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DNV-OS-E302 Offshore Mooring Chain
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Ch.2
SECTION 1
Materials Ch.2 Sec.1
A. General Requirements
Ch.2 Sec.1
A 100 Scope
Ch.2 Sec.1 A
101 Sub-section A specifies the general requirements for rolled
steel bars, steel forgings and steel castings to be used in the
manufacture of offshore mooring chain and accessories. Specific
requirements are given in B to D. If the specific requirements differ
from these general requirements, the specific requirements shall
prevail. Separate requirements for materials for studs are given
in E.
Ch.2 Sec.1 A
102 The steels concerned are classified by specified minimum ultimate
tensile strength into five grades: R3, R3S, R4, R4S and R5. Ch.2 Sec.1
A 200 Manufacture
Ch.2 Sec.1 A
201 The steels shall be manufactured by an electric or one of the
basic oxygen processes or any other approved process involving secondary
refining. Steel grades R4S and R5 shall be vacuum degassed.
Ch.2 Sec.1 A
202 The steels shall be killed and fine grain treated. The austenite
grain size shall be 5 or finer in accordance with ASTM E112. The
fine grain size requirement shall be deemed to be fulfilled if the
steels contain Al, Nb, V or Ti, either singly or in any combination,
as follows: When Al is used singly, the minimum total content shall
be 0.020% or, alternatively, the Al to N ratio shall be
minimum 2:1. When Al and Nb are used in combination, the minimum
total Al content shall be 0.015% and the minimum Nb content
shall be 0.010%. When Al and V are used in combination,
the minimum total Al content shall be 0.015% and the minimum
V content shall be 0.030%.
Ch.2 Sec.1 A
203 For steel grades R4S and R5, the following information shall
be supplied by the manufacturer to the mooring chain or accessory
manufacturer and the results included in the chain documentation:- Each heat shall be examined
for non-metallic inclusions according to ISO 4967 or equivalent.
The level of inclusions shall be quantified and assessed to be sure
inclusion levels are acceptable for the final product.
- A sample from each heat shall be macro etched according to
ASTM E381 or equivalent to be sure there is no injurious segregation
or porosity.
- Jominy hardening ability data according to ASTM A255 or
equivalent shall be supplied with each heat.
Ch.2 Sec.1 A
204 The manufacturer shall ensure that effective manufacture and
process controls are implemented in production. Where deviation
from the controls occurs and this could produce products of inferior
quality, the manufacturer shall investigate to determine the cause
and establish countermeasures to prevent its recurrence. Investigation
reports to this effect shall be made available to the purchaser
on request.Ch.2 Sec.1
A 300 Chemical composition
Ch.2 Sec.1 A
301 Specifications for chemical composition shall be agreed between
the manufacturer and purchaser. Steel grades R4, R4S and R5 shall
contain a minimum of 0.20% molybdenum.
Ch.2 Sec.1 A
302 The chemical composition of each heat shall be determined on
a sample taken preferably during the pouring of the heat and shall
comply with the specified limits. When multiple heats are tapped
into a common ladle, the ladle analysis shall apply.
Ch.2 Sec.1 A
303 The composition shall be determined after all alloying additions
have been made and sufficient time allowed for such an addition
to homogenize.
Ch.2 Sec.1 A
304 Elements designated as residual and impurity elements in the
individual specifications shall not be intentionally added to the
steels. The content of such elements shall be reported.
Ch.2 Sec.1 A
305 Adequate controls shall be in place to prevent accumulation
of harmful elements such as tin, antimony and arsenic in the final
product. Ch.2 Sec.1
A 400 Heat treatment
Ch.2 Sec.1 A
401 Materials shall be heat treated for mechanical properties as
specified in B to D. Heat treatment shall be carried out in a properly
constructed furnace which is efficiently maintained and has adequate
means for temperature control and is fitted with recording-type
pyrometers. The furnace dimensions shall be such as to allow the
whole furnace charge to be uniformly heated to the necessary temperature.
Ch.2 Sec.1 A
402 Sufficient thermocouples shall be connected to the furnace
charge where it is composed of forged or cast components. Thermocouples
should be connected by capacitor discharge welding.
Ch.2 Sec.1 A
403 Records shall identify the furnace used, furnace charge, date,
temperature and time at temperature.
Ch.2 Sec.1 A
404 The manufacturer shall ensure that the specified heat treatment
is adhered to. Where deviation from the specified heat treatment
occurs, the manufacturer shall ensure that affected products are
tested or submitted to reheat treatment and that an investigation
is carried out according to A204. Ch.2 Sec.1
A 500 Mechanical testing
Ch.2 Sec.1 A
501 Products shall be grouped in test units and sampled for mechanical
testing as detailed in B to D. Test material from which test pieces
are prepared shall be of equivalent cross section and be fully representative
of the sample product and, where appropriate, shall not be cut,
or partially cut from the sample product leaving a ligament, until
heat treatment has been completed. Test material and test pieces
shall not be separately heat treated in any way.
Ch.2 Sec.1 A
502 Test material and test pieces shall be marked to identify them
with the products represented.
Ch.2 Sec.1 A
503 For each test unit, one tensile and three Charpy V-notch test
pieces shall be taken. Rolled steel bars and steel forgings shall
be tested in the longitudinal direction. The longitudinal axis of
test pieces shall be located one-third of the radius or, in the
case of non-cylindrical sections, one-sixth of the diagonal from
the outer surface.
Ch.2 Sec.1 A
504 The preparation of test pieces and the procedures used for
mechanical testing shall comply with the relevant requirements of
DNV-OS-B101.
Ch.2 Sec.1 A
505 The materials shall comply with the mechanical properties
specified in Table E1.
Ch.2 Sec.1 A
506 If the results from tensile testing do not meet the specified
requirements, two further tensile tests may be made from the same
sample. If both of these additional tests are satisfactory, the
test unit may be accepted.
Ch.2 Sec.1 A
507 If the results from a set of three impact test pieces do not meet
the specified requirements, three additional test pieces from the
same sample may be tested and the results added to those previously
obtained to form a new average. If this new average complies with
the requirements and if not more than two individual results are
lower than the required average and, of these, not more than one
result is below 70% of the specified average value, the
test unit may be accepted.
Ch.2 Sec.1 A
508 Where forgings or castings and the associated test material
are submitted to re-heat treatment, they may not be re-austenitised
more than twice. All the tests previously performed shall be repeated
after re-heat treatment and the results must meet the specified
requirements. Ch.2 Sec.1
A 600 Inspection
Ch.2 Sec.1 A
601 Materials are subject to visual inspection, non-destructive
testing (NDT) and measurements of dimensions as detailed in B to
D. The manufacturers shall prepare written procedures for NDT. NDT
personnel shall be qualified and certified according to ISO 9712,
EN 473, SNT-TC-1A or equivalent. NDT operators shall be qualified
to at least level I.
Ch.2 Sec.1 A
602 NDT shall be performed in accordance with the general practice
of recognised standards, e.g.:
Magnetic particle testing (MT)
of forgings:
| — | EN 10228-1, ASTM A275, using wet continuous magnetisation
technique |
Ultrasonic testing (UT) of forgings:
Magnetic particle testing (MT)
of castings:
| — | ASTM E709, using wet continuous magnetisation
technique |
Ultrasonic testing (UT) of castings:
Ch.2 Sec.1 A
603 MT of forged or cast accessories shall be carried out after
proof load testing. Where a forging or casting is delivered in an
intermediate condition for subsequent processing and final MT by
the purchaser, the manufacturer should perform suitable intermediate
inspections taking into consideration the quality level required
in finished condition. In such cases the extent of testing and acceptance
criteria shall be agreed between manufacturer and purchaser. See
also C600, D600, and Sec.2
C.
Ch.2 Sec.1 A
604 UT of forgings or castings shall be carried out at an appropriate
stage after the final heat treatment for mechanical properties,
e.g. after proof load testing of finished accessories. Ch.2 Sec.1
A 700 Repair
Ch.2 Sec.1 A
701 Surface defects may be removed by grinding as detailed in
B to D. The resulting grooves shall have a bottom radius of approximately
three times the depth and shall be blended into the surrounding
surface to avoid any sharp contours. Complete elimination of the
defective material shall be verified by suitable NDT.
Ch.2 Sec.1 A
702 Except as provided for steel castings, repair by welding is
not permitted. Ch.2 Sec.1
A 800 Identification
Ch.2 Sec.1 A
801 Each bar, forging, or casting shall be suitably identified with
at least the following:- identification number, heat
number or other marking that will enable the history of the item
to be traced,
- steel grade designation.
Ch.2 Sec.1
A 900 Records
Ch.2 Sec.1 A
901 The manufacturer shall maintain traceable records of the following
and present them to the purchaser on request:- steelmaking process and chemical
composition
- heat treatment
- mechanical testing
- inspection
- repair.
Ch.2 Sec.1
B. Rolled Steel Bars
Ch.2 Sec.1
B 100 Scope
Ch.2 Sec.1 B
101 These requirements are supplementary to A and apply to hot
rolled steel bars to be used in the manufacture of offshore mooring
chain and accessories. Ch.2 Sec.1
B 200 Manufacture
Ch.2 Sec.1 B
201 Bars shall be made from ingots or continuous cast blooms or
billets. Ingots shall be cast in chill moulds with the larger cross-section
up, and with efficient feeder heads. Sufficient discard shall be
made to ensure soundness in the finished bar. Surface and skin defects,
which may be detrimental during the subsequent working and forming
operations, shall be removed.
Ch.2 Sec.1 B
202 The rolling reduction ratio shall be at least 5:1. The rolling
reduction ratio shall be calculated as the ratio average cross-sectional
area of the cast material to cross-sectional area of the finished
bar. Ch.2 Sec.1
B 300 Chemical composition
Ch.2 Sec.1 B
301 The chemical composition shall comply with the agreed specification.Ch.2 Sec.1
B 400 Condition of supply and heat
treatment
Ch.2 Sec.1 B
401 Unless otherwise agreed, the bars shall be delivered in the
as rolled condition.
Ch.2 Sec.1 B
402 For mechanical testing and hydrogen embrittlement testing,
bar material shall be tested in the condition of heat treatment
used for the chain as advised by the chain manufacturer. Ch.2 Sec.1
B 500 Mechanical testing
Ch.2 Sec.1 B
501 A test unit shall consist of bars of the same nominal diameter,
made from the same heat of steel, and with a total mass not exceeding
50 tonnes.
Ch.2 Sec.1 B
502 Test material shall consist of a suitable length cut from one
bar in each test unit. The test material shall be heat treated in
full cross-section, see 402.
Ch.2 Sec.1 B
503 For each test unit, one tensile and three Charpy V-notch test
pieces shall be taken. For Charpy V-notch impact testing, the notch
shall be cut in a face of the test piece which was originally approximately
perpendicular to the rolled surface.
Ch.2 Sec.1 B
504 The mechanical properties shall comply with the values given
in Table E1.Ch.2 Sec.1
B 600 Hydrogen embrittlement testing
Ch.2 Sec.1 B
601 For grade R3S, R4, R4S and R5, each heat of steel shall be
tested for hydrogen embrittlement by slow strain rate tensile testing.
Samples shall be taken from two bars representing the front end
and tail end of the billet string in case of continuous casting,
or two ingots in case of ingot casting.
Ch.2 Sec.1 B
602 Two tensile test pieces shall be taken from the central region
of each bar. The test pieces shall have a diameter of 20 mm, or
alternatively 14 mm. One test piece shall be tested within three
hours after machining for a 20 mm diameter test piece, or 1.5 hours
for a 14 mm diameter test piece. The other test piece shall be tested
after baking at 250°C for four hours for a 20 mm diameter test piece,
or two hours for a 14 mm diameter test piece. The test pieces shall
be loaded at a strain rate not exceeding 0.0003 per second until
fracture occurs.
Ch.2 Sec.1 B
603 As an alternative to testing within the time limits given in
602 the test pieces may be cooled to -60°C immediately after
machining and kept at that temperature for a maximum period of five
days before testing.
Ch.2 Sec.1 B
604 The reduction of area values shall be determined. The ratio
Z1 to Z2, where Z1 is the value without baking
and Z2 is the value after
baking, shall not be less than 0.85. Alternatively, the ratio shall
not be less than 0.80 provided Z1 is
at least 50%.
Ch.2 Sec.1 B
605 If the results do not meet the specified requirements, the bar
material may be subjected to a hydrogen degassing treatment. The
embrittlement tests shall be repeated after degassing and the results
must meet the specified requirements.Ch.2 Sec.1
B 700 Dimensions and tolerances
Ch.2 Sec.1 B
701 The tolerances on diameter and roundness shall be in accordance
with Table E2. Measurements
shall be made on at least 1% of the bars.Ch.2 Sec.1
B 800 Inspection
Ch.2 Sec.1 B
801 All bars supplied in a machined (peeled) condition shall be
visually inspected. All bars supplied without machining shall be
tested for longitudinal imperfections by magnetic or electrical
methods in accordance with the general practice of recognised standards.
Ch.2 Sec.1 B
802 All bar material shall be subjected to ultrasonic testing at
an appropriate stage of manufacture.
Ch.2 Sec.1 B
803 All bars shall be free from injurious pipe, cracks, seams, laps
or other imperfections which, due to their nature, degree or extent,
will interfere with the use of the bars.Ch.2 Sec.1
B 900 Repair
Ch.2 Sec.1 B
901 Defects may be removed by grinding to a depth of 1% of the
nominal bar diameter.Ch.2 Sec.1
C. Steel Forgings
Ch.2 Sec.1
C 100 Scope
Ch.2 Sec.1 C
101 These requirements are supplementary to A and apply to steel
forgings to be used in the manufacture of chain accessories. Additional
requirements for the finished accessories are given in Sec.2 C.Ch.2 Sec.1
C 200 Manufacture
Ch.2 Sec.1 C
201 Forgings shall be made from ingots or continuous cast blooms
or billets. Ingots for forgings shall be cast in chill moulds with
the larger cross-section up, and with efficient feeder heads. Adequate
top and bottom discards shall be made to ensure freedom from piping
and harmful segregations in the finished forgings. Surface and skin
defects, which may be detrimental during the subsequent working
and forming operations, shall be removed.
Ch.2 Sec.1 C
202 The material shall be progressively hot worked by hammer or
press, and shall be forged as close as practical to the finished
shape and size.
Ch.2 Sec.1 C
203 The reduction ratio shall be calculated with reference to the
average cross-sectional area of the cast material. Where an ingot
is initially upset, this reference area may be taken as the average
cross-sectional area after this operation. The total reduction ratio
shall be at least 3:1. For forgings made by upsetting, the length
after upsetting is to be not more than one-third of the length before
upsetting or, in the case of an initial forging reduction of at
least 1.5:1, not more than one-half of the length before upsetting.
Ch.2 Sec.1 C
204 Welding to forgings is not permitted. This includes the welding
of brackets, bosses, or attachments.Ch.2 Sec.1
C 300 Chemical composition
Ch.2 Sec.1 C
301 The chemical composition shall comply with the agreed specification.Ch.2 Sec.1
C 400 Heat treatment
Ch.2 Sec.1 C
401 Forged accessories in grade R3 and R3S shall be supplied in
the normalised, normalised and tempered, or quenched and tempered
condition. Grade R4, R4S and R5 shall be supplied in the quenched
and tempered condition. Quenched and tempered accessories with diameter
over 120 mm shall receive an annealing or normalising heat treatment
prior to quenching and tempering.
Ch.2 Sec.1 C
402 For grade R4, R4S and R5, tempering temperatures shall not
be less than 590°C and cooling after tempering shall be in water.
Ch.2 Sec.1 C
403 Where forgings are to be quenched and tempered and cannot
be hot worked close to shape, they shall be rough machined prior
to being subjected to this treatment.
Ch.2 Sec.1 C
404 All hot forming operations shall be conducted prior to the
final heat treatment. If a forging is subsequently heated for further
hot forming, the forging shall be re-heat treated.Ch.2 Sec.1
C 500 Mechanical testing
Ch.2 Sec.1 C
501 Forged accessories shall be mechanically tested as given in Sec.2 C.Ch.2 Sec.1
C 600 Inspection
Ch.2 Sec.1 C
601 All forgings shall be visually inspected on accessible surfaces.
Where applicable, this is to include the inspection of internal
surfaces and bores. The surfaces shall be adequately prepared for
inspection. Black forgings shall be suitably de-scaled.
Ch.2 Sec.1 C
602 Forgings shall be free from injurious pipe, cracks, seams,
laps or other imperfections which, due to their nature, degree or
extent, will interfere with the use of the forgings.
Ch.2 Sec.1 C
603 All finished accessories are subject to magnetic particle testing,
see A600 and Sec.2 C.
Ch.2 Sec.1 C
604 Ultrasonic testing shall be carried out on all forgings after
the final heat treatment when the surfaces have been brought to
a condition suitable for UT. Both radial and axial scanning shall
be used when appropriate for the shape and dimensions of the forging
being tested. Unless otherwise agreed with the purchaser the entire
volume of the forgings shall be tested.
Ch.2 Sec.1 C
605 For calibration, reference blocks shall be made from steel
that is similar in chemistry and processing history to the production
forgings. The distance amplitude curve (DAC) shall be based on 3
mm flat bottom hole. No indications equal to or larger than the
reference DAC are acceptable.Ch.2 Sec.1
C 700 Repair
Ch.2 Sec.1 C
701 Defects on non-machined surfaces may be removed by grinding
to a depth of 5% of the nominal diameter. Grinding is not
permitted on machined surfaces, except for slight inspection grinding
on plane surfaces in order to investigate spurious indications.
Welding and weld repairs are not permitted.Ch.2 Sec.1
D. Steel Castings
Ch.2 Sec.1
D 100 Scope
Ch.2 Sec.1 D
101 These requirements are supplementary to A and apply to steel
castings to be used in the manufacture of chain accessories. Additional
requirements for the finished accessories are given in Sec.2 C.Ch.2 Sec.1
D 200 Manufacture
Ch.2 Sec.1 D
201 Castings shall be manufactured according to drawings showing
the positions of gates, risers and chills (if used).
Ch.2 Sec.1 D
202 Where flame cutting, scarfing or arc-air gouging to remove
surplus metal is undertaken, the affected areas shall be either
machined or ground smooth.Ch.2 Sec.1
D 300 Chemical composition
Ch.2 Sec.1 D
301 The chemical composition shall comply with the agreed specification.Ch.2 Sec.1
D 400 Heat treatment
Ch.2 Sec.1 D
401 Cast accessories in grade R3 and R3S shall be supplied in
the normalised, normalised and tempered, or quenched and tempered
condition. Grade R4, R4S and R5 shall be supplied in the quenched
and tempered condition. Quenched and tempered accessories with diameter
over 120 mm shall receive an annealing or normalising heat treatment
prior to quenching and tempering.
Ch.2 Sec.1 D
402 For grade R4, R4S and R5, tempering temperatures shall not
be less than 590°C and cooling after tempering shall be in water.Ch.2 Sec.1
D 500 Mechanical testing
Ch.2 Sec.1 D
501 Cast accessories shall be mechanically tested as given in Sec.2 C.Ch.2 Sec.1
D 600 Inspection
Ch.2 Sec.1 D
601 All castings shall be visually inspected on accessible surfaces.
Where applicable, this is to include the inspection of internal
surfaces and bores. The surfaces shall be adequately prepared for
inspection.
Ch.2 Sec.1 D
602 Castings shall be free from adhering sand, scale, cracks, hot
tears or other imperfections which, due to their nature, degree
or extent, will interfere with the use of the castings.
Ch.2 Sec.1 D
603 All finished accessories are subject to MT, see A600 and Sec.2 C.
Ch.2 Sec.1 D
604 Ultrasonic testing shall be carried out on all castings after
the final heat treatment when the surfaces have been brought to
a condition suitable for UT. Both radial and axial scanning shall
be used when appropriate for the shape and dimensions of the casting
being tested. Unless otherwise agreed with the purchaser the entire
volume of the castings shall be tested.
Ch.2 Sec.1 D
605 For calibration, reference blocks shall be made from steel
that is similar in chemistry and processing history to the production
castings. The distance amplitude curve (DAC) shall be based on 3
mm flat bottom hole for testing to a depth of 25 mm below the surface
and 6 mm flat bottom hole for testing the remaining volume. No indications
equal to or larger than the reference DAC are accepted.Ch.2 Sec.1
D 700 Repair
Ch.2 Sec.1 D
701 Defects on non-machined surfaces may be removed by grinding
to a depth of 5% of the nominal diameter. Grinding is not
permitted on machined surfaces, except for slight inspection grinding
on plane surfaces in order to investigate spurious indications.
Ch.2 Sec.1 D
702 Where the repair entails removal of more than 5% of
the diameter or thickness, the defective area shall be repaired
by welding. The excavations shall be suitably shaped to allow good
access for welding. The resulting grooves shall be subsequently
ground smooth and complete elimination of the defective material
shall be verified by NDT.
Ch.2 Sec.1 D
703 Weld repairs are classified as major or minor. A weld repair
is considered major when the depth of the groove prepared for welding
exceeds 25% of the diameter or 25 mm, whichever is smaller.
All other weld repairs are considered minor.
Ch.2 Sec.1 D
704 Major weld repairs require the approval of the purchaser before
the repair is commenced. Proposals for major repairs shall be accompanied
by sketches or photographs showing the extent and positions of the
repairs. A grain refining heat treatment shall be given to the whole
casting prior to major repairs.
Ch.2 Sec.1 D
705 Minor weld repairs must be recorded on sketches or photographs
showing the extent and positions of the repairs.
Ch.2 Sec.1 D
706 All weld repairs shall be done by qualified welders using qualified
procedures. Welders shall be qualified according to EN 287, ISO
9606, ASME IX, ASTM A488 or equivalent. Procedures shall be qualified
according to EN 288, ASME IX, ASTM A488 or equivalent with the following
additional requirements: Charpy V-notch impact tests with notch
locations in weld metal, fusion line and heat affected zone + 2
mm and + 5 mm from fusion line, respectively. Test results
shall meet the requirements specified for the parent metal.
Ch.2 Sec.1 D
707 The welding consumables used shall be of a suitable composition
giving a weld deposit with mechanical properties similar to those
of the parent castings. Low hydrogen consumables shall be used.
Welding consumables shall be stored and handled so as to maintain
the hydrogen classification and in accordance with the consumable
manufacturer's recommendations.
Ch.2 Sec.1 D
708 When repair welding is done after the casting has been heat
treated for mechanical properties, the repaired casting shall be
given a furnace stress relieving or tempering heat treatment as
detailed in the qualified procedure.
Ch.2 Sec.1 D
709 On completion of heat treatment the weld repairs and adjacent
material shall be ground smooth. All weld repairs are subject to
NDT as required by 600. Ch.2 Sec.1
E. Materials for Studs
Ch.2 Sec.1
E 100 Scope
Ch.2 Sec.1 E
101 These requirements apply to forged or cast steel materials
to be used in the manufacture of studs.Ch.2 Sec.1
E 200 Chemical composition
Ch.2 Sec.1 E
201 The chemical composition shall be similar to that of the chain
link or in compliance with a specification that provides for similar
response to heat treatment.
Ch.2 Sec.1 E
202 The carbon content should not exceed 0.25% or the
carbon equivalent (IIW) should not exceed 0.58% if the
studs are to be welded in place.Ch.2 Sec.1 E
| Table E1 Minimum mechanical
properties for chain cable materials |
| Steel
grade | Yield stress | Tensile strength | Elongation | Reduction of area | Charpy V-notch |
| Re | Rm | A5 | Z | Temperature 1) | Average energy | Single energy |
| N/mm2 | N/mm2 | % | % | °C | J | J |
| R3 | 410 | 690 | 17 | 50 2) | 0 | 60 | 45 |
| -20 | 40 | 30 |
| R3S | 490 | 770 | 15 | 50 2) | 0 | 65 | 49 |
| -20 | 45 | 34 |
| R4 | 580 | 860 | 12 | 50 3) | -20 | 50 | 38 |
| R4S | 700 | 960 | 12 | 50 3) | -20 | 56 | 42 |
| R5 | 760 | 1000 | 12 | 50 3) | -20 | 58 | 44 |
1) For grade R3 and R3S, testing
may be carried out at either 0°C or -20°C.
2) For cast accessories, the
minimum value shall be 40%.
3) For cast accessories, the
minimum value shall be 35%. |
Ch.2 Sec.1 E
| Table E2 Dimensional
tolerances for rolled bars |
Nominal bar
diameter | Tolerance on
diameter | Tolerance on
roundness |
| mm | mm | (dmax - dmin)
mm |
| 51 - 80 | -0 +2.0 | 1.50 |
| 81 - 100 | -0 +2.6 | 1.95 |
| 101 - 120 | -0 +3.0 | 2.25 |
| 121 - 160 | -0 +4.0 | 3.00 |
| 161 - 210 | -0 +5.0 | 4.00 |
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