Procedure 3-1

Materials and

Qualification

Procedures for

Ships

Book C

Procedure 3-1

Approval of a Steelworks for the Manufacture of Ship Steels and Boiler and Pressure Vessel Steels with the option of Specified Through-Thickness Properties

Revision 4, Sept 2015

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

Page 2 of 27

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

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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 2015. All rights reserved.

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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 Ship Steels and Boiler and Pressure Vessel Steels with the option of Specified Through-Thickness Properties

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-Rolled (AR), Normalised (N),

Normalised Rolled/ Control Rolled (NR), Thermo-mechanically Controlled Rolled (TM)

and Quench and Tempered (QT). This procedure does not refer to High Strength steel

(Q&T) grades (as per LR Rules for Materials Chapter 3 Section 10).

1.2.3 This procedure can also include steel plate with specified through-thickness properties

as included in Chapter 3 Section 6 of Lloyd’s Register Rules for Materials Chapter 3,

Section 8.

1.2.4 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.

1.2.5 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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1.4 Related Materials and Qualification Procedures for Ships

MQPS 3-0. Approval of a Steelworks for the Manufacture of Steel and Semi-finished

Products

MQPS 3-2. Approval of a Steelworks for the Manufacture of Ferritic Steels for Low

Temperature Application

MQPS 3-3. Approval of a Steelworks for the Manufacture of Corrosion Resistant Steel

for Cargo Oil Tanks of Crude Oil Carrier in compliance with IMO Resolution

MSC289(87)

MQPS 3-4. Approval of a Steelworks for the Manufacture of High Strength Quench

and Tempered Steels

MQPS 3-5. Approval of a Steelworks for the Manufacture of Austenitic and Duplex

Stainless Steels

MQPS 3-6. Approval of a Works for the Manufacture of Clad Steel Plate for Tank

Production

MQPS 3-7. Approval of a Steelworks for the Manufacture of Bar Material for Chain

Cable


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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.


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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

(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.


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(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.


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(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)

(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.


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(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

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

(g) Visual inspection practices

(h) Ultrasonic examination for quality control purposes

(i) Facilities and control procedures for metallographic testing and microstructure control

(j) Storage of finished products

(k) Heat treatment facilities and control

(l) 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.

5 Approval test programme

5.1 Selection of material


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5.1.1 Generally, the initial approval test programme is to be carried out on at least two casts

of each product and grade selected for approval testing except that tests on certain

grades can be taken in lieu of tests on other grades (see Section 5.2 below). The

testing is in respect of specific types of products and if, for example, a works requests

approval for both plates and sections or bars, it will be necessary to carry out tests on

two casts rolled into plates and two casts rolled into sections or bars.

5.1.2 The dimensions of the products from each cast submitted for approval tests are to be

representative of the range which will be manufactured and should include at least

one batch of material of the maximum thickness and width or diameter which it is

proposed to supply, i.e. material where the amount of hot working is at the minimum

value proposed by the manufacturer. If an example representing the maximum width

or diameter cannot be included, then agreement needs to be made on what the

maximum width or diameter will be granted manufacturing approval based on the

samples supplied.

5.1.3 With the exception of hot coiled strip, approval tests are to be carried out on a

minimum of 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 15 to 20mm

thick and on another of the maximum thickness that will be produced, up to 100mm.

If specified through-thickness properties are required to be approved, wherever

possible, the tests are to be carried out on one plate of approximately 25mm thickness

and on another of approximately 50mm thickness. 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 a cast and the other of material poured when the

ladle is nearly empty.

5.1.4 For thicknesses/diameters greater than those covered by the LR Rules for Materials,

additional testing at maximum thickness may also be required. For instance, testing

material at the centreline region of the product.

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 representative of material from an ingot top

end and an ingot bottom end or, in the case of continuously cast material, from the

beginning of one cast and from the end of the other. Additionally one coil should be

of the maximum thickness that it is proposed to supply. In the case of Works approval

for plate cut from coil, works with de-coiling plant which are already approved for

plate will be allowed a reduction in the number of tests required.

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. Copies of any material specifications should be submitted

where these are not National/International standards. English copies are preferred

although documents annotated in English will be acceptable.


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5.2 Tests, test samples and specimens

5.2.1 Approval for any strength of steel also covers approval for any lower toughness grade

in the same strength level, provided that the aim analyses, rolling schedule and

condition of supply are similar.

5.2.2 Provided the steelmaking process, de-oxidation and fine grain practice, casting method

and condition of supply are the same throughout, for high tensile steels, with the

exception of steels of strength level 47, approval tests on one strength level could

cover the strength levels as shown in Table 3-1.1. Also, approval tests on the lowest

and highest toughness levels cover the intermediate toughness levels.

Grade Tested

Grades Approved

A A

B B A

D D B A

E E D B A

AH27S AH27S

DH27S DH27S AH27S

EH27S EH27S DH27S AH27S

FH27S FH27S EH27S DH27S AH27S

AH32 AH32 AH27S

DH32 DH32 AH32 DH27S AH27S

EH32 EH32 DH32 AH32 EH27S DH27S AH27S

FH32 FH32 EH32 DH32 AH32 FH27S EH27S DH27S AH27S

AH36 AH36 AH32 AH27S

DH36 DH36 AH36 DH32 AH32 DH27S AH27S

EH36 EH36 DH36 AH36 EH32 DH32 AH32 EH27S DH27S AH27S

FH36 FH36 EH36 DH36 AH36 FH32 EH32 DH32 AH32 FH27S EH27S DH27S AH27S

AH40 AH40 AH36 AH32 AH27S

DH40 DH40 DH36 AH36 DH32 AH32 DH27S AH27S

EH40 EH40 DH40 AH40 EH36 DH36 AH36 EH32 DH32 AH32 DH27S AH27S

FH40 FH40 EH40 DH40 AH40 FH36 EH36 DH36 AH36 FH32 EH32 DH32

AH32 EH27S DH27S AH27S

EH47 EH47


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Table 3-1,1 Guidance of scope of approval based upon grade tested


Page 16 of 27

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

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

steels.

5.2.4 Approval of any normal or 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 3 of the LR Rules for Materials.

In the following tables ‘Top’ and ‘Bottom’ refer to the top section and the bottom

section of the rolled piece.


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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

specimens

Remarks

Chemical

Analysis (ladle

and product)

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

Sb and B

Weldability

composition

functions

Top (a) Carbon equivalent calculation (Rules for Materials, Chapter 3, Section 3.4.2).

(b) Cold cracking susceptibility calculation (Rules for Materials, Chapter 3, Section 3.4.2).

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 (ReH

), Tensile strength (Rm), Elongation (A

5)

and Reduction in Area (RA) 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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Tensile test

(normalised)

Top and bottom

transverse

Required for Normalised Rolled (NR) steels only

Impact tests on

non aged

specimens

(Notes 2 and 3)

Top and bottom

- longitudinal

Testing temperature (C)

A, B, AH27S, AH32, AH36, AH40

Top and bottom - longitudinal -40 -20 0 +20

D, DH27S, DH32, DH36, DH40

-60 -40 -20 0

E, EH27S, EH32, EH36, EH40

-80 -60 -40 -20 0

FH27S, FH32, FH36, FH40

-100 -80 -60 -40 -20

A, B, AH27S, AH32, AH36, AH40

Top – transverse -40 -20 0 +20

D, DH27S, DH32, DH36, DH40

-60 -40 -20 0

E, EH27S, EH32, EH36, EH40, EH47

-80 -60 -40 -20 0

FH27S, FH32, FH36, FH40

-100 -80 -60 -40 -20

EH47 -80 -60 -40 -20 0

Impact test on

strain aged

specimens for

grades:

Top -

longitudinal

Deformation 5% + 1 hour at 250°C.

AH27S, AH32,

AH36, AH40 -40 -20 0 +20

DH27S, DH32,

DH36, DH40 -60 -40 -20 0

EH27S, EH32,

EH36, EH40 -80 -60 -40 -20 0

FH27S, FH32,

FH36, FH40 -100 -80 -60 -40 -20

EH47 -80 -60 -40 -20 0


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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 E, EH27S, EH32, EH36, EH40, EH47, FH27S, FH32, FH36, FH40 above 16 mm thickness. The Nil Ductility Test Temperature (NDTT) is to be reported.

Through thickness tensile

Top and bottom Optional for grades with improved through thickness properties

Weldability Tests (Note 4)

Applicable to E, AH27S, AH32, AH36, AH40, DH27S, DH32, DH36, DH40, EH27S, EH32, EH36, EH40, EH47, FH27S, FH32, FH36, FH40

Bead-on-plate test

If the CEV value of the proposed aim specification is greater or equal to 0.41%, 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).

CTOD (E, EH27S, EH32, EH36, EH40, EH47, FH27S, FH32, FH36, FH40 only)

Where the approved minimum thickness exceeds 16

mm, CTOD testing in accordance with MQPS Book A

Procedure 0-3. Test temperature is -10°C. CTOD tests

will also be required where new steels or processes have

been developed.

Notes

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

(2) For plates having thickness higher than 40 mm one additional set of impact specimens is to be taken with the axis located at mid-thickness.

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

(4) 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.


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5.3.2.2 EH 47 requires additional testing as follows:

(i) CTOD test according to LR Rules for Materials Chapter 2, Section 6. The results are to be reported

(ii) ESSO crack arrest toughness test or an alternative Crack Arrest Test (CAT).

The results are to be reported

5.3.2.3 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 5.3.1 and 5.3.3 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.

.


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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:

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

Remarks

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

Segregation assessment (Note1)

Top and bottom

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

Micro examination Top and bottom

Micrographic examination: 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 Ferrite grain size should be determined for each photomicrograph.

Tensile Test Top and bottom – longitudinal

ReH

, Rm, A

5(%), RA(%) are to be reported

Impact tests on non aged specimens (Note 2)

Test temperatures (C)

A, B, AH27S, AH32,

AH36, AH40

Top and

bottom -

longitudinal

-20 0 +20

D, DH27S, DH32,

DH36, DH40 -40 -20 0

E, EH27S, EH32,

EH36, EH40 -60 -40 -20 0

FH27S, FH32, FH36,

FH40

-80 -60 -40 -20


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Impact test on

strain aged

specimens for

grades:

Top -

longitudinal

Deformation 5% + 1 hour at 250°C.

AH27S, AH32,

AH36, AH40 -40 -20 0 +20

DH27S, DH32,

DH36, DH40 -60 -40 -20 0

EH27S, EH32, EH36,

EH40 -80 -60 -40 -20

FH27S, FH32, FH36,

FH40 -100 -80 -60 -40

EH47 -80 -60 -40 -20

Bend Test Top and

bottom –

longitudinal

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.

Notes



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


Page 23 of 27

Sulphur prints/Inclusion assessment (Note1)

Beginning and end of each coil

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

Micro examination Beginning and end of each coil



Beginning and end of each coil

Ferrite grain size should be determined for each photomicrograph.

Tensile Test Beginning and end of each coil – longitudinal plus transverse if width >600mm or in the case of decoiled plate

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

Drop weight test in accordance with ASTM E208

Top Only for grades E, EH27S, EH32, EH36, EH40, EH47, FH27S, FH32, FH36, FH40 above 16 mm thickness. The Nil Ductility Test Temperature (NDTT) is to be reported.

Weldability of plate cut from coil

Samples of plate cut from coil

Weldability tests as for plate given in Section 5.3.2

Assessment of the residual stress in the de-coiled plate

Flame cut a 500 x 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.


Page 24 of 27

Impact tests on

non aged

specimens (Note

2)

Testing temperature (�C)

A, B, AH27S, AH32, AH36, AH40

Beginning and end of each coil - longitudinal

-40 -20 0 +20

D, DH27S, DH32, DH36, DH40

-60 -40 -20 0

E, EH27S, EH32, EH36, EH40

-80 -60 -40 -20 0

FH27S, FH32, FH36, FH40

-100 -80 -60 -40 -20

Bend Test Beginning and end of each coil – longitudinal plus transverse if width >600mm

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.

Notes



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


Remarks

Chemical Analysis Top & bottom 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 and include the full cross section.


Page 25 of 27

Micro examination Top and bottom



Top and bottom

Ferrite grain size should be determined for each photomicrograph.

Tensile Test (Note 2) Top and bottom – longitudinal

ReH

, Rm, A

5(%), RA(%) are to be reported

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

Testing temperature (°C)

A, B, AH27S, AH32, AH36, AH40

Top and bottom - longitudinal

-40 -20 0 +20

D, DH27S, DH32, DH36, DH40

-60 -40 -20 0

E, EH27S, EH32, EH36, EH40

-80 -60 -40 -20 0

FH27S, FH32, FH36, FH40

-100 -80 -60 -40 -20

Bend Test (not required for round bar)

Top and bottom – longitudinal

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.

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.



Page 26 of 27

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.

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.


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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.