GL 德国劳氏船级社规范VI-9-2白铜管的制造与检验规程

Rules for Classification and Construction VI Additional Rules and Guidelines 9 Materials and Welding 2 Guidelines for the Fabrication and Inspection of Welded Pipelines of Copper-Nickel-Alloys Edition 2007 The following Guidelines come into force on May 1st, 2007 Germanischer Lloyd Aktiengesellschaft Head Office Vorsetzen 35, 20459 Hamburg, Germany Phone: +49 40 36149-0 Fax: +49 40 36149-200 headoffice@gl-group.com www.gl-group.com "General Terms and Conditions" of the respective latest edition will be applicable (see Rules for Classification and Construction, I - Ship Technology, Part 0 - Classification and Surveys). Reproduction by printing or photostatic means is only permissible with the consent of Germanischer Lloyd Aktiengesellschaft. Published by: Germanischer Lloyd Aktiengesellschaft, Hamburg Printed by: Gebrüder Braasch GmbH, Hamburg Table of Contents Section 1 General Principles and Requirements A. Scope .......................................................................................................................................... 1- 1 B. Other Relevant Standards ........................................................................................................... 1- 1 C. Requirements for the Manufacturer ............................................................................................ 1- 1 D. Materials .................................................................................................................................... 1- 1 E. Welding Consumables and Auxiliary Materials ......................................................................... 1- 1 Section 2 Production Fundamentals A. General ....................................................................................................................................... 2- 1 B. Forming ...................................................................................................................................... 2- 1 C. Welding Joints ............................................................................................................................ 2- 1 D. Welder’s Qualification Tests ...................................................................................................... 2- 1 E. Welding Procedure Tests ........................................................................................................... 2- 2 Section 3 Inspection of Welded Pipelines A. Visual Inspection ........................................................................................................................ 3- 1 B. Penetrant Inspection ................................................................................................................... 3- 2 C. Radiographic Inspection ............................................................................................................. 3- 2 D. Hydrostatic Test ......................................................................................................................... 3- 7 Section 4 Documentation of Approval, Assessment Forms and Certificates VI - Part 9 GL 2007 Table of Contents Chapter 2 Page 3 Section 1 General Principles and Requirements A. Scope 1. These Guidelines give technical principles regarding the production and inspection of welded pipes made of copper-nickel alloys designed for the use on ships. Concerning other components made of this material these Guidelines could be correspond- ingly adopted. 2. These Guidelines are meant to be a supple- ment of the Rules for Classification and Construction I – Ship Technology Part 1 – Seagoing Ships, Chapter 2 – Machinery Installations, Section 11, which have to be definitely observed for the vessel’s construction under class of Germanischer Lloyd (GL). 3. Germanischer Lloyd reserves the right to modify or to complement these Guidelines according to the technical development and – as the case may be – to the coming into force of new Rules for Classifica- tion and Construction. B. Other Relevant Standards 1. These Guidelines refer to the standard series DIN 85004 „Pipelines of Copper-Nickel-Alloys“ re- spectively adopt them accordingly. 2. If there are differences concerning the re- quirements between these Guidelines and the stan- dards which also apply, the requirements of these Guidelines shall take precedence unless otherwise stipulated. C. Requirements for the Manufacturer 1. The production works must provide qualified equipments in order to carry out the welding appropri- ate to these Guidelines. 2. Equipments and installations in external places, e.g. concerning the non-destructive testing, can be taken into account for the evaluation of the shop if the conditions for an appropriate testing are given at that place. 3. The manufacturer has to notify welding su- pervisors, who verify the welding work with responsi- bility. Only welders and welding procedures, both approved according to Section 2, D. and E. respec- tively, are allowed to be used for the work. 4. With regard to the workshop approval, the GL Rules II – Materials and Welding, Part 3 – Weld- ing, Chapter 1 – General Requirements, Proof of Qualifications, Approvals, Section 2 and DIN 2303 (military equipment) respectively are to be observed. D. Materials 1. The materials have to be appropriate to the intended use. 1.1 For pipe manufacturing, pipes made of cop- per-nickel-alloy 90/10 acc. to the GL Rules II – Mate- rials and Welding, Part 1 – Metallic Materials, Chap- ter 3 – Non-Ferrous Metals, Section 2 (CuNi10Fe1Mn acc. EN 12449) are to be used or similar material (CuNi10Fe1,6Mn acc. to WL 2.1972). 1.2 For the use of other alloys, requirements for the properties of welded joints have to be defined separately. Possible restrictions of analysis for pipe material suitable for welding acc. to the standards are to be observed. E. Welding Consumables and Auxiliary Ma- terials 1. The welding consumables have to be chosen that way, that the requirements established for the material are also fulfilled by the weld metal and the joint. This is the case if e.g. welding consumables of the type CuNi30 to EN14640 (SG-CuNi30Fe to DIN 1733-1) are used for welding of CuNi10Fe1Mn. 1.1 If possible, welding consumables and auxil- iary materials already tested and approved by GL shall be used, see also the GL Rules II – Materials and Welding, Part 3 – Welding, Chapter 1 – General Re- quirements, Proof of Qualifications, Approvals, Sec- tion 5. 1.2 The evidence can also be provided through a welding procedure test acc. to Section 2, E. at the user. This kind of recognition is restricted to the user’s work and only valid for max. one year, if an annual repeat test is not carried out. VI - Part 9 GL 2007 Section 1 General Principles and Requirements Chapter 2 Page 1–1 E Section 2 Production Fundamentals A. General 1. The working place of copper-nickel-materials has to be separated from the working of steel compo- nents. 2. Pipes and pipe fittings have to be handled in a proper condition, that means that dirt of each kind, rests of oil and grease as well as sand, cuttings and other are to be removed. 3. Until installation on board, the openings of the pipes and fittings are to be protected against the penetration of dirt. B. Forming 1. The procedures of forming (T-Drill process), flanging and reducing of pipes at the manufacturer have to be approved by GL. 2. Cold bending of pipes can be carried out, if the bending diameter is larger than 2 times the exter- nal diameter. Occurred bending ripples are to be re- moved. 3. Pipe branching can be performed by fittings, welded connections or forming (T-Drill process). In the case of forming, the calculated wall thickness has to be observed. If relevant cold works have to be car- ried out, annealing is required at a temperature of approx. 750 °C. C. Welding Joints 1. The welding has to be preferably carried out with the tungsten inert gas arc welding process (141) under argon shielding gas, also for root side. 2. In case of multilayer welding of pipes with wall thickness more than 6 mm, manual arc welding (111) with basic covered rod electrodes can be used for the fill and final pass. The root pass must be welded by TIG-process. 3. Other procedures can also be approved on request, if sufficient quality properties are proved by a welding procedure test. 4. The pipelines are to be constructed in that way that as most as possible welding seams can be produced in the shop. Welding shall be executed - as far as possible – in a flat position (PA). 5. With regard to pipes with a wall thickness up to 2.5 mm, the preparation of square butt weld is to be considered; regarding bigger wall thickness, a prepara- tion of single-V butt joint with an included angle up to 90° is necessary. 6. The joint area has to be metallic clean before welding. Root gap and misalignment have to be mini- mised as most possible. 7. Tack welds, that are not to be removed, have to be made in the same quality than the welded roots. It is not allowed to over weld broken tack welds. They have to be machined out before fabrication welding. 8. The arc shall only be stroked off in the weld- ing gap. The heat input is to be restricted. 9. Welding spatters, excessive weld and root reinforcement have to be removed, but the wall thick- ness shall not fall below the minimum. D. Welder’s Qualification Tests 1. Welder’s qualification tests acc. to EN ISO 9606-3 are required for all welders executing welding by hand guided welding apparatus (e.g. TIG, manual arc welding). 2. The qualification of the operating staff for automatic welding machine (e.g. orbital welding) is to be proved by welded test pieces acc. to EN 1481/ISO 14732, e.g. as part of the procedure test. 3. The welder or operator having successfully passed the welding procedure test in accordance with E. is qualified for the corresponding scope acc. to EN ISO 9606-3 and EN 1418 / ISO 14732 respectively, provided that the decisive test requirements are ful- filled. 4. Apart from the specifications and require- ments of the a.m. standards, the requirements of the GL Rules II – Materials and Welding, Part 3 – Weld- ing, Chapter 1 – General Requirements, Proof of Qualifications, Approvals, Section 3 are to be ob- served. VI - Part 9 GL 2007 Section 2 Production Fundamentals Chapter 2 Page 2–1 D E. Welding Procedure Tests 1. Before starting the fabrication, it must be proved by means of a welding procedure test that pipe joints acc. to the required quality properties can be manufactured in the workshop. 2. The welding supervisor has to indicate all details in a manufacturer’s welding procedure specifi- cation (WPS) how to carry out the welding works. The welding of test pieces is made upon this preliminary welding procedure specification. 3. Concerning the TIG-welding with preparation of the square butt joint, a welder must weld a piece each with a diameter d1 = 150 up to 200 mm and a wall thickness s = 2,5 up to 3 mm in a horizontal pipe axis (pos. PA, PF, PE) and in a vertical pipe axis (pos. PC), see Fig. 2.1. 4. If multilayer welding is applied, another set of test pieces with corresponding wall thickness has to be welded. If the welding is restricted to the flat posi- tion (PA), e.g. welding on rotating device, the welder can only weld the test pieces in that position. 5. In the case that the measurements of the pipes used during the fabrication are differing too much from the a.m. dimensions of the test piece, an adjusted test program has to be agreed with GL. 6. Prior to sectioning, the welded test pieces are to be examined over the entire length of the seam by non-destructive testing in order to find external or internal welding failures by visual, penetrant and ra- diographic examination (VT, PT, RT). The evaluation of the imperfections will be assessed according Section 3, Table 3.1, 3.2 and 3.4. 7. The sectioning of the test pieces and the di- mensions of the specimens concerning the mechani- cal-technological testing are described in Figure 2.2 and Fig. 2.3. One test set shall be made up of the fol- lowing specimens – if not agreed otherwise: − 2 transverse tensile test specimens (Z) per welding position − 2 transverse bend test specimens per welding posi- tion, one is to be bent with the final pass (FBB) and one with the root pass (RBB) in tension − 1 macrographic (M) per welding position � � � ���� � � � �� �� �� � � � ���� �� �������������������������� � ����������������������� ������������������ �������������������� ���������� ���������� ������� �! Fig. 2.1 Test pieces for welding procedure tests �������������������������������� ���������� ������������������� ����������������������"������"��������������� ���� �� �� � �� # # # $ $ $�%% &%% &%% &%% �%% �%% # $ &%% �%% ������! ��������� Fig. 2.2 Positions and preparation of specimens for welding procedure tests Chapter 2 Page 2–2 Section 2 Production Fundamentals VI - Part 9 GL 2007 E '�������������(��� (����������� ) & * +, + +! ������������������(�� +!���+,�-�. ) &) �/������������ /���� �����0��������������(����%%�������&%% '�������������(��� (����������� Fig. 2.3 Dimensions of tensile and bend test specimens Table 2.1 Requirements for the welded joints Type of test Requirements Tensile test transversal to weld (Z) Tensile strength Rm as stipulated for the base material at least 290 N/mm2. The minimum elongation A ≥ 15 % shall be checked with an initial gauge length of L0 = 5,56 0S . Transverse bend test (FBB, RBB) Bending angle 180° with a mandrel diameter of 3 times the wall thickness. Minor open defects up to a maximum length of 3 mm may be tolerated. Macrographic specimen (M) Imperfections are to be within the specified limits of Table 3.1, 3.2 and 3.4. 8. In welding procedure and production tests on copper-nickel-alloy 90/10, the butt weld specimens must meet the minimum requirements shown in Table 2.1. 9. A successfully passed welding procedure test is valid for the examinated welding process, for the used copper-nickel-alloy, for the used welding con- sumable type and for the tested welding position(s). The scope of the wall thickness and the diameter is determined according to the welder’s qualification test acc. to EN ISO 9606-3. 10. Depending upon the pipe class, the validity of a welding procedure is determined in Chapter 1 – General Requirements, Proof of Qualifications, Ap- provals, Section 3 and Chapter 3 – Welding in the Various Fields of Application, Section 4 of the GL Rules II – Materials and Welding, Part 3 – Welding. VI - Part 9 GL 2007 Section 2 Production Fundamentals Chapter 2 Page 2–3 E Section 3 Inspection of Welded Pipelines A. Visual Inspection 1. The external condition of all weld seams are to be inspected, even the root sides of the seams, as far as accessible. 2. Unevenness of the weld seams inside the pipelines, e.g. welding beads or sagging drops of weld, has to be removed, but the minimum wall thick- ness has to be respected. 3. The root reinforcement shall not exceed the values given in Table 3.1. The misalignment of the inside does not exceed the half of the wall thickness or 2 mm max. The sum of root reinforcement and the inside misalignment has not to be more than the values described in Table 3.1. The evaluation of other imperfections has to be made according to Table 3.2. Table 3.1 Limits of internal excess Pipe-nominal width DN Maximum permissible inside advantage mm ≤ 40 1,5 50 to 150 2 175 to 250 2,5 ≥ 300 3 Table 3.2 Imperfection of welded joints According to EN ISO 6520-1 Designation Classification number Symbol Remark Gas pore 2011 Aa see Table 3.4 Clustered porosity 2013 − not permissible 1,2 Linear porosity 2014 − not permissible 2 Worm-hole 2016 Ab not permissible Tungsten inclusion 3041 H not permissible 3 Lack of fusion 401 C not permissible Lack of penetration 402 D not permissible Undercut, continuous 5011 F not permissible Undercut, intermittent 5012 F conditionally permissible Shrinkage groove 5013 − not permissible Crack 100 E not permissible Irregular bead appearance 514 − permissible Poor restart 517 − not permissible 1 Pores up to 0,5 mm are ignored for wall thickness of 2 mm and above. 2 Pores up to 0,3 mm are not evaluated. 3 Tungsten inclusions up to 0,5 mm are ignored for wall thickness of 2 mm and above; tungsten inclusions up to 0,3 mm are not evaluated. VI - Part 9 GL 2007 Section 3 Inspection of Welded Pipelines Chapter 2 Page 3–1 A B. Penetrant Inspection 1. A penetrant testing of weld seams of the pipelines of pipe class I and II are to be carried out in a spot check way. 2. The GL Rules II – Materials and Welding, Part 3 – Welding, Chapter 2 – Design, Fabrication and Inspection of Welded Joints, Section 4, N. specifies the requirements for the execution of the penetrant inspection. 3. The evaluation of the imperfections has to be executed according to Table 3.2. C. Radiographic Inspection 1. Radiographic sources and test classes 1.1 The radiographic examination upon welded pipe lines of copper-nickel-alloys has to be carried out according DIN 85004-9. X-rays is the preferable source for the radiographic examination upon the a.m. pipe lines. Test class B according to EN 444 is the basis. The maximum of the tube voltage can be in- creased by 50 kV, see Fig. 3.1. ��� ��� ��� ��� ��� �� � �� �� �� �� �� � � � � � � � �� �� �� �� �� � ����� ����������������������������� � �� ��� �� �� �� ��� �� ������ ����! ������"� �!"����"� Fig. 3.1 Maximum x-ray voltages as func- tion of penetrated thickness 1.2 In the case of repair where already installed pipes cannot be tested by x-rays because of access problems, the examination with gamma rays (e.g. Ir192 or Se75) according to test class B acc. to EN 444 is admissible. If the penetrated wall thickness is smaller than 10 mm, only Se75 is to be used. 1.3 If a further distance reduction is necessary because of access problems or for a central radio- graph, one can examine the pipe with Se75 according to test class A, but the minimum of the optical density has to be increased up to ≥ 2.5. 1.4 When taking radiographs with gamma rays, one has to make specimen radiographs because of the loss of sensitivity with regard to the source-film- distance according to test class B and A respectively. 1.5 Exposure time and film systems are to be chosen that way that the optical density according to 3. is achieved. 2. Film systems and intensifying screens 2.1 Class C3 and C4 films according to EN 584-1 are to be used. With regard to the tube voltage Ur ≤ 150 kV C3 films and Ur ≥ 150 kV respectively with Ir192 and Se75 C4 films are to be used. 2.2 Intensifying screens are to be chosen accord- ing to EN 444 in case of front intensifying screens (VF) or rear intensifying screen (HF). In case of tube voltage Ur ≤ 150 kV, 0.02 mm front intensifying screens (VF) and rear intensifying screens (HF) are preferably to be used. 2.3 One has to make sure that the films are very close to the screens (vacuum packaging). 3. Optical density, image quality and image quality indicator 3.1 Optical density Following EN 444, an optical density of ≥ 2.0 and in case of gamma rays of ≥ 2.3 is required within the scope of radiographic images. When using gamma ray sources acc. to test class A, the minimum of the optical density is 2,