO TEST
CHARPY
FUSION LINE V-NOTCH
HAZ + 2 mm TESTS
HAZ + 5 mm
BEND TESTS
TENSILE TEST
Fig. 6
HARDNESS/MACRO TEST Sampling of test specimens in full penetration T-joints
Fig. 4
Sampling of test specimens in pipes C 400 Branch connection
C 300 Full penetration T-, Y-, and K- joints assembly (see Fig.7):
301 WPQT's for full penetration groove welds between — 12 Charpy V-notch tests sampled at 9 o'clock in the branch
plates at right angles or inclined, i.e. T- or Y- and K- configu- pipe and with the notch location as given in 107
rations, shall cover a weld length of minimum 350 mm (see — two macrosection tests (metallographic examination +
Fig.5). hardness measurements) at 12 and 6 o'clock.
DET NORSKE VERITAS

D2
D. Non Destructive Testing of Test Assemblies
D 100 Butt welds and full penetration T-joints
t2 101 The extent of the testing shall be as follows:
— 100% visual inspection
— 100% radiographic or ultrasonic testing
a
a — 100% surface crack detection (dye penetrant or magnetic
particle testing).
12 6 a The soundness of the weld shall comply, unless otherwise
α 9 specified, with ISO 5817 level B for ferrous materials or ISO
D1
10042 level B for aluminium.
D 200 Fillet welds and partial penetration welds
t1
201 The extent of the testing shall be as follows:
a = minimum value 150 mm — 100% visual inspection
D1 = outside diameter of the main pipe
t1 = wall thickness of the main pipe — 100% surface crack detection (dye penetrant or magnetic
D2 = outside diameter of the branch pipe particle testing).
t2 = wall thickness of the branch pipe. The soundness of the weld shall comply, unless otherwise
Fig. 7 specified, with ISO 5817 level B for ferrous materials or ISO
Test assembly for branch connections 10042 level B for aluminium. If the stop/restart spot is includ-
ed in the test length, special attention shall be paid to this posi-
tion with respect to profile, proper fusion and absence of crater
C 500 Fillet welds defects.
501 The two plates are assembled and positioned edgewise
so as to constitute a tee-assembly with no clearance. As far as
possible the plates shall be of a sufficient size to ensure a rea-
sonable heat distribution. For fillet welds the test assembly E. Destructive Testing
shall be as defined in Fig.8.
E 100 Transverse tensile test
101 The tensile strength shall not be below the specified
minimum tensile strength for the steel grade in question.
E 200 Bend test
201 The test specimens shall be bent on a mandrel with di-
ameter 4xt, where t is the thickness of the specimen, except for
150 extra high strength steels grades 550, 620, and 690 where the
L
diameter shall be 5xt. The bending angle shall be at least 180°.
a After bending, the test specimens shall not reveal any open de-
fects in any direction greater than 3 mm. Defects appearing at
the corners of a test specimen during testing shall be ignored in
150
the evaluation.
Fig. 8 E 300 Macrosection and hardness testing

Test assembly for fillet welds
301 Cracks and lack of fusion are not accepted. The welded
joints shall have a regular profile with smooth transitions to the
For manual and semi-automatic welding the length of the test base materials and without significant or excessive reinforce-
piece shall be: ment.
302 The hardness testing shall be in accordance with ISO
Lmin = 350 mm. 6507/1 or equivalent, and is only required for grades NV27S
and higher. Normally, the Vickers method (HV10) is used. In-
For automatic welding the length shall be: dentations shall be made along traverses in the weld, HAZ and
Lmin = 1 000 mm. the parent metal approximately 1 mm below the surface. For
each traverse a minimum of 3 indentations shall be made in the
Weld and fit-up shall be as detailed in the pWPS. The test as- weld, HAZ (both sides) and parent metal (both sides). For
sembly shall be welded on one side only. For manual and semi- HAZ the first indentation shall be placed as close to the fusion
automatic welding, the stop/restart position is normally to be line as possible.
included in the test length and shall be clearly marked for sub- 303 For material grades up to NV 460 a maximum hardness
sequent examination. The ends of the specimen are exempted limit of 350 HV10 shall normally be met. For single run fillet
from examination over a length of 50 mm. welds a maximum hardness limit of 380 HV10 shall be met.
502 The following tests shall be performed:
E 400 Impact testing
— two macrosection tests (metallographic examination, 401 Hull construction
hardness measurements). One of the macrosections shall
be taken at the marked position of the stop/restart (for The test temperature and absorbed energy shall be in accord-
more details see 106). For hardness testing, see E302. ance with the following requirements:
DET NORSKE VERITAS

given in Fig.9 are those required for the plate of grade D in the
left assembly and for the plate of grade E in the right assembly.
Impact test temperatures: For grades:
+20°C B, A27S, A32, A36 and A40
0°C D, D27S, D32, D36 and D40
-20°C E, E27S, E32, E36 and E40
-40°C F32, F36 and F40 grade D grade E
Guidance note:
If tested, the average value for absorbed energy in weld metal, fu-
sion line and HAZ shall not be less than 27 J at 20°C for NVA.
---e-n-d---of---G-u-i-d-a-n-c-e---n-o-t-e---
The average value for absorbed energy in weld metal, fusion

line and HAZ shall not be less than:
grade E grade EH
— for manual and semi-automatic welding in all welding po-
sitions except vertical: 47 J
— for automatic welding: 34 J (NV 40 grades 41 J)
— for manual and semi-automatic welding in vertical posi-
tion: 34 J (NV 40 grades 41 J).
Fig. 9
For extra high strength structural steels the Charpy V-notch Butt welded plate joints of different grades
test temperature and the average value for absorbed energy in
weld metal, fusion line and HAZ shall be the same as required
for the base material. 502 Impact testing may be required from both sides of the
weld.
402 For pressure vessels and production/drilling plants relat-
ed equipment, structures and systems the Charpy V-notch test Guidance note:
temperature and the average value for absorbed energy in weld Welds between cast or forged material and rolled plate should be
metal, fusion line and HAZ shall be the same as required for impact tested from both sides of the weld.
the base material. ---e-n-d---of---G-u-i-d-a-n-c-e---n-o-t-e---
403 The average impact requirements shall be satisfied for
each notch location, but one single value of three values from E 600 Retesting
specimens from the same notch location may be below the av- 601 If the WPQT fails to comply with any of the require-
erage requirements, but not below 70% of minimum average. ments for NDT one extra WPQT shall be welded and subjected
404 In the case of reduced Charpy V-notch test specimens to the same testing. If this additional test does not meet the rel-
(10 x 7.5 mm and 10 x 5 mm), the impact energy values to be evant requirements, the actual WPS shall be considered as not
obtained shall satisfy Table E1: qualified and a re-specification of the WPS shall be made prior
to a new qualification test.
Table E1 Impact energy requirement for subsize specimens
Dimensions of Charpy V-notch test specimen Impact energy
10 x 10 mm KV
F. Validity of Approved Welding Procedures
10 x 7.5 mm 5/6 KV
10 x 5 mm 2/3 KV F 100 General
405 Where the results from a set of three impact test speci- 101 The validity of an approved WPS shall be restricted to
mens do not comply with the requirements, an additional set of the builder or subcontractor performing the qualification or re-
three impact test specimens may be taken. The results obtained ceiving the approval. It is a prerequisite that the workshops/
shall be combined with the original results to form a new aver- yards belonging to the builder and/or subcontractor are under
age which, for acceptance, shall be not less than the required the same technical management and working in accordance
value. Additionally, for these combined results not more than with the same QA – program and – procedures.
two individual values shall be less than the required average 102 Qualification of a welding procedure remains valid pro-
value, and of these, not more than one shall be less than 70% vided the parameters are kept within the qualified ranges dur-
of the average value. Further re-tests may be made at the sur- ing production welding. The qualified ranges are given in F
veyor's discretion, but these shall be made on a new welded as- 200. When one or more variations outside the qualification
sembly (revised WPS) and shall include all tests required for ranges occur, the welding procedure qualification shall be con-
the original assembly, even those which were previously satis- sidered invalid, and the welding procedure is therefore to be re-
factory. specified and re-qualified.
Guidance note:
E 500 Welds between different material grades
Note that a qualified procedure is always based on a welding pro-
501 When a butt weld is made between two plates of differ- cedure test (WPQT) and that approval of a WPS based on a weld-
ent grades, the test temperature and achieved impact energy ing procedure test is only required for the type of services listed
shall comply with the minimum specified requirements for the in B203.
lower steel grade (see E401 and E402). In the same way, the ---e-n-d---of---G-u-i-d-a-n-c-e---n-o-t-e---
tensile strength to be obtained on the welded assembly shall be
in agreement with the requirements relating to the plate steel
having the lower strength. As an example the test temperature, F 200 Range of qualification
impact energy and tensile strength for the butt welded joints 201 A qualified welding procedure shall be used within the
DET NORSKE VERITAS

ranges of the parameters below. Table F2 Range of qualification for material thickness and
Base material throat thickness of fillet welds
The following changes shall lead to a new qualification: Range of qualification
Thickness
t (mm) Throat thickness
a) In general, significant change of material properties which of test piece Material
will obviously affect the weldability and mechanical prop- thickness Single run Multi-run
erties. t < 30 0.5 t to 1.2 t 0.75 a to 1.5 a 1) No restriction
b) More specifically, structural steels are grouped in three t ≥ 30 ≥5 a 2) No restriction
categories: 1) a is the throat as used for the test piece
2) for special applications only. Each throat thickness has to be proofed
i) Normal strength steel, grades A, B, D and E or equiv- separately by a welding procedure test.
alent structural steels with tensile strength 400–520 N/
mm2.
Note: Where a fillet weld is qualified by means of a butt weld test, the throat
ii) High strength steel, grades A27S, D27S, E27S, A32, thickness range qualified shall be based on the thickness of the deposit mate-
D32, E32, F32, A36, D36, E36, F36, A40, D40, E40, rial.
F40 or equivalent structural steels with minimum
specified yield strength 265–390 N/mm2. Diameter of pipes and branch connections
iii) Extra high strength steels, grades A-F 420, A-F 460, The qualification of a welding procedure test on diameter D
A-F 500, A-F 550, A-F 620, A-F 690 or equivalent shall include qualification for diameters in the following rang-
structural steels with minimum specified yield es as given in Table F3.
strength 420-690 N/mm2.
Table F3 Qualified range for pipe and branch connection
The qualification on steel grades of higher toughness require- diameters
ments will qualify the grades of lower toughness but not vice Diameter of the test piece
versa. D (mm) 1) 2) Qualification range
Thickness D ≤ 25 0.5 D to 2 D
Thickness, t, is defined as follows: D > 25 ≥ 0.5 D and plates
1) D is the outside diameter of the pipe or outside diameter of the branch
a) For a butt weld: pipe.
The base metal thickness, which for welds between dis- 2) Qualification given for plates also covers pipes when the outside diam-
similar thicknesses is that of the thinner material. eter is greater than 500 mm.
b) For a fillet weld: Angle of branch connections

The base metal thickness, which for welds between dis- A WPQT carried out on a branch connection with angle α shall
similar thicknesses is that of the thicker material.
qualify all branch connection angles in the range of α to 90°.
c) For a set-on branch connection:
The thickness of the branch pipe. Welding consumables
The following changes shall lead to a new qualification:
d) For a set-in or set-through branch connection:
The thickness of the main pipe. — any change in consumable classification
e) For a T-joint in plate: — change of consumable brand when impact testing is re-
The thickness of the prepared plate. quired at temperatures below -20°C
— any significant change of mixture/composition (e.g.
The requirements to qualified thickness range for butt welds change from argon/mixed gas to CO2 gas, see Sec.4 Table
shall be as given in Table F1. A8), flow rate, filling time and filling volume for shielding
and purging gases.
Table F1 Qualified thickness range
Thickness Welding positions
t (mm) Qualification range 1) The following changes shall lead to a new qualification.
of test piece
Change from one principal welding position (see Figs. 10, 11,
Single run
or single run Multi-run 12) to another, unless complying with Table F4.
from both sides
t < 12 0.5 t to 1.3 t Up to 2 t
0.5 t to 2 t
12 ≤ t ≤ 100 0.5 t to 1.1 t (max. 150)
t > 100 Not applicable 50 to 2 t
1) The qualification range for vertical downward position is 0.5 t to 1.1 t
Range of qualification for material thickness and throat thick-

ness of fillet welds shall be as given in Table F2.
DET NORSKE VERITAS

Type of joint
— change from fillet weld to butt weld
— change from two sided welding to one side, but not vice
versa
— deletion of back gouging
1G (PA) FLAT
— addition or deletion of ceramic backing
— change from butt joint in plates to butt joints in pipes with
3G (PF-UPWARDS
PG-DOWNWARDS)
outside diameter less than 500 mm.
VERTICAL — any change of groove dimensions specified in the WPS.
Welding condition
— any change of welding process
— change from spray arc to short arc or pulsed arc or vice
2G (PC) HORIZONTAL -
4G PE) OVERHEAD
versa
VERTICAL — change in heat input beyond ±25%
Fig. 10 — any decrease in preheat temperature
Plate test positions — change of interpass temperature beyond 25°C
— addition or deletion of post weld heat treatment; the tem-
perature range validated is the holding temperature used in
the welding procedure test ±20ºC.
THROAT OF WELD AXIS OF WELD

VERTICAL HORIZONTAL
AXIS OF WELD
HORIZONTAL
FLAT POSITION 1F (PA)

Note: One plate must be horizontal
HORIZONTAL POSITION 2F (PB)
AXIS OF WELD VERTICAL
AXIS OF WELD
HORIZONTAL
VERTICAL POSITION 3F Note: One plate must be horizontal

(PF-UPWARDS OVERHEAD POSITION 4F (PD)
PG-DOWNWARDS)
Fig. 11 Fig. 12
Pipe test positions Positions of test plate for fillet welds
DET NORSKE VERITAS

Table F4 Qualified principal positions for butt welds and fillet welds, steel
Qualified positions 3)
Test weld Principal positions Butt welds
Joint configuration 1)2) Fillet welds
Plates Pipes plates or pipes
2G + 3G All All
1G 1G 1F
Butt welds in plates 2G 1G, 2G, 4G 1F, 2F, 4F
3G 3G 3F
4G 1G, 4G 1F, 4F
2G + 5G = 6G All All All
1G 1G 1G 1F
Butt welds in pipes 2G 1G, 2G, 4G 1G, 2G 1F, 2F, 4F
5G All 1G, 5G All
2F + 3F All
1F 1F
2F 1F, 2F, 4F
Fillet welds 3F 3F
4F 1F, 2F, 4F
5F All
1) Pipes with D > 500 mm are considered equivalent to plates (apply only to the main pipe in branch connections.
2) Branch connections shall be qualified separately.
3) The vertical downwards position shall be qualified separately.
G. Additional Requirements WPQT for Lique- 1) If the impact test pieces from plate materials are taken with
fied Gas Systems their longitudinal axes transverse to the main direction of
rolling, the average value from 3 tests shall not be less than
G 100 Welds in plates and pipes 27 J for weld metal, fusion line, heat affected zone and par-
ent material. One single test may give a value below the re-
101 Test assembly shall be as described in C101 or C201. quired average, but not lower than 19 J.
102 From each test assembly for plates the following addi- 2) If the impact test pieces from plate materials are taken with
tional test specimens shall be taken: their longitudinal axes parallel with the main direction of
rolling the average value from 3 tests is for the fusion line
— one set of Charpy V test specimens (each set consists of 3 and the heat affected zone not to be less than 41 J, and for
specimens) with the notch 1 mm from the fusion line. the weld metal not to less than 27 J. One single test may
For austenitic stainless steels, only one set of Charpy V test give a value below the required average but not lower than
specimens with the notch in the centre of the welds are re- 29 J and 19 J respectively. For testing of thin materials
quired for design temperature below -105°C. where it is impossible to use a standard test piece 10 x 10
mm, the larger of the following pieces shall be used:
G 200 Test requirements
— 10 x 7.5 mm, 10 x 5 mm, 10 x 2.5 mm.
201 The butt weld tensile test shall comply with the follow-
ing requirements: The impact values are then reduced to respectively 5/6, 2/3 and
Generally, the tensile strength shall not be less than the speci- 1/2 of the required values of the standard test pieces.
fied minimum tensile strength for the parent material. In cases 303 If the impact test (3 specimens) fails to meet the require-
where the Society has approved the use of welding consuma- ments, 3 additional impact test specimens may be prepared and
bles which give lower tensile strength in the weld metal than tested provided that only one of the below mentioned three cas-
that required for the parent material, the approved value for the es occurred in the first test:
welding consumable in question applies. The position of frac-
ture shall be reported. 1) The average value was below the requirement, one value
being below the average requirement but not below the
202 Charpy V testing shall be conducted at the temperature minimum requirement for a single value.
prescribed for the base material (ref. Pt.5 Ch.5 Sec.2 of the
Rules for Classifcation of Ships). When specimens of 10 x 10 2) The average value met the requirement. Two values were
mm cross-section are used, the average value from 3 tests shall below the average requirement but not below the require-
not be less than 27 J for weld metal. One single test may give ment for a single value.
a value below the required average but not lower than 19 J. 3) The average met the requirement. Two values were above
For fusion line and heat affected zone the requirement for min- or equal to the average requirement and one value was be-
imum average value is the same as for the base material. low the requirement for a single value. The initial 3 impact
values and the additional 3 values shall form a new aver-
G 300 Weld production test requirements age of six values. If this new average complies with the re-
301 In general the tests requirements shall comply with quirement and no more than two individual results of all
G100. six specimens are lower than the required average and no
more than one result is lower than the required value for a
302 Impact testing is for carbon-manganese steels, austenitic single specimen, the test may be accepted.
chromium-nickel steels and nickel steels to be conducted at the
temperature prescribed for the base material. For austenitic 304 If the impact values do not comply with the require-
chromium-nickel steels, testing is only required for design ments in 302 and 303, the results may be submitted for consid-
temperature below -105°C. For welding of plates the following eration. The production weld test may be accepted subject to
apply when pieces of 10 x 10 mm cross section are used: acceptable results from additional test prescribed by the Soci-
DET NORSKE VERITAS

ety. examined at 400X magnification and shall be free from grain

boundary carbides and precipitates. The ferrite content in the
weld metal root and un-reheated weld cap shall be determined
in accordance with ASTM E 562 and be in the range of 25-
H. Additional Requirements WPQT for Ferritic- 70%.
Austenitic Stainless Steel
H 300 Validity of a qualified welding procedure
H 100 Welds in plates and pipes 301 Reference is made to D200 and any change in the fol-
101 Test assembly shall be as described in C101 or C201. lowing additional essential variables which shall lead to a new
qualification:
102 From each test assembly the following additional test
specimens shall be taken: — variation in the heat input greater than ±15%.
— one corrosion test according to ASTM G48-76 Method A
— one microsection test specimen.
H 200 Test requirements I. Additional Requirements WPQT for Auste-
201 Corrosion test according to ASTM G48-76 Method A. nitic Stainless Steel
The test specimen shall be in the as welded state after normal I 100 Welds in plates and pipes
weld cleaning operation. The test specimens shall be exposed
to the solution at a constant temperature of 20°C for 24 hours. 101 Test assembly shall be as described in C101 or C201.
Test requirements : 102 Impact testing is not required for design temperatures
above -105°C.
— no pitting attack shall be visible on the test face(s)
— general weight loss shall not exceed 20 mg. I 200 Test requirements
Guidance note: 201 If impact testing is required, the testing shall be conduct-
Welds between Ferritic-Austenitic steels and other grades of ed at -196°C meeting an average impact energy level of 34 J.
stainless, C/Mn steels or for welds in “non corrosive “ area may
not need to be corrosion tested.
---e-n-d---of---G-u-i-d-a-n-c-e---n-o-t-e--- J. Welding procedures for aluminium
202 Impact testing shall be as described in C107 using an im- J 100 General
pact test temperature of -20°C. The average value for absorbed
energy shall not be less than 27 J. 101 Basic requirements are given in A General and B Weld-
203 Concerning the micro structural examination, the test ing procedures.
samples shall comprise the weld metal, heat affected zone and 102 Welding consumables shall be one of those recommend-
base metal. The microstructure shall be suitably etched and ed in Table J1.
Table J1 Selection of suitable consumables for combinations of aluminium alloys

NV-5052, NV-5754 NV-5083 NV-6060, NV-6061
Base metal alloy NV-5154, NV-5454 NV-5383 NV-6063, NV-6005A
NV-5086 NV-5059 NV-6082
NV-5052, NV-5754
NV-5154, NV-5454 5356, 5556, 5183 5356, 5556, 5183 5356, 5556, 5183
NV-5086
NV-5083, NV-5383 5183 1)
5356, 5556, 5183 5356, 5556, 5183
NV-5059 5556
NV-6060, NV-6061
NV-6063, NV-6005A 5356, 5556, 5183 5356, 5556, 5183 5356, 5556, 5183
NV-6082
Note: All consumables are covered by the AWS specification. The prefix «ER» is omitted.
1) Other consumables may be used if allowable stresses are reduced, see Table J2.
J 200 Butt welds in plates — 1 tensile test specimen

201 Test assembly shall be as described in C101. — 1 root and 1 face or 2 side bend specimens
— 1 macro test specimen.
assembly:
DET NORSKE VERITAS

Discard 25mm Top for fixed pipe

Area 1 for:
- 1 tensile specimen
- 1 root and 1 face or
2 side bend specimens
Welding direction
Area 2 for:
- Additional test Area 1 for:
specimens if required - Additional test
specimens if required
Area 2 for:
- 1 tensile specimen
- 1 root and 1 face or
2 side bend specimens
Area 3 for:
- 1 macro test specimen
Fig. 15
Discard 25mm Location of test specimens for a butt weld in pipe
Fig. 13
Location of test specimens for a butt weld on plate 303 One tensile specimen shall be taken from each of the
welded assemblies. The test specimen, 25 mm wide and with
full plate thickness and orientated transverse to the weld, is
203 One tensile specimen shall be taken from each of the shown in Fig.14.
welded assemblies. The test specimen, 25 mm wide and with 304 Side-bend tests shall be carried out for thickness equal to
full plate thickness and orientated transverse to the weld, is and above 10 mm. Two bend specimens shall be taken from
shown in Fig.14. each of the welded assemblies. The bend test specimens shall
be machined to the dimensions given in K300.
T WELD T
305 For thickness below 10 mm one face bend and one root
bend test specimens shall be taken. The diameter of the bend-
25
35
ing mandrel shall be as given in J702.

100 GAUGE LENGTH ( ~ 3 x T ) 100
306 One macrosection shall be prepared from the test assem-
bly to reveal the weldment macro structure. The macrosection
shall be visually inspected using a magnification of 5 to 10X.
Fig. 14
Tensile test specimen J 400 Branch connections
assembly (see Fig.7):
204 Side-bend tests shall be carried out for thickness equal to
and above 10 mm. Two bend specimens shall be taken from — two macrosection tests at 12 and 6 o'clock.
each of the welded assemblies. The bend test specimens shall
be machined to the dimensions given in K300. J 500 Fillet welds
205 For thickness below 10 mm one face bend and one root 501 Test assembly shall be as described in C501.
bend test specimens shall be taken. The diameter of the bend- 502 The following tests shall be performed:
ing mandrel shall be as given in J702.
— two macrosection tests. One of the macrosections shall be
206 One macrosection shall be prepared from the test assem- taken at the marked position of the stop/restart. The mac-
bly to reveal the weldment macro structure. The macrosection rosection shall include about 10 mm of unaffected base
shall be visually inspected using a magnification of 5 to 10X. material and shall be prepared and etched on one side to
clearly reveal the fusion line and the HAZ.
J 300 Butt welds in pipes
J 600 Non destructive testing of test assemblies
301 Test assembly shall be as described in C201.
601 Non destructive testing shall be according to D100 for
302 The following mechanical tests are required from each butt welds and D200 for fillet welds and partial penetration
assembly: welds.
— 1 tensile test specimen J 700 Destructive testing
— 1 root and 1 face or 2 side bend specimens 701 The tensile strength of the test specimens shall not be
— 1 macro test specimen. less than specified for the parent alloy in Table J2.
DET NORSKE VERITAS

Table J2 Mechanical properties in the welded condition

Tensile strength Yield strength
Alloy Temper Filler Rm minimum in HAZ, Rp0.2 minimum
(N/mm2) (N/mm2)
0, H111,
NV-5052 5356 170 65
H32, H34
NV-5754 0, H111, H24 5356-5183 190 80
0, H111
NV-5154A 5356-5183 215 85
H32, H34
NV-5454 0, H111, H32, H34, 5356-5183 215 85
0, H111, H112
NV-5086 5356-5183 240 100
H116, H321, H34
0, H111, H112 t < 6 mm 5183 270 125
0, H111, H112 t > 6mm 5356-5183 270 115
NV-5083 H116, H321 5356 270 115
H116, H321 5183 270 125
0, H111,
NV-5383 5183 290 145
H116, H321
0, H111,
NV-5059 5183 330 160
H116, H321
NV-6060 T4, T5, T6 5356-5183 95 65
T4 165 115
NV-6061 5356-5183
T5 or T6 165 115
T4, T5 100 65
NV-6063 5356-5183
T6 100 65
NV-6005A T4, T5 or T6 5356-5183 165 115
T4 170 110
NV-6082 5356-5183
T5 or T6 170 115
702 The bend test specimens shall be bent on a mandrel with 802 A qualified welding procedure shall be used within the
maximum diameter as given in the formula below. The bend- ranges of the parameters below.
ing angle shall be at least 180°. After bending, the test speci- Base material
mens shall not reveal any open defects in any direction greater
than 3 mm. Smaller cracks developing from the edges of the The following changes shall lead to a new qualification:
specimens shall not normally be considered as significant, un-
less there is definite evidence that they result from inclusions a) In general, significant change of material properties which
or other defects.«Wrap around» bending as shown in K300 is will obviously affect the weldability and mechanical prop-
the preferred bending method. erties.
b) More specifically, aluminium alloys are grouped in the
(100 xt s ) following categories:
d= − ts
A i) NV-5052, NV-5754A, NV-5154, NV-5454
where ii) NV-5086, NV-5083, NV-5383, NV-5059
d = maximum former diameter iii) NV-6060, NV-6061, NV6063, NV-6005A, NV-6082
ts = thickness of the bend test specimen (this includes side
bends) The qualification on aluminium alloys in category iii) will
A = minimum tensile elongation required by the material qualify for the alloys in category ii) and category i) but not vice
specification (for combination between different alloys, versa. The qualification on aluminium alloys in category ii)
the lowest individual value shall be used). will qualify for the alloys in category i) but not vice versa.
703 The macrosections shall show a regular weld profile Thickness
with smooth transitions to the base materials and without sig- Thickness, t, is defined as follows:
nificant or excessive reinforcement. Cracks and lack of fusion
are not acceptable. a) For a butt weld: The base metal thickness, which for welds
704 When a butt weld is made between two plates of differ- between dissimilar thicknesses is that of the thinner mate-
ent alloys the tensile strength to be obtained on the welded as- rial.
sembly shall be in agreement with the requirements relating to b) For a fillet weld: The base metal thickness, which for
the alloy having the lower strength. welds between dissimilar thicknesses is that of the thicker
705 If the WPQT fails to comply with any of the require- material. However, for each thickness range qualified, as
ments for NDT one extra WPQT shall be welded and subjected in Table B2 there is an associated range of qualified throat
to the same testing. If this additional test does not meet the rel- thickness as given below.
evant requirements, the actual WPS shall be considered as not c) For a set-on branch connection: The thickness of the
qualified and a re-specification of the WPS shall be made prior branch pipe.
d) For a set-in or set-through branch connection: The thick-
J 800 Range of qualification ness of the main pipe.
801 The validity of approved welding procedure shall be as e) For a T-butt joint in plate: The thickness of the prepared
given in F100. plate.
DET NORSKE VERITAS

The requirements to qualified thickness range for butt welds — any change of welding process
shall be as given in Table J3. — change from spray arc to short arc or pulsed arc or vice
versa
Table J3 Qualified thickness range — change in heat input beyond ±25%
Thickness — any decrease in preheat temperature
t (mm) Qualification range — change of interpass temperature greater than 25°C
of test piece — change of post weld heat treatment parameters.
t<3 0.5 t to 2 t
3 ≤ t ≤ 20 3 to 2 t Table J6 Qualified principal positions for butt welds and fillet
t > 20 ≥ 0.8 t welds, aluminium
Qualified positions 3)
In addition to the requirements of Table J3, the range of quali- Test weld Fillet welds
fication of the throat thickness "a" of fillet welds is given in Ta- Joint Principal Butt welds plates or
ble J4. configuration 1)2) positions pipes
Plates Pipes
Table J4 Range of qualification for the throat thickness for 1G 1G 1G 1F
plates and pipes Butt welds in 2G 1G, 2G, 3G 1F, 2F, 3F
Throat thickness plates 3G 1G, 2G, 3G 1F, 2F, 3F
Range of qualification 4G All All
of the test piece a
a < 10 0.75 a to 1.5 a 1G 1G 1G 1F
Butt welds in
a ≥ 10 ≥ 7.5 2G 1G, 2G, 3G 2G 1F, 2F, 4F
pipes 5G All 1G, 5G All
Where a fillet weld is qualified by means of a butt weld test, 1F 1F
the throat thickness range qualified shall be based on the thick- 2F 1F, 2F, 3F
ness of the deposited weld metal. Fillet welds 3F 1F, 2F, 3F
4F All
Diameter of pipes and branch connections 5F All
The qualification of a welding procedure test on diameter D 1) Pipes with D > 500 mm are considered equivalent to plates (apply only
to the main pipe in branch connections).
shall include qualification for diameters in the following rang-
es as given in Table J5. 2) Branch connections shall be qualified separately.
3) The vertical downwards position shall be qualified separately.
Table J5 Qualified range for pipe and branch connection
diameters J 900 Retesting
Diameter of the test 901 If the WPQT fails to comply with any of the require-
piece Qualification range ments for NDT one extra WPQT shall be welded and subjected
D (mm) 1) to the same testing. If this additional test does not meet the rel-
D ≤ 25 0.5 D to 2 D evant requirements, the actual WPS shall be considered as not
D > 25 ≥ 0.5 D and plates qualified and a re-specification of the WPS shall be made prior
1) D is the outside diameter of the pipe or outside diameter of the branch
pipe.
Angle of branch connections

A WPQT carried out on a branch connection with angle α shall
K. Testing
qualify all branch connection angles in the range of α to 90°. K 100 General
Welding consumables 101 Testing of welds shall be carried out as specified in 200
The following changes shall lead to a new qualification: to 300. Reference is also made to relevant paragraphs in Ch.1
Sec.2.
— any change in consumable classification
— any significant change of shielding gas mixture. K 200 Tensile testing at ambient temperature
201 For tensile testing of all-weld-metal and butt welds two
Welding positions different types of test specimens may be used, round test spec-
The following changes shall lead to a new qualification: imens or flat test specimens (see Fig.16 ) as described below.
— change from one principal welding position (see figures in a) Deposited metal tensile test
F200) to another, unless complying with Table J6. Normally, round test specimens with the following dimen-
sions shall be used:
Type of joint
The following changes shall lead to a new qualification: d = 10 mm
Lo = 50 mm
— change from fillet weld to butt weld Lc = 60 mm
— change from two sided welding to one side, but not vice R ≥ 5 mm
versa b) Butt weld tensile test
— deletion of back gouging
Flat test specimens with the weld machined flush with the
— addition or deletion of ceramic backing surface of the plate, shall be used. The dimensions shall be
— change from butt joint in plates to butt joints in pipes with as follows:
outside diameter less than 500mm.
— any change of groove dimensions specified in the WPS. a = thickness of plate, t
b = 25 mm
Welding condition L0 = Lc = 3t or 2t + width of weld, whichever is the
The following changes shall lead to a new qualification: greatest
DET NORSKE VERITAS

R = 25 mm.
Fig. 16
Tensile test specimen.
Fig. 18
K 300 Bend testing Wrap around bend test.
301 Flat bend test specimens, as given in Fig.17 shall be
used. Edges on tension side to be rounded to a radius of 1 to
2mm. 302 When the wrap around bend test, exemplified in Fig.18
is used, e.g. for the side bend test of a weld, the length of the
test specimen has to be greater than the length 11a shown in
Fig.17.
303 For butt weld bend test specimens, the weld shall be ma-
chined flush with the surface of the plate.
304 For transverse face-bend and root-bend test specimens
for butt weld test the dimensions shall be as follows:
a = as rolled thickness t of the plate
b = 30 mm.
If the as rolled thickness t is greater than 25 mm, it may be re-
duced to 25 mm by machining on the compression side of the
Fig. 17 test specimen.
Bend test specimen. 305 For transverse side-bend test specimens for butt weld
test the dimensions shall be as follows:
a = 10 mm
b = as rolled thickness t of the plate.
If t ≥ 40 mm, the side-bend test specimen may be subdivided,
each part being at least 20 mm wide.
306 When a longitudinal face-bend or root-bend weld test is
required, a test specimen according to an appropriate standard
will be accepted.
DET NORSKE VERITAS

SECTION 6
FABRICATION AND TOLERANCES
A. General 104 The effect of work hardening and risk of cracked edges
shall be considered if shearing is used for cutting of material.
A 100 Application 105 Correction by welding as compensation for improper
101 This section specifies general requirements for steel fab- cutting shall be in accordance with procedures for repairs.
rication processes, including essential variables, which shall be
maintained and controlled by the builders. E 200 Forming
201 Forming and straightening of materials shall be per-
formed according to procedures which outline the succession
of the controlled steps.
B. Material Identification
202 The degree of cold forming for steels in structural mem-
B 100 General bers shall be carried out within the deformation range recom-
mended by the manufacturer. Should however such
101 A material identification system which ensures correct documentation not be available, the deformation rate for car-
installation and documentation of the material grades shall be bon manganese steels shall be less than 10 %, respectively
established. 20% for austenitic and ferritic-austenitic steels. If the deforma-
tion exceeds 10%, respectively 20% either heat treatment or
strain ageing test shall be carried out in accordance with an
agreed procedure as stipulated in Pt.3 Ch.1 Sec.3 C1100
C. Approval of Shop Primers (Rules for Classification of Ships).
C 100 General Guidance note:
101 Shop primer applied over areas, which will subsequently The plastic deformation e may be calculated by the following
simplified formulae:
be welded, shall be of approved type as having no detrimental
effect on the finished weld. Single-curvature deformation
Guidance note: Cold rolling or pressing of plates to cylindrical forms:
Type approved shop primers are listed under “Non-Metallic Ma- e = (t/D) x 100%
terials(K)” in the DNV register of approved products and manu- Cold bending of straight pipes to bends:
facturers, available on the DNV Internet site. e = (D/2Rc) x 100%
---e-n-d---of---G-u-i-d-a-n-c-e---n-o-t-e--- Double curvature deformation
Forming of plates to spheres:
102 Approved shop primers or thin coatings of linseed oil
may be applied to welds subject to tightness test in agreement e = (t(1 + í)/2Rc) x 100%
with the manufacturer’s recommendation. In general the ap- t = material thickness
plied film thickness on welds shall not exceed 50 microns. D = outside diameter of pipe of vessel
Rc = forming radius
N = Poisson’s ratio (0.5 for plastic condition).
D. Welding Environment ---e-n-d---of---G-u-i-d-a-n-c-e---n-o-t-e---
D 100 General 203 Forming of steels at high temperatures shall be effectu-

ated with due regard to adverse effects of the material’s prop-
101 Welding work shall not be carried out in environmental erties. Forming of steels above 650ºC shall be subject to
conditions that may have a detrimental effect such as wind, agreement with the Society.
damp and cold.
102 Welding processes sensitive to draughts shall be ade- E 300 Assembly and Welding
quately protected. 301 Members to be welded shall be brought into correct
103 The grooves shall by dry at all time of welding. alignment and held in position by clamps, tack welds, or other
suitable devices, until welding has been completed or pro-
104 Preheating temperature, whenever required, shall in any gressed to a stage where in control of the process. Such ar-
case be within the limit of essential variables, see E306. rangement shall be suitably arranged to minimise distortion
105 The welding interpass temperature shall not drop below and built-in stresses.
the minimum required preheating temperature. 302 Fit-up shall be checked for dimensional accuracy before
welding. Special attention shall be drawn to assure correct fit-
up of areas, of which direct visual inspection is impossible.
E. Cutting, Forming, Assembly and Welding 303 Surfaces to be welded shall be free from mill scale, slag,
rust, paint or other contaminating substances.
E 100 Cutting 304 Grooves shall be within the groove profile particulars
101 Cut edges are to be accurate and uniform in order to pro- given by the welding procedure specification (WPS). Grooves
vide a shape compatible with the weld joint design. shall be slag free.
102 Deviation of cut edges shall generally be within the 305 All welding, including tack welding, seal welding, weld-
standard specified by IACS Shipbuilding and Repair Standard ing of lifting lugs and repair welding, shall be performed with-
Part A. in the limits of essential variables of the welding procedure
103 Attention shall be paid to avoid excessive local harden- specification (WPS).
ing and carbon contaminations by thermal cutting. 306 Preheating, when required, shall be applied in accord-
DET NORSKE VERITAS

ance with agreed procedures. Special attention shall be paid to followed by grinding.
temperature control during the welding process such that the 203 Repair welding in the same area may be carried out
preheat temperature is kept uniformly in affected part of the twice. Further repairs shall be subject to agreement with the
welded object. Society.
Guidance note:
204 All weld repairs shall at least be re-inspected with the
Normal strength steels may require preheating depending on the same NDT methods as originally applied.
combined plate thicknesses and the degree of joint restraint.
Preheating is normally required for welding of high and extra F 300 Flame straightening
high strength steels depending on chemical composition, rolling
process, joint restraint and combined plate thickness. Post heat- 301 Members distorted by welding may be straightened by
ing may additionally be required for extra high strength steels. mechanical means or by a limited amount of localised heat.
---e-n-d---of---G-u-i-d-a-n-c-e---n-o-t-e--- 302 Corrective measures relating to flame straightening shall
be carried out with due regard to possible degradation of the
307 The welding sequence shall be such that the amount of material properties.
shrinkage, distortions and residual stresses are minimised.
308 Welds shall be terminated in a manner such that all
welds are sound and without end craters. Run-off plates shall
be used, where practicable, and be removed upon completion G. Inspection and Tolerances
and cooling of the weld. Cut welds shall be made smooth and G 100 General
flush with the edges of the abutting parts.
101 Inspection shall be carried out in accordance with in-
309 Tack welding shall be carried out in accordance with ap- spection and test plans to confirm that work is carried out in ac-
proved welding procedure specifications (WPS), specifying cordance with established project procedures and plans such
the applied minimum welding length. that all project requirements are complied with to the satisfac-
310 Tack welds used for assembly shall be removed before tion of the Society.
welding leaving the effected area free from defects. 102 Due consideration shall be given to the access and the
311 Tack welds, if retained as part of the welding process, time required for adequate inspection during fabrication.
shall be free from defects and provide adequate conditions for 103 High non-conformance rates in execution of the work or
pass welding. in the product itself shall call for special considerations in
312 Storage and handling of welding consumables shall be agreement with the Society. Such special considerations may
in accordance with the manufacturer’s recommendations, and include, but not be limited to, increased inspection, re-qualifi-
in accordance with procedures giving details regarding condi- cation of personnel or other agreed remedial actions.
tions in storage rooms, temperature in storage ovens and quiv-
ers, length of exposure and conditions, as applicable. G 200 Alignment and straightness
313 Consumables which have been contaminated by mois- 201 Allowable acceptable alignment shall be established on
ture, rust, oil, grease, dirt or other deleterious matters, shall be the criticality of the design. Special requirements relating to
discarded unless properly reconditioned. special type and service are given in Pt.5.
314 Recycling of fluxes for submerged arc welding (SAW) 202 In general fabrication tolerances shall be in compliance
shall be performed in a manner that ensures a mixture of new with IACS Shipbuilding and Repair Quality Standard, Part A.
and used flux with continually homogenous properties.
G 300 Special building tolerances
301 Special building tolerances and/or weld finish as a result
of operations in harsh environment and/or vessels with in-
F. Repairs creased target design life, relating to Class Notations PLUS-1
and PLUS-2, ref Pt.3 Ch.1 Sec.15 and Sec.16 (Rules for Clas-
F 100 General sification of Ships), shall be readily included in the fabrication
101 Guidance to general welding repair work is given in instructions and procedures, see Sec.1.
IACS Shipbuilding and Repair Quality Standard Part A.
G 400 Weld production test requirements
102 Defects in welds may be repaired by grinding, machin-
ing and/or welding. In order to verify complete removal of de- 401 The Society may require weld production tests to be car-
fects, effected areas shall be examined with suitable NDT ried out. The extent and type of testing shall be agreed with the
methods. Society.
402 When production weld tests are required the test assem-
F 200 Repair welding bly and test requirements shall comply with the relevant re-
201 Repairs by welding shall be carried out in accordance quirements of Sec.5.
with approved welding procedure specifications (WPS). Me- 403 If the achieved test results do not comply with the re-
chanical properties shall satisfy the minimum specified prop- quirements of Sec.5, the results may be submitted for consid-
erties of the material in question. eration. The production weld test may be accepted subject to
202 Defects shall be completely removed before necessary acceptable results from additional test prescribed by the Soci-
repairs are carried out. Repairs with arc-air gouging shall be ety.
DET NORSKE VERITAS

SECTION 7
NON DESTRUCTIVE TESTING OF WELDS
A. General B 300 Magnetic particle testing

301 Magnetic particle testing shall be carried out as specified
A 100 Application in the approved written procedures. Where possible, both sides
101 This section provides requirements for quality control of the welds shall be tested. Magnetic particle testing shall be
of ship hull welds during newbuilding. The section contains re- applied for welds in ferro-magnetic materials if not otherwise
quirements for the application of non-destructive testing agreed.
(NDT) - methods, extent of testing and required quality level
for satisfactory workmanship. B 400 Radiographic testing
102 Additional requirements to extent of testing are given in 401 Radiographic testing shall be carried out as specified in
Pt.5 for the relevant ship types. the approved written procedures established in accordance
with a recognized standard.
A 200 Basic requirements 402 For radiographic inspection, X-ray source shall be used
201 The rules are based on the following conditions men- whenever possible. Gamma-ray sources may be used as out-
tioned below. lined in Classification Note No.7.
Weld joint types 403 Processing and storage shall be such that the radiographs
maintain their quality throughout the agreed storage time. The
The following main weld joints are covered (see figures in radiographs shall be free from imperfections due to develop-
Sec.5): ment processing.
— butt joints 404 Suspect planar indications discovered by radiographic
— T-joints (with and without full penetration) testing that is left un-repaired shall be type determined, located
— fillet welds. and sized by ultrasonic testing.
Types of imperfections B 500 Ultrasonic testing
The main types of imperfections in fusion welding are given in 501 Ultrasonic testing shall be carried out as specified in the
EN ISO 6520-1 “Welding and Allied Processes – Classifica- approved written procedures. Ultrasonic test procedures shall
tion of Geometric Imperfections in Metallic materials, Part 1: contain sketches for each type of joint and dimensional range
Fusion Welding”. of joints which clearly show scanning pattern and probes to be
used. Ultrasonic testing shall not be used for thickness less
Testing methods than 10 mm. Ultrasonic testing of welds shall include testing
— For detection of surface imperfections the following meth- of the area adjacent to the weld for laminations and scanning
ods applies: Visual testing (VT), Magnetic particle testing for transverse defects in the weld and base material.
(MT) and Penetrant testing (PT). 502 The testing records shall include the imperfection posi-
— For detection of sub-surface imperfections the following tion, the echo height, the dimensions (length), and the depth
methods applies: Ultrasonic testing (UT) and Radiograph- below the surface and, if possible, the defect type.
ic testing (RT).
B 600 Penetrant testing
The choice of test methods to be applied in each case depends 601 Penetrant testing shall be carried out as specified in the
on the component- or weld shape, the material and the defects approved written procedures. Where possible, both sides of the
to be detected. welds shall be tested. Penetrant testing shall only be applied for
202 For NV 420 grades and higher, final inspection and welds in non-ferro magnetic materials if not otherwise agreed.
NDT shall not be carried out before 48 hours after completion.
C. Personnel Qualifications
B. NDT Procedures
C 100 General
B 100 General 101 All testing shall be carried out by qualified and certified
101 Welds shall be subjected to visual survey and inspection, personnel. The NDT operators shall be certified according to a
as fabrication proceeds. NDT shall be performed according to recognized certification scheme accepted by the Society, e.g.
approved procedures and if required, qualified for the work. EN 473, ISO 9712. The certificate shall clearly state the qual-
The approved procedures shall be in accordance with DNV ifications as to which testing method and within which catego-
Classification Note No.7 or other recognised standard for the ry the operator is certified.
test method.
102 Unless otherwise agreed, the surface to be tested shall be
presented clean and smooth, i.e. free from dirt, scale, rust,
welding spatter, etc. which may influence the results of the D. Extent of NDT
testing. D 100 General
B 200 Visual testing 101 The extent of testing is defined as the percentage of the
201 If necessary mechanical aids (gauges and rulers) should length of welds which shall be tested by a specific method. The
be used to assess and size the discontinuities. Unless otherwise extent of testing will depend on the type of ship and the loca-
agreed, visual testing shall be completed before other NDT tion of the joints.
methods are applied. 102 The basic requirements for all ship types are that all
DET NORSKE VERITAS

welds are subject to 100% visual testing. In addition, welds

shall be subjected to testing with other test methods as given in
the table below.
Table D1 Minimum extent (in%) of NDT for structural welds

Testing method
Area Type of connection
MT/PT1) RT/UT2)
Butt- and T-Joints, full penetration 2% 2%
General T-joints, partly penetration 2% -
Fillet welds - -
Deck/bottom plating within 0.4 L T-joints, partly penetration 5% -
amidship Fillet welds - -
Critical areas T-joints, partly penetration 20% -
Fillet welds 20% -
1) Magnetic particle testing shall be applied for ferro-magnetic materials.
2) Radiographic testing shall not be applied for T-joints.
103 The different areas in Table D1 are defined as follow: to the hull strength
Critical areas ---e-n-d---of---G-u-i-d-a-n-c-e---n-o-t-e---
Areas in way of critical load transfer points and large stress General
concentrations where a failure will endanger the safety of the
ship, such as: Areas not mentioned above.
— stress concentrations in rudders or intersection between 104 NDT shall cover start and stop points of automatically
rudder structure and hull welded seams.
— for twin hull vessels stress concentrations in way of con-
nections between hull and wet deck
— deck beams in open hatch container ships
— strength deck plating at outboard corners of cargo hatch E. Acceptance Criteria for NDT
openings in container carriers and other ships with similar E 100 General
hatch opening configuration
— other areas where the likelihood of occurrence of detri- 101 All welds shall show evidence of good workmanship.
mental defects is considered to be extra high. For visual inspection "IACS Rec. No.47 "Shipbuilding and Re-
pair Quality standard part A" may be applied. Acceptance cri-
Guidance note: teria for NDT shall normally comply with ISO 5817 quality
Areas to be considered for classification under this item are: level C, intermediate. For critical areas more stringent require-
- welds produced by welding methods which the yard has little ments such as ISO 5817 level B, may be applied.
or no user experience
- welds produced by high heat input (>5 kJ/mm) welding meth- E 200 Non-conforming weldments
ods 201 If a non-conforming discontinuity is detected the lengths
- welds in large thickness (>50mm).
welded immediately before and after the section containing the
---e-n-d---of---G-u-i-d-a-n-c-e---n-o-t-e--- discontinuity shall be examined by the same method. If sys-
tematically repeated discontinuities are revealed, the extent of
Deck and bottom plating within 0.4L amidship testing shall be increased at the Surveyors discretion for welds
manufactured under same conditions and where similar defects
— Sheer strake at strength deck. may be expected.
— Stringer plate in strength deck.
— Deck strake at longitudinal bulkhead. 202 If non-conforming discontinuities are found to occur
— Strength deck plating at corners of cargo hatch openings in regularly, the welding procedures shall be reassessed before
bulk carriers, ore carriers, combination carriers and other continuation of the welding, and necessary actions shall be tak-
ships with similar hatch opening configuration. en to bring the production to the required quality level.
— Bilge strake. 203 Detected non-conforming discontinuities shall be re-
— Longitudinal hatch coamings of length greater than 0.15 L. paired unless they are found acceptable by the Society. Re-
— End brackets and deck house transition of longitudinal car- moval of weld discontinuities and repair shall be performed in
go hatch coamings. accordance with a procedure approved by the Society.
— All watertight bulkheads independent of location.
204 After repair welding has been performed, the complete
Guidance note: weld, (i.e. the repaired area plus at least 100 mm on each side)
For ships with no clearly defined strength deck e.g. cruise ships, shall be subjected to at least to the same NDT method(s) as
the above extents shall be applied to the decks contributing most specified for the original weld.
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SECTION 8
STRUCTURAL AND TIGHTNESS TESTING
A. General fore application of the protective coating. All pipe connections

to tanks shall be fitted before structural testing.
A 100 Application When structural testing at the building berth is undesirable or
101 This section specifies general requirements to structural impossible, structural testing afloat may be accepted. The
and tightness testing of tanks and holds. structural testing shall be carried out by filling each tank sepa-
102 For Tanker for Liquefied Gas additional requirements rately to the test head. Examination of bottom and lower side
are given in Pt.5 Ch.5 (Rules for Classification of Ships). structures shall be made in empty tanks at the maximum prac-
tical attainable draught.
202 Leak testing shall be carried out prior to the protective
coating being applied to the welds. Shop primer may be ap-
B. Testing plied to welds.
B 100 Definitions An efficient indicating liquid shall be applied, when air is used
as the test medium. The air pressure shall be kept at a maxi-
101 The following terms are used in B: mum pressure of 20 kN/m2 for 1 hr. and shall be reduced to 15
Structural testing is a hydrostatic test, carried out in order to kN/m2 before inspection. In addition to an effective means of
demonstrate the tightness of the tanks and the structural ade- reading the air pressure, a safety valve, or a reliable equivalent
quacy of the design. Where hydrostatic testing is not practical- alternative, shall be connected to the compartment being test-
ly feasible, hydropneumatic testing may be carried out instead ed.
under provision that the test is simulating, as far as practicable, Guidance note:
the actual loading of the tank. Apart from compulsory structur- Silicate based shop primer may be applied to welds before leak
al tests to Tanker for Chemicals ESP, structural tests do not testing. The layer of the primer should be maximum 50 microns.
need to be repeated for subsequent vessels in a series of iden- Other primers of uncertain chemical composition shall be maxi-
tical newbuildings, unless considered necessary by the Socie- mum 30 microns.
ty. ---e-n-d---of---G-u-i-d-a-n-c-e---n-o-t-e---
Leak testing is an air or other medium test, carried out in order
to demonstrate the tightness of the structure. 203 For hose testing, the hose pressure shall be at least 200
kN/m2 and applied at a maximum distance of 1.5 m. The noz-
Hydropneumatic testing is a combination of hydrostatic and air
testing, carried out in order to demonstrate the tightness of the zle inside diameter shall be at least 12.0 mm.
tanks and the structural adequacy of the design. B 300 Specific requirements for extent and type of test-
Hose testing is a water test carried out to demonstrate tightness ing
of structural items. 301 The requirements in 302 and 303 give conditions for
Shop primer is a thin coating applied after surface preparation testing for:
and prior to fabrication as a protection against corrosion during
fabrication. — gravity tanks included independent tanks of 5 m3 or more
in capacity
Protective coating is a final coating protecting the structure — watertight or weathertight structures.
from corrosion.
Watertight means capable of preventing the passage of water 302 Leak testing shall be carried out on all weld connections
through the structure under a head of water for which the sur- of tank boundaries, pipe penetrations and erection joints on
rounding structure is designed. tank boundaries, except for automatic weld joints and FCAW
semi automatic full penetration butt welds of erection joints.
Weathertight means that in any sea conditions water will not
penetrate into the ship. Selected locations of automatic erection welds and pre-erec-
tion manual or automatic welds may be required to be similarly
B 200 General requirements tested at the discretion of the surveyor taking account of the
201 Structural testing may be carried out after a protective quality control procedures operating in the shipyard.
coating has been applied, provided a leak test is carried out be- 303 Extent of testing is given in Table B1.
Table B1 Extent of testing

Item to be tested Type of testing Structural test pressure Extent of structural testing
All ship types
The greater of the following:
Tank boundary tested from at
Tanks containing liquid and the — head of water up to top of overflow least one side 1), 2)
structures forming boundaries of Structural testing — 2.4 m head of water above highest point of Test of aft peak tank to be car-
tanks containing liquid tank. For FRP tanks: 1.0 m above highest ried out after the stern tube has
point of tank been fitted
— pressure valve opening pressure
See SOLAS Ch. II-1/
Fore peak not used as tank 14
After peak not used as tank Leak testing
Chain locker (if aft of collision Structural testing Head of water up to top
bulkhead)
Double plate rudders Leak testing
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Table B1 Extent of testing (Continued)

Item to be tested Type of testing Structural test pressure Extent of structural testing
Watertight doors below free-
board or bulkhead deck and wa- See SOLAS Ch. II-1/ Each door and hatch cover 7)
18
tertight hatch covers
Weathertight doors, hatch cov- Hose testing
ers, and closing appliances
Watertight bulkheads and decks See SOLAS Ch. II-1/ 3), 5), 6)
14.3 and II-1/19.5
Ballast ducts Structural testing Ballast pump maximum pressure
Hose test. See SO- 6)
Trunks, tunnels and ventilators LAS Ch. II-1/19.5
Cofferdams Structural testing — head of water up to top of overflow 4)
— 2.4 m head of water above highest point of
tank
— head of water up to top of overflow
Independent tanks Structural testing — 0.9 m head of water above highest point of
tank
Dry bulk cargo carrier
The greater of the following: 1), 2)
In the structural testing, a minor
Ballast holds Structural testing — head of water up to top of overflow amount of water leakage from
— 0.9 m head of water above highest point of hatch cover sealing may be al-
tank lowed
Combination carriers (OBOs)
At least every second hatch cov-
Watertight hatch covers of cargo Structural testing — head of water up to top of overflow er, provided that leak testing is
tanks — 2.4 m head of water above hatch coaming carried out for all hatch covers
Chemical carriers
1) Integral and independent tanks with a de-
sign pressure of less than 0.7 bar, the greater
of the following:
— 2.4 m head of water above the highest Tank boundary tested from at
Integral and independent cargo Structural testing point of the tank
tanks least one side 1), 2)
— pressure valve opening pressure.
2) Independent tanks with a design pressure
exceeding 0.7 bar shall be tested to 1.5
times the pressure valve opening pressure
1) Except for cargo space boundaries of Tanker for Chemical ESP, leak or hydropneumatic testing may replace structural testing, pro-
vided that at least one tank of each type is structurally tested.
2) Structural testing need not be repeated for subsequent vessels in a series of idential newbuildings, unless surveyors deem the repetition
necessary. This relaxation does not apply to cargo space boudaries for vessels with the class notation Tanker for Chemical ESP.
3) When a hose test cannot be performed without possible damage to outfitting (machinery, cables, switchboards, insulation, etc.) already
installed, it may be replaced, at the Society's discretion, by a careful visual inspection of all the crossings and welded joints; where nec-
essary, dye penetrant test, leak test or an ultrasonic leak test may be required.
4) Leak or hydropneumatic testing may be accepted under the conditions specified under 301 when, at the Society's discretion, the latter is
considered significant in relation to the construction techniques and the welding procedures adopted.
5) Testing main compartments (not tanks for liquids) by filling them with water is not compulsory. When such testing is not carried out, a
hose test is compulsory. This test shall be carried out in the most advanced stage of the fitting out of the ship. In any case, a thorough
inspection of the watertight bulkheads shall be carried out.
(SOLAS Ch. II-1/14.3)
6) After completion, a hose or flooding test shall be applied to watertight decks and a hose test to watertight trunks, tunnels and ventilators.
(SOLAS Ch. II-1/19.5)
7) Before installation (i.e. normally at the manufacturers) the watertight access doors/hatches shall be hydraulically tested from that side
which is most prone to leakage. Test pressure = design pressure. Acceptance criteria:
— doors or hatches with gaskets: no leakage
— doors or hatches with metallic sealing: maximum water leakage 1 litre per minute.
DET NORSKE VERITAS

Fabrication and Testing of Structures: Ships / High Speed, Light Craft and Naval Surface Craft

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RULES FOR

SHIPS / HIGH SPEED, LIGHT CRAFT AND

MATERIALS AND WELDING

FABRICATION AND TESTING OF

DET NORSKE VERITAS

Coming into force 1 January 2006

Comments to the rules may be sent by e-mail to rules@dnv.com

SEC. 1 GENERAL REQUIREMENTS .......................... 5 Systems ............................................................................... 19

A. General...................................................................................9 B. Material Identification....................................................... 25

A. General.................................................................................12 D. Welding Environment........................................................ 25

C. Welding Procedure Test Assembly and Sampling of F. Repairs ................................................................................ 26

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C. Personnel Qualifications .................................................... 27 SEC. 8 STRUCTURAL AND TIGHTNESS

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A. General hull structures shall possess a documented and implemented

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A. General A 200 Basic groups and grades

Table A1 Grades of welding consumables

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Table A7 Selection of suitable consumables for combinations of aluminium alloys

1) Other consumables may be use if allowable stresses are reduced.

Table A8 Grouping of shielding gases, 1)

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A. General cation in question. The welding procedure test on which

B 200 Approved welding procedure specification lmin = 400 mm

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Round tensile test

Fusion line Charpy

Flat tensile test

102 The following mechanical tests are required from each

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be perpendicular to the plate surface. For plate thicknesses >50

Edge preparation and fit-up as detailed in the pWPS

Edge preparation and fit-up as detailed in the pWPS

a = minimum value 150 mm

202 The following mechanical tests are required from each

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Fig. 8 E 300 Macrosection and hardness testing

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The average value for absorbed energy in weld metal, fusion

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b) For a fillet weld: Angle of branch connections

Range of qualification for material thickness and throat thick-

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THROAT OF WELD AXIS OF WELD

FLAT POSITION 1F (PA)

AXIS OF WELD VERTICAL

VERTICAL POSITION 3F Note: One plate must be horizontal

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ety. examined at 400X magnification and shall be free from grain

Table J1 Selection of suitable consumables for combinations of aluminium alloys

J 200 Butt welds in plates — 1 tensile test specimen

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Discard 25mm Top for fixed pipe