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Materials and Qualification Procedures for

Ships

Book C

Procedure 3 – 2

Approval of a Steelworks for the Manufacture of Ferritic Steels and Nickel Steels for Low Temperature Applications

Revision 4, Aug 2017

Material and Qualification Procedures for Ships Book C Procedure 3 - 1

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Lloyd’s Register Group Limited, its subsidiaries and affiliates and their respective officers, employees or agents are, individually and collectively, referred to in this clause as ‘Lloyd’s Register’. Lloyd’s Register assumes no responsibility and shall not be liable to any person for any loss, damage or expense caused by reliance on the information or advice in this document or howsoever provided, unless that person has signed a contract with the relevant Lloyd’s Register entity for the provision of this information or advice and in that case any responsibility or liability is exclusively on the terms and conditions set out in that contract.

© Lloyd's Register Group Limited 2017. All rights reserved.

Except as permitted under current legislation no part of this work may be photocopied, stored in a retrieval system, published, performed in public, adapted, broadcast, transmitted, recorded or reproduced in any form or by any means, without the prior permission of the copyright owner. Enquiries should be addressed to Lloyd's Register Global Technology Centre, Southampton Boldrewood Innovation Campus, Burgess Road, Southampton, SO16 7QF


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Approval of a Steelworks for the Manufacture of Ferritic Steels and Nickel Steels for Low Temperature Applications

1. General Requirements

1.1. The Approval Process

1.1.1. The approval scheme is intended to verify the manufacturer’s capability to provide satisfactory products under effective process, production and inspection controls in accordance with the Rules for the Manufacture, Testing & Certification of Materials Chapter 1.

1.1.2. In order that consideration may be given to approval of a works for the manufacture of ship steels and boiler and pressure vessel steels, the surveyors are to follow the process defined in Section 2.

1.1.3. Works are to communicate to Surveyors the information which will result in the following reports, each of which is to be submitted to the Materials and NDE Department (MNDE) by the surveyor:

• An initial report giving the information listed in Sections 3 and 4, together with a proposed test programme in accordance with section 5.

• A final report containing the results of approval tests carried out under Sections 5 and 6.

1.1.4. The name of approved works will appear in Lloyd’s Register’s List of Approved

Steelmakers and Manufacturers of Rolled Steel Plates, Strip, Sections & Bars which is published on Lloyd’s Register’s Class Direct web site (www.cdlive.lr.org)


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1.2. Related Documents

1.2.1. This procedure applies to hot rolling practices including heat treatment, when applicable for the grade of steel.

1.2.2. Delivery conditions covered by this procedure are as stated in LR Rules for Materials Chapter 3 Section 6, Table 3.6.2.

1.2.3. Where the approval process does not demonstrate capability of certain processes, e.g. heat treatment, such processes may be specifically excluded from the scope of approval.

1.2.4. Where any manufacturing processes are carried out by subcontractors, full details of the sub-contractor must be included and confirmed by survey at the sub-contractor’s facility. Details of this sub-contractor may be specified on the scope of approval.

1.3. Related Rules

1.3.1. Lloyd’s Register’s Rules and Regulations for the Classification of Ships (hereinafter referred to as the Rules for Ships).

1.3.2. Lloyd’s Register’s Rules for the Manufacture, Testing and Certification of Materials (hereinafter referred to as the Rules for Materials).


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2. Application for Approval

2.1. Stages of approval

2.1.1. This section sets out the five stages involved in the granting of Lloyd’s Register approval as follows.

a) Preliminary Review [Stage 1] The purpose of the preliminary review is to confirm the general capabilities of the works and identify any major non-compliance which will need to be addressed prior to further consideration of the approval process. This review may involve a preliminary assessment visit to the works. During the course of the review the works shall also demonstrate to the satisfaction of the surveyor that they operate a robust Health & Safety Management System. Based upon the findings of the preliminary review, the surveyor will issue a report to the company : • Giving a recommendation that the works approval process proceeds to the next stage (see the Flow Chart below) or • Giving the reasons why the works is not considered suitable for LR approval at this time.

b) Submission of Works Approval Information [Stage 2] Following the surveyor’s recommendation to progress with the approval process, the manufacturer will be invited to compile and submit the detailed information requested in Sections 3 and 4 to the local Lloyd’s Register office. The report shall be formatted to follow the sections and sub-sections of this procedure and shall preferably be submitted in electronic format. The report and all supporting documents should be presented in English or annotated in English in an appropriate manner. Additionally, the manufacturer must submit a proposed test programme in accordance with Section 5. The local surveyor will review the submitted information from the works and shall conduct an on-site survey during which the contents of the submitted information are verified and any technical or procedural issues related to the approval are resolved.

On satisfactory review of these documents, the surveyor will submit the following to the Materials & NDE Department:

• A short visit report

• The information submitted by the works in accordance with Sections 3 & 4

• A proposed test programme in accordance with Section 5


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c) Review of Submission by Materials & NDE Department [Stage 3]

Lloyd’s Register Materials & NDE Department shall review the submitted information before any manufacture and testing commences. Any testing carried out before notification of test plan acceptance by MNDE shall be at the manufacturer’s risk. Where necessary, clarification will be sought regarding major issues that are discovered during this stage of review of the submitted information. The outcome of the review will be conveyed to the surveyor and the Materials & NDE Department will confirm the approval test programme and any other actions they require the surveyor to carry out during the surveyor’s attendance at the manufacturer whilst witnessing approval manufacture and testing. The surveyor will communicate this information to the manufacturer.

d) Approval Tests & Survey [Stage 4]

Following Materials & NDE Department agreement to the test plan, the Works will manufacture the approval rolled products. The Lloyd’s Register surveyor will arrange to attend the works to survey the manufacture and witness the testing of the approval test materials. In addition, during attendance, the surveyor will follow up on actions requested by the Materials & NDE Department. The surveyor will appropriately appraise and endorse all test reports which are required by this procedure. The surveyor will review a manufacturer’s report which collates all required information in a clear and concise manner. The format of the report must follow the sections and sub-sections of this procedure and it should preferentially be in electronic form. If the report is found to be satisfactory by the surveyor, it will be endorsed by the manufacturer and verified and stamped by the LR surveyor. It will then be forwarded to the Materials & NDE Department for final review and approval.

e) Review of Results [Stage 5] The surveyor’s report and endorsed test results will be reviewed by Lloyd’s Register Materials & NDE Department. During this process, points of clarification may be required to be followed up with the surveyor in cooperation with the manufacturer. On satisfactory review the works will be added to Lloyd’s Register’s list of approved manufacturers and a Certificate of Approval will be issued.

f) Unless otherwise agreed with the MNDE Department, the above stages are to be carried out as five distinct entities. In particular, Stage 3 - test plan approval is required before testing is commenced in order to avoid delays in the approval process.


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3. Written information required for the manufacturing capability review

3.1. Works Background Information, History, Contact Details and Scope of Approval Request

3.1.1. The manufacturer is to provide the following product related details in writing to the

local surveyor:

a) Details of the plant and its history in brief.

b) Types of products and grades of steel in general production.

c) Maximum and minimum dimensions of each product which can be manufactured.

d) Estimated total annual production of finished products.

e) Products, maximum thicknesses and grades of steel for which approval is required.

f) Contact details that the manufacturer would like shown on the published approved

list including sales telephone number, fax number, email address and website.

g) The year of issue for the copy of the Rules for Materials which are held by the Works and the means whereby possible Rule changes are incorporated into company procedures.

h) The MQPS documents which are used for the approval application, including their revision numbers

i) Details of the inspection and quality control systems established in the works, including details of the personnel involved

j) Third party certification held (e.g. ISO 9001, ISO 14001 and/or ISO 18001, etc), as applicable.

k) A flow diagram showing all stages of production, testing and inspection points.

l) An organogram showing the organisational structure shall be submitted indicating the lines of responsibility of the quality manager and production manager and the senior management to whom they report. This should also indicate the quality department with number of personnel qualifications and responsibilities


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3.2 Process Specific Information

3.2.1 The manufacturer is to provide the following process related details in writing to the local surveyor:

a) Details of the steel composition to be used for each grade, including the grain refining elements to be used and their specified limits. The aim and maximum carbon equivalent is to be stated for each grade. For higher strength steels the aim and maximum Pcm should be additionally stated for each grade. This will constitute the approved composition for each grade and would include for any variation which would be required for different thicknesses of product.

It is important to note that the chemical compositional range approved for each grade must be adhered to. Any changes to the approved range of composition, including micro-alloying elements (eg aluminium, niobium, titanium and vanadium), may require approval by Materials and NDE Department following additional procedure tests.

b) If steelmaking is undertaken in the works, the requirements of MQPS 3-0 are also to be provided.

c) If steelmaking is not undertaken at the works, details of usual suppliers of ingots, continually cast products or other semi-finished products. Details of the products supplied are required. All suppliers must be approved by Lloyd’s Register for the supply of these products.

d) Where applicable, details of the system employed for checking incoming stock for rolling, acceptance criteria employed and storage prior to use.

e) Details of each rolling line. This should detail the rolling stands used in each rolling line, methods for controlling temperature, methods of descaling and any equipment used for cooling.

f) For products produced from continuously cast stock (slabs, blooms billets or bars), proposed minimum amount of hot working expressed as the ratio of the cross-sectional area of the billet (perpendicular to the rolling direction) to the cross-sectional area of the finished rolled product.

g) For delivery conditions other than quench and tempered, the methods used to determine the re-crystallisation stop temperature, minimum final rolling temperature, Ar3 temperature and normalising temperature should be stated.

h) For quench and tempered delivery conditions, the controls which are in place for this process, which will include austenitising temperature and holding time and tempering temperature and holding time.

i) Details of the rolling schedule. This should include, but not be limited to, final rolling temperature and accelerated cooling start and finish temperatures (if applicable)


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j) Details of the reheating and heat treatment facilities after rolling, together with the

number of furnaces used, including the dimensions, type of fuel used and facilities for temperature measurement and control. Additionally, positions of thermocouples should be indicated and the method, frequency and acceptance parameters of furnace uniformity surveys. Also included would be details of how each furnace is loaded including restrictions of volume, mass, number of items, etc; details of the loading temperatures, heating rates, holding times (including how these have been determined) and cooling rates. Details of quenching facilities, as applicable.

k) Facilities and practices for mechanical testing; details should include the practices used for manufacture and preparation of mechanical test specimens and the name of the manufacturer, model number or description, manufacturers unique serial number, maximum test capacity and calibration status for tensile and impact test equipment.

l) Production statistics of mechanical testing (yield strength, tensile strength, elongation and impact properties) for finished products of applicable grades produced including the internal acceptance ranges.

m) Details of any subcontracted activities and particulars relating to the related requirements of the appropriate sections above (eg Section (g) applies to subcontracted heat treatment)

n) If specified through-thickness properties are required to be approved, then NDE procedures and technique sheets that will be used for the approval tests. The procedure is to be in compliance with either EN 10160 Level S1/E1 or ASTM A 578 Level C. These documents, which must be authorised by a Level III qualified NDE operator.

4. Survey of the manufacturing, testing and inspection capabilities

4.1 The local surveyor will carry out a survey of the works and any subcontractors, as applicable, which will include the manufacturing, inspection and testing facilities and procedures. As a minimum, the following manufacturing areas are to be included in the survey, with a view towards verification of the information contained in the manufacturer’s written report (see Section 3 above). If permitted, photographs might be used to support appropriate information. a) Inspection and checking of incoming stock for rolling.

b) Rolling stock storage area.

c) Reheating process for ingots, slabs and billets

d) Product and test material identification and control

e) The rolling process


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f) Facilities for scale removal and for other surface finishing processes

g) Details of system used for identification of materials at all stages of manufacture

h) Visual inspection practices of all rolled products and associated acceptance standards or criteria.(e.g. for surface quality, flatness and dimensional tolerance).

i) The frequency of routine ultrasonic examination for quality control purposes.

j) Facilities and control procedures for metallographic testing and microstructure control

k) Description of procedures and facilities for storage of finished products

l) Heat treatment facilities and control

m) Facilities and practices for chemical analysis and mechanical testing

4.2 Where responses to any questions raised by the survey are not forthcoming from the manufacturer, the reasons for omission must be clearly stated in writing.

4.3 Following review of submitted documentation and its verification through the site survey, the surveyor will issue a report of their findings together with a proposed scope of approval testing based upon the guidance given in Section 5 and Section 6. The surveyor will issue a final recommendation stating their opinion as to whether the works should be considered for the next stage of approval. If the surveyor decides that approval application would not be appropriate at this time, this will be communicated to the works together with the reasons why this decision was made and suggestions as to actions which could be undertaken to improve the application. If the surveyor deems the approval application to be suitable for progression, the documents listed in 3.2.1, the proposed test programme and the surveyor’s report of the activities carried out in Section 4 will be sent to the Materials & NDE Department for specialist review before testing commences.


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5 Approval test programme

5.1 Selection of material

5.1.1 Manufacturers already approved for Grade DH36 ship steel may supply C-Mn steels in Grades LT-DH27S, LT-DH32 and LT-DH36 in the same supply condition if they are rolled to the same schedule, provided the drop weight test requirements of Section 5.3.2.1 can be satisfied.

5.1.2 Except as provided in 5.1.1, approval tests are to be carried out on at least two casts of each type of product and supply condition for which approval is requested. Tests on certain grades can be taken in lieu of tests on other grades (see Section 5.2 below).

5.1.3 Approval tests are to be carried out on two rolled products of different thickness or diameter from each cast. For plate, wherever possible these tests are to be carried out on one plate 12 mm to 20 mm thick and on another of the maximum thickness which will be produced. For ingot cast material, one plate is to be representative of the top of the first ingot and the other is to be representative of the last ingot from the ladle. Similarly for continuous casting, one plate is to be representative of the beginning of the cast and the other of material poured when the ladle is nearly empty.

5.1.4 For thickness greater than 40 mm (cf. Rules the Construction and Classification of Ships for the Carriage of Liquefied Gases in Bulk, Chapter 6), additional testing at maximum proposed thickness may also be required.

5.1.5 For hot coiled strip, materials for approval are to be taken from two coils selected from different casts. The coils selected are to be those produced from slab produced at the beginning of one cast and from the end of the other. Additionally one coil should be of the maximum thickness which it is proposed to supply.

5.1.6 Testing shall be carried out according to Chapter 3 of LR Rules for Materials or to an agreed National Standard or proprietary specification. Details of the applicable testing standards shall be submitted.

5.1.7 Applicable specification must be stated. Copies of specifications should be submitted where these are not National/International standards. English copies are preferred although documents annotated in English will be acceptable.

5.2 Tests, test samples and specimens

5.2.1 For C-Mn steels, approval for any strength of steel also covers approval for any lower toughness grade in the same strength level and lower strength levels, provided that the steelmaking process, de-oxidation, fine grain practice, casting method, aim analyses, rolling schedule and condition of supply are the same throughout. The details are as shown below:


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Table 5.2, 1 Guidance of scope of approval based upon grade tested

5.2.2 Where there is insufficient justification to permit the range of approval shown in Table

3-2,1 additional grades of material will require testing to approve the intended range of steels.

Grade Tested

Grades Approved

LT-AH27S

LT-AH27S

LT-AH27S

LT-AH27S

LT-AH27S

LT-AH27S

LT-AH27S

LT-AH27S

LT-AH27S

LT-AH27S

LT-AH27S

LT-AH27S

LT-AH27S

LT-DH27S

LT-DH27S

LT-DH27S

LT-DH27S

LT-DH27S

LT-DH27S

LT-DH27S

LT-DH27S

LT-DH27S

LT-DH27S

LT-DH27S

LT-DH27S

LT-DH27S

LT-EH27S

LT-EH27S

LT-EH27S

LT-EH27S

LT-EH27S

LT-EH27S

LT-EH27S

LT-EH27S

LT-EH27S

LT-EH27S

LT-EH27S

LT-EH27S

LT-EH27S

LT-FH27S

LT-FH27S

LT-FH27S

LT-FH27S

LT-FH27S

LT-FH27S

LT-FH27S

LT-FH27S

LT-FH27S

LT-FH27S

LT-FH27S

LT-FH27S

LT-FH27S

LT-AH32

LT-AH32

LT-AH32

LT-AH32

LT-AH32

LT-AH32

LT-AH32

LT-AH32

LT-AH32

LT-AH32

LT-AH32

LT-AH32

LT-AH32

LT-DH32

LT-DH32

LT-DH32

LT-DH32

LT-DH32

LT-DH32

LT-DH32

LT-DH32

LT-DH32

LT-DH32

LT-DH32

LT-DH32

LT-DH32

LT-EH32

LT-EH32 LT-EH32

LT-EH32

LT-EH32

LT-EH32

LT-EH32

LT-EH32

LT-EH32

LT-EH32

LT-EH32

LT-EH32 LT-EH32

LT-FH32 LT-FH32 LT-FH32

LT-FH32

LT-FH32

LT-FH32

LT-FH32

LT-FH32

LT-FH32

LT-FH32

LT-FH32

LT-FH32 LT-FH32

LT-AH36

LT-AH36

LT-AH36

LT-AH36

LT-AH36

LT-AH36

LT-AH36

LT-AH36

LT-AH36

LT-AH36

LT-AH36

LT-AH36

LT-AH36

LT-DH36

LT-DH36

LT-AH36

LT-DH32

LT-AH32

LT-DH27S

LT-AH27S

LT-EH36

LT-EH36 LT-DH36

LT-AH36

LT-EH32

LT-DH32

LT-AH32

LT-EH27S

LT-DH27S

LT-AH27S

LT-FH36 LT-FH36 LT-EH36

LT-DH36

LT-AH36

LT-FH32

LT-EH32

LT-DH32

LT-FH27

LT-EH27S

LT-DH27S

LT-AH27S

LT-AH32

LT-AH40

LT-AH40

LT-AH36

LT-DH40

LT-DH40

LT-AH40

LT-DH36

LT-AH36

LT-EH40

LT-EH40 LT-DH40

LT-AH40

LT-EH36

LT-DH36

LT-AH36

LT-FH40 LT-FH40 LT-EH40

LT-DH40

LT-AH40

LT-FH36

LT-EH36

LT-DH36

LT-AH36

1.1/2Ni 1.1/2Ni

2.25Nii 2.25Ni

3.1/2Ni 3.1/2Ni

5Ni 5Ni

9Ni 9Ni


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5.2.3 Approval of any higher strength grade also covers approval of the carbon-manganese

grades of boiler and pressure vessel steels of the same strength level, provided that the supply condition is similar and applicable to boiler steels.

5.3 Tests, test samples and specimens

5.3.1 The positions from which the test samples are taken, the dimensions of the test specimens and mechanical testing procedures are to be in accordance with the requirements of Section 5 of this document and Chapter 2 and 3 of the LR Rules for Materials.

5.3.2 For plates and flats with a finished width exceeding 600 mm, the following tests are to be carried out on each piece submitted for approval testing:

Type of Test Position of the samples and direction of the test specimens

Remarks

Chemical Analysis Top C, Mn, Si, P, S, Ni, Cr, Mo, Al, N, Nb, V, Cu, As, Sn, Ti, Sb and B

Segregation assessment (Note 1)

Top Sulphur prints are to be taken from plate edges which are perpendicular to the axis of the slab or ingot. These sulphur prints are to be approximately 600 mm long taken from the centre of the face selected, i.e. on the slab or ingot centreline, and are to include the full plate thickness.

Micro examination Top and bottom

Micrographic examination: the micrographs are to be representative of the full thickness. For thick products at least three examinations are to be made at surface, one quarter and mid-thickness of the product. All photomicrographs are to be taken at x100 magnification and where ferrite grain size exceeds ASTM grain size 10, additionally at x500 magnification. Results to be presented in the form of a report which gives details of the etchants used and a description of the microstructure shown.

Grain size determination Top and bottom

Ferrite grain size should be determined for each photomicrograph.

Tensile Test Top and bottom – longitudinal & transverse direction

Yield strength, Tensile strength, Elongation and Reduction in Area are to be reported

Tensile test (stress relieved) only for TM steels

Top and bottom transverse

Stress relieving at 600 °C (Heating rate of 2 min/mm with minimum 1 hour holding time.)


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Impact tests on non aged specimens (Note 2)

Testing temperature (°C).

LT-AH27S, LT-AH32, LT-AH36, LT-AH40

Top and bottom - longitudinal

-40 -20 0 +20

LT-DH27S, LT-DH32, LT-DH36, LT-DH40

-60 -40 -20 0

LT-EH27S, LT-EH32, LT-EH36, LT-EH40, LT-EH47

-80 -60 -40 -20 0

LT-FH27S, LT-FH32, LT-FH36, LT-FH40

-100 -80 -60 -40 -20

1.1/2Ni -105 -85 -65 -45 2.25Ni -110 -90 -70 -50 3.1/2Ni -125 -115 -95 -75 5Ni -150 -130 -110 -90 9Ni -196 LT-AH27S, LT-AH32, LT-AH36, LT-AH40

Top – transverse

-40 -20 0 +20

D, DH27S, DH32, DH36, DH40

-60 -40 -20 0

LT-EH27S, LT-EH32, LT_EH36, LT-EH40

-80 -60 -40 -20 0


-100 -80 -60 -40 -20

1.1/2Ni -105 -85 -65 -45 2.25Ni -110 -90 -70 -50 3.1/2Ni -125 -115 -95 -75 5Ni -150 -130 -110 -90 9Ni -196 Impact test on strain aged specimens for grades:

Top - longitudinal

Deformation 5% + 1 hour at 250°C.


-40 -20 0 +20


-60 -40 -20 0

LT-EH27S, LT-EH32, LT-EH36, LT-EH40

-80 -60 -40 -20 0


-100 -80 -60 -40 -20

1.1/2Ni -105 -85 -65 -45 2.25Ni -110 -90 -70 -50 3.1/2Ni -125 -115 -95 -75 5Ni -150 -130 -110 -90 9Ni -196


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Bend Test Top – longitudinal and transverse

Bend test specimens are to be the full thickness of the material and with a width of approximately 1,5 times the thickness. Where the capacity of the testing machine is insufficient to test the material in full thickness, the test specimens may be reduced to a thickness of 25 mm by machining on one side only. The original rolled surface is to be tested in tension. The specimens are to be bent at room temperature through an angle of 180°, over a former with a diameter not exceeding three times the thickness of the test specimen. Subsequently the sides are to be closed until they touch, or fracture occurs.

Drop weight test in accordance with ASTM E208

Top Only for grades EH27S, EH32, EH36, EH40,,FH27S, FH32, FH36, FH40 and nickel steels above 16 mm thickness. NDTT values are to be as follows:

Grades NDTT (°C) maximum LT-AH27S, LT-AH32, LT-AH36, LT-AH40

-15


-35


-55


-75

1.1/2Ni -80 2.25Ni -85 3.1/2Ni -100 5Ni -125 9Ni -196

Through thickness tensile tests

Top and bottom

Only for grades with improved through thickness properties

Weldability Tests (Note 3)

Top Applicable to all grades covered by this procedure.

Bead-on-plate test Testing in accordance with MQPS 0-3. Samples should be taken from the ¼ width in accordance with the Rules for Materials, Chapter 3, Figure 3.1.2 (a).

Butt Weld Assembly Testing in accordance with MQPS 0-3. Samples should be taken from the ¼ width in accordance with the Rules for Materials, Chapter 3, Figure 3.1.2 (a).Charpy test temperatures should be as given in LR Rules for Gas Ships Chap 6 Section 6.2 table 6.2.

CTOD (LT-EH27S, LT-EH32, LT-EH36, LT-EH40, LT-FH27S, LT-FH32, LT-FH36, LT-FH40 and nickel steels)

Where the approved minimum thickness exceeds 16mm, CTOD testing in accordance with MQPS Book A Procedure 0-3. Testing in accordance with MQPS 0-3. Test temperatures are to be agreed before commencement of testing.

CTOD tests will also be required where new steels or processes have been developed.


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5.3.2.1 For steel grades which require approval for specified through thickness properties, the dimensions of test specimens and mechanical testing procedures are to be in accordance with the requirements of Ch 3, Section 8 of the Rules for Materials. Testing additional to tables 5.3.2 is required to as follows:

a) Prior to the preparation of mechanical test specimens, each plate is to be ultrasonically examined in accordance with the steelmaker's procedure. The ultrasonic examination is to be witnessed by the Surveyor. The results of this examination are to be reported.

b) Through-thickness tensile tests. Three specimens are to be taken from the centre of the top and bottom ends and from near each corner, i.e. six sets of specimens. The tensile strength and percentage reduction of area are to be reported.

c) Ultrasonic testing in accordance with the approved UST procedure, using a probe of frequency 3-5 MHz.

5.3.3 For flats 600 mm in width and sections, the following tests are to be carried out on the top and bottom ends of each piece submitted for approval tests:

Notes

(1) Other tests for determination of centreline cleanliness may be proposed and will be subject to acceptance by MNDE

(2) In addition to the determination of the energy value, also the lateral expansion and the percentage crystallinity are to be reported.

(3) Where a steel is to be approved for welding heat input above 50 kJ/cm, additional weldability tests are to be carried out at the maximum heat input to be approved.


Remarks

Chemical Analysis Top C, Mn, Si, P, S, Ni, Cr, Mo, Al, N, Nb, V, Cu, As, Sn, Ti, Sb and B


Top Sulphur prints are to be taken from plate edges which are perpendicular to the axis of the slab or ingot. These sulphur prints are to be approximately 600 mm long taken from the centre of the face selected, i.e. on the slab or ingot centreline, and are to include the full plate thickness.


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Micrographic examination: the micrographs are to be representative of the full thickness. For thick products at least three examinations are to be made at surface, one quarter and mid-thickness of the product. All photomicrographs are to be taken at x100 magnification and where ferrite grain size exceeds ASTM grain size 10, additionally at x500 magnification. Results to be presented in the form of a report which gives details of the etchants used and a description of the microstructure shown.

Grain size determination Top and bottom


Tensile Test Top and bottom – longitudinal

Yield strength, Tensile strength, Elongation and Reduction in Area are to be reported

Impact tests on non-aged specimens (Note 2)




-40 -20 0 +20


-60 -40 -20 0


-80 -60 -40 -20 0


-100 -80 -60 -40 -20

1.1/2Ni -105 -85 -65 -45 2.25Ni -110 -90 -70 -50 3.1/2Ni -125 -115 -95 -75 5Ni -150 -130 -110 -90 9Ni -196 Bend Test Top –

longitudinal and transverse


Notes (1) Other tests for determination of centreline cleanliness may be proposed and will be subject to acceptance by MNDE (2) In addition to the determination of the energy value, also the lateral expansion and the percentage crystallinity are to be reported.


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5.3.4 For hot coiled strip the following tests are to be carried out on the top and bottom ends of each piece submitted for approval tests:


Remarks

Chemical Analysis Beginning and end of each coil

C, Mn, Si, P, S, Ni, Cr, Mo, Al, N, Nb, V, Cu, As, Sn, Ti, Sb and B


Beginning and end of each coil

Sulphur prints are to be taken, and are to include the full plate thickness.

Micro examination Beginning and end of each coil

Micrographic examination: the micrographs are to be representative of the full thickness. For thick products at least three examinations are to be made at surface, one quarter and mid-thickness of the product. All photomicrographs are to be taken at x100 and x400 magnification.. Results to be presented in the form of a report which gives details of the etchants used and a description of the microstructure shown.

Grain size determination Beginning and.end of each coil


Tensile Test Beginning, middle and end of each coil.– longitudinal plus transverse if width>600 mm or for the case of plate cut from coil.

Yield strength, Tensile strength, Elongation are to be reported

Tensile test (stress relieved) only for TM steels

Beginning and end of each coil transverse

Stress relieving at 600 °C (Heating rate of 2 min/mm with minimum 1 hour holding time.)

Impact tests on non aged specimens (Note 2)



Beginning and end of each coil longitudinal

-40 -20 0 +20


-60 -40 -20 0


-80 -60 -40 -20 0


-100 -80 -60 -40 -20

1.1/2Ni -105 -85 -65 -45 2.25Ni -110 -90 -70 -50 3.1/2Ni -125 -115 -95 -75 5Ni -150 -130 -110 -90 9Ni -196


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Beginning and end of each coil – transverse

-40 -20 0 +20

D, DH27S, DH32, DH36, DH40

-60 -40 -20 0

LT-EH27S, LT-EH32, LT_EH36, LT-EH40

-80 -60 -40 -20 0


-100 -80 -60 -40 -20

1.1/2Ni -105 -85 -65 -45 2.25Ni -110 -90 -70 -50 3.1/2Ni -125 -115 -95 -75 5Ni -150 -130 -110 -90 9Ni -196 Impact test on strain aged specimens for grades:

Beginning of each coil - longitudinal

Deformation 5% + 1 hour at 250°C.


-40 -20 0 +20


-60 -40 -20 0


-80 -60 -40 -20 0


-100 -80 -60 -40 -20

1.1/2Ni -105 -85 -65 -45 2.25Ni -110 -90 -70 -50 3.1/2Ni -125 -115 -95 -75 5Ni -150 -130 -110 -90 9Ni -196 Bend Test Beginning and

end of each coil – longitudinal plus transverse if width >600mm



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5.3.5 For bars, the following tests are to be carried out on each piece submitted for approval tests:

Drop weight test in accordance with ASTM E208

Beginning of each coil

Only for grades E, EH27S, EH32, EH36, EH40,,FH27S, FH32, FH36, FH40 and nickel steels above 16 mm thickness. NDTT values are to be as follows:

Grades NDTT (°C) maximum LT-AH27S, LT-AH32, LT-AH36, LT-AH40

-15


-35


-55


-75

1.1/2Ni -80 2.25Ni -85 3.1/2Ni -100 5Ni -125 9Ni -196

Weldability Tests (Note 3)

Samples of plate cut from coil

Weldability tests as for plate given in Section 5.3.2.1 .

Assessment of the residual stress in the de-coiled plate

Flame cut a 500x 500 mm section from the mid width of a de-coiled plate, at least 500 mm from the edge of the plate (see diagram). Alternatively an actual production cut section can be used of similar size and location

The flatness of the plate should be assessed in accordance with a recognised standard e.g. EN 10029. A cut section should then be assessed for any distortion, which should not exceed the flatness tolerance as measured on the parent plate.

Notes

(1) Other tests for determination of centreline cleanliness may be proposed and will be subject to acceptance by MNDE

(2) In addition to the determination of the energy value, also the lateral expansion and the percentage crystallinity are to be reported.


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Remarks

Chemical Analysis Top & bottom C, Mn, Si, P, S, Ni, Cr, Mo, Al, N, Nb, V, Cu, As, Sn, Ti , Sb and B


Top Sulphur prints are to be taken and include the full cross section.


The micrographs are to be representative of the full thickness. For thick products in general at least three examinations are to be made at surface, one quarter and mid-thickness of the product. All photomicrographs are to be taken at x100 and x400 magnification. Results to be presented in the form of a report which gives details of the etchants used and a description of the microstructure shown.

Grain size determination

Top and bottom


Tensile Test (Note 2) Top and bottom – longitudinal

ReH, Rm, A5(%), RA(%) are to be reported

Impact tests on non-aged specimens (Notes 2 and 3)

Testing temperature (°C)



-40 -20 0 +20


-60 -40 -20 0


-80 -60 -40 -20 0


-100 -80 -60 -40 -20

1.1/2Ni -105 -85 -65 -45 3.25Ni -110 -90 -70 -50 3.1/2Ni -125 -115 -95 -75 5Ni -150 -130 -110 -90 9Ni -196 Notes (1) Other tests for determination of centreline cleanliness may be proposed and will be subject to acceptance by MNDE (2) The specimens for the tensile and impact tests are to be taken from the position shown in Rules for Materials, Ch 3, Fig. 3.1.1(f). For bars intended for machinery, with a rolling reduction ratio of less than 6:1, an additional tensile specimen and set of impact specimens from the centre of the bar are to be tested. (3) In addition to the determination of the energy value, also the lateral expansion and the percentage crystallinity are to be reported.


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6 Specific approval test results

6.1 General

6.1.1 Following Materials & NDE Department agreement to the test plan, the Works will manufacture approval test materials. The various stages of manufacture and all approval testing is to be witnessed by the Lloyd’s Register surveyor. All test results will be endorsed by the surveyor. All details listed in Section 6.2 together with the test results will be submitted to the Materials & NDE Department for review.

6.2 Approval test submission

6.2.1 For each product submitted for approval tests the manufacturer is to provide the following information:

a) Summary of the manufacturing process

b) Chemical composition specification to which the steel has been made. This is to include

internal controls on chemistry that the works applies to the grade.

c) Weight and dimensions of semi-finished product and method of casting.

d) Results of tests undertaken in accordance with 5.2.

e) Dimensions of products manufactured.

6.2.2 The surveyor will submit the information requested in Section 3.1.2 and 6.2 to the Materials & NDE Department together with any additional survey reports that were requested by Materials & NDE Department specialists. Photographs may be used to support the submitted information.


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7 Validity of approval certificate

7.1 Initial approval

7.1.1 On satisfactory review of the submitted approval test report Materials & NDE Department will enter the manufacturer onto the List of Approved Manufacturers and an initial approval certificate will be issued.

7.1.2 The approval certificate will state the approved product type (i.e. plate, sections), the grain refine elements, the steel grades and the maximum thickness. If specified through-thickness properties are approved, the appropriate details will be stated.

7.1.3 The initial approval certificate will have a validity of three years.

7.2 Extension of the scope of approval

7.2.1 Manufacturers who intend to extend their scope of approval will be required to carry out additional testing to cover the extended scope. The test plan is to be agreed between the manufacturer and Lloyd’s Register.

7.3 Re-approval of works

7.3.1 For the validity to be renewed for a further three years the Surveyors should undertake a periodic inspection in accordance with Procedure 1-1. To ensure continuity, this should be carried out within six months previous to the approval expiry date.

7.3.2 It is a Rule requirement that during material surveys the works will be subject to regular visits to confirm continued compliance with the original approval. The frequency of visits will depend on the frequency of material surveys. Records of these visits will be kept by the surveyors.

7.3.3 Manufacturers that have not produced products under Lloyd’s Register survey during the approval period must either conduct new approval tests (according to Sections 5 and 6) or contact Lloyd’s Register to agree on any additional requirements to continue approval.

7.3.4 Where a manufacturer physically moves the location of an approved works from the approved location to a new site, the manufacturer will be required to follow the initial approval process in full unless they can present a satisfactory case to the Materials & NDE Dept that this would not be necessary.

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