Paragraph 2.1 – General principles
1 Normal and higher strength Corrosion Resistant
Steels as defined within this Unified Interpretation, is steel
whose corrosion resistance performance in the bottom or top of the
internal cargo oil tank is tested and approved to satisfy the requirements
in resolution MSC.289(87) in addition
to other relevant requirements for ship material, structure strength
and construction. It is not the intention of this document to suggest
that Corrosion Resistant Steels be used for corrosion resistant applications
in other areas of a ship.
2
Corrosion Resistant Steels are
similar to conventional ship construction steels in terms of chemical
composition and mechanical properties.
3 The weldability of Corrosion Resistant
Steels is similar to the weldability of conventional ship construction
steels and, therefore, normal shipyard welding requirements in terms
of qualification by the approval of welding consumables and welding
procedure qualification also apply.
Paragraph 2.2 – Technical File
1 The shipbuilder is to prepare and submit the
Technical File to the Administration for verification. If the applicable
corrosion protection method varies for different locations, the information
required for the Technical File is to include each location and corrosion
protection method separately. Once verified, one copy of the Technical
File is to be placed on board the ship. The following construction
records are to be included in the Technical File:
1.1 The copy of the Type Approval Certificate.
1.2 Other technical data is to include:
1.3 Application records
-
(a) Areas of application/location of corrosion
resistant steel.
-
(b) Brand of corrosion resistant steel and thickness.
-
Note: Items (a) and (b) above may be substituted by the
information given in the hull-related approved drawings. However,
each brand of corrosion resistant steel used and its location is to
be indicated on the approved drawings, the drawings are to be included
in the Technical File.
1.4 The test certificates and actual measured
values of plate thickness of each corrosion resistant steel, and individual
welding conditions need not be included.
2 After the ship enters service, the shipowner
or operator is to maintain repair data in the Technical File for review
by the Administration. The information required is to include each
location and corrosion protection method separately. These records
should include:
2.1 Where repairs are made in service to the cargo
oil tank in which corrosion resistant steel is used, the following
information is to be added to the Technical File:
-
(a) areas of repair work;
-
(b) repair method (replacement by corrosion resistant
steel or coating);
-
(c) records of the brand of corrosion resistant
steel used, plate thickness and welding consumables (brand name and
welding method) if corrosion resistant steel is used; and
-
(d) records in accordance with the Performance
standard for protective coatings for cargo oil tanks of crude oil
tankers (resolution MSC.288(87)),
if coating is used.
2.2 Repairs that require records to be maintained
as mentioned in paragraph 2.1 above include the following:
-
(a) replacement by corrosion resistant steel;
-
(b) application of coating on members in which
corrosion resistant steel is used (including cases where corrosion
resistant steel is replaced with conventional steel and coating); (Note
1) and
-
(c) repairs of pitted parts.(Note 2)
-
Note 1: Details of coating on repairs to corrosion resistant
steel are to be recorded in the Corrosion Resistant Steel Technical
File. In such cases, duplicates of these coating records do not need
to be included in the Coating Technical File.
-
Note 2: The wastage limit of the pitted part or area is
to be as deemed appropriate by the classification society and/or Administration.
However, the standard value of the permissible wastage amount is to
be taken as about 40% of the original thickness. In this case weld
repairs are required. Only welding consumables approved for the relevant
corrosion resistant steel are to be used. The full depth of the pitting
is to be filled up by the weld metal. If non-approved welding consumables
are used, an appropriate area around the repaired part is to be coated
suitably after the repairs in accordance with the IMO Performance
standard for protective coatings for cargo oil tanks of crude oil
tankers.
2.3 Plate thickness records during periodical
surveys need not be recorded in the Technical File.
Paragraph 3.3 – Special application
1 Where other items of structure, such as appurtenances,
are not clearly identified, the application of the PSPC-COT
Alt to these items is described here.
1.1 Means of access, to be used for ship inspections,
which are not integral to the ship structure.
1.1.1 Permanent means of access which are not
integral to the ship's structure include:
- – adders
- – rails
- – independent platforms
- – steps
1.1.2 Appropriate corrosion protection measures
are to be adopted for permanent means of access mentioned in paragraph
1.1.1 above.
1.1.3 When corrosion resistant steel is used,
in principle, a corrosion resistant steel of the same brand as used
in the main structure is to be used for the means of access and the
attachments.
1.1.4 When conventional steel is used, and is
welded to corrosion resistant steel, corrosion protection measures
for the attachment and weld are recommended to be in accordance with
the Performance standard for protective coatings for cargo oil
tanks of crude oil tankers (resolution MSC.288(87)).
1.1.5 Other corrosion protection measures are
to be left to the discretion of the Administration.
1.1.6 Where other corrosion protection measures
other than those stated above, for example cathodic protection are
used, the performance of the corrosion resistant steel of the surrounding
structure is not to be impaired
1.2 Access arrangements integral to the ship's
structure
1.2.1 The phrase "Access arrangements that are
integral to the ship structure" in paragraph 3.2.2 of the annex to
the Performance standard for alternative means of corrosion
protection for cargo oil tanks of crude oil tankers (resolution MSC.289(87)) means access arrangements
integral to the ship structure such as the items mentioned below,
for access in the cargo oil tanks of crude oil tankers.
- – Stiffeners and girders with increased depth for walkways
1.2.2 Appropriate corrosion protection measures
are to be adopted for access arrangement given in paragraph 1.2.1.
If coating is applied, the provisions of the Performance standard
for protective coatings for cargo oil tanks (resolution MSC.288(87)) are to be followed. If corrosion
resistant steel is used on the above arrangements, in principle, corrosion
resistant steel of the same brand/type as that used in the cargo oil
tanks of crude oil tankers, is to be used.
1.3 Supporting members, etc.
1.3.1 It is recommended that pipes and supporting
members for measuring equipment or outfitting items that are not strength
members of the hull be protected either by coating or by use of corrosion
resistant steel in accordance with the provisions of paragraph 1.1.4.
1.4.1 In the case of attachments (conventional
steel) used only during construction work such as hanging pieces,
if welding consumables which are not indicated on the Type Approval
Certificate of the corrosion resistant steel are used, it is recommended
that the welded part is coated in accordance with figure 3.3.1.
Paragraph 3.2 – Area of application
1 Structural members in the COT that require protection
measures against corrosion are specified in the Performance standard
for alternative means of corrosion protection for cargo oil tanks
of crude oil tankers (resolution MSC.289(87).
2 Different methods of corrosion protection (coating
and corrosion resistant steel) may be adopted for (a) and (b) above.
Moreover, a combination of different corrosion protection methods
may be used for each of the structural members within the areas identified
by (a) and (b).
3 Acceptable combinations of corrosion protection
methods are shown in table 1.
Table 1 Acceptable combinations of
corrosion protection methods
Member
|
Lower surface of strength deck
(a)
|
Upper surface of inner bottom plating
(b)
|
Corrosion protection
method
|
Case 1
|
Corrosion resistant steel – Brand
A*
|
Corrosion resistant steel – Brand
B*
|
Case 2
|
Coating
|
Corrosion resistant steel – Brand
B*
|
Case 3
|
Corrosion resistant steel – Brand
A*
|
Coating
|
Case 4
|
Corrosion resistant steel – Brand
C*
|
Corrosion resistant steel – Brand
C*
|
*Corrosion Resistant Steel and coating may be used on the same
member.
|
4 If different corrosion protection methods (coating
and corrosion resistant steel) are selected for either (a) or (b),
the selected procedure for each member is to comply with the relevant
performance standards.
5 Where corrosion resistant steel is used it is
to be type approved by the Administration.
6 Where different brands of corrosion resistant
steels are used in the same structural member, see figure 3.4.1, the
weld joining the two different steels is to be coated. Coating is
to be in accordance with the Performance standard for protective
coatings for cargo oil tanks of crude oil tankers (resolution MSC.288(87)). However, coating of the weld
is not required if the welding consumable used to produce the weld
has been subject to the necessary corrosion tests. In such a case,
a type approval certificate is required for the both steel brands
in association with the welding consumable used.
7 When corrosion resistant steel and conventional
steel are used together in an area where corrosion protection is necessary,
see figure 3.4.2, the conventional steel and the weld is to be coated
in accordance with the Performance standard for protective coatings
for cargo oil tanks of crude oil tankers (resolution MSC.288(87)),
8 Where the welding consumable used is different
from that indicated on the Type Approval Certificate of corrosion
resistant steel, the weld is to be coated in accordance with the Performance
standard for protective coatings for cargo oil tanks of crude oil
tankers (resolution MSC.288(87)),
see figure 3.4.3.
1.1 The steel must be approved and graded accordingly.
1.2 The approval procedure for corrosion testing
of corrosion resistant steel is described in the annex to the Performance
standard for alternative means of corrosion protection for cargo oil
tanks of crude oil tankers (resolution MSC.289(87)).
1.3 The Administration's approval is not needed
for the testing laboratory where a surveyor of the Administration
is present at specified stages to witness the approval tests.
1.4 In the case where the Administration is not
present at specified stages to witness the approval tests, the testing
laboratory is to be approved.
1.5 Where the scope of approval changes, for example
for additions to the applicable welding consumables, the effects of
these changes are to be subjected to corrosion resistance tests for
the welded joints specified in the annex to the Performance
standard for alternative means of corrosion protection for cargo oil
tanks of crude oil tankers (resolution MSC.289(87)).
2 Type Approval Certificate
2.1 The Type Approval Certificate for approved
corrosion resistant steel is to include the following items:
-
(a) brand name, manufacturer and certificate number;
-
(b) steel grade and area of application designation;
-
(c) chemical composition range (including additive
and/or controlling element percentages to improve corrosion resistance);
-
(d) maximum thickness;
-
(e) steelmaking process;
-
(f) casting process;
-
(g) delivery condition;
-
(h) brand of welding consumables and welding method;
and
-
(i) period of validity of approval.
2.2 The Type Approval Certificate is valid for
a maximum period of 5 years from the date of approval. When the renewal
of approval is carried out, the period of validity will be a maximum
period of 5 years from the next day after the expiry date of the previous
validity.
Paragraph 5 – Inspection and verification requirements
1.1 The general requirements are as follows:
-
(a) Corrosion resistant steel type approved by
the Administration is to be used.
-
(b) Welding consumables used are to be the Brand
specified on the type approval certificate.
-
(c) Welding work is to be implemented according
to the approved welding procedure.
-
(d) The correct use of corrosion resistant steel
is verified by engineering review and survey.
-
(e) The shipbuilder is to prepare a Technical
File after the construction work has been completed, and submit it
to the Administration for verification
-
(f) The Technical File is to be maintained on
board the ship.
1.2 If any of the items in 1.1(a) to 1.1(f) above
are not complied with, the Administration notifies the shipbuilder
immediately who confirms the corrective action to be followed and
its completion. A SOLAS Safety Construction Certificate should not
be issued until all required corrective actions have been closed to
the satisfaction of the Administration
2 Procedure applicable to new ships
2.1. Product inspection is to be carried out as
part of material certification. The control range of the chemical
composition is determined as follows:
2.1.1 The manufacturer is to supply data relating
to the control of applicable chemical elements that the manufacturer
has intentionally added or is controlling to improve corrosion resistance.
Upper and lower limits for all such elements and any relationship
between these elements are to be disclosed. The manufacturer is to
obtain the Administration's approval for these additions and the relationships.
2.1.2 The effect of variation of each element
is to be assessed by using sufficient corrosion tests to determine
the effects of variation with variations of other elements used to
enhance corrosion resistance.
2.1.3 The corrosion resistance test is to be conducted
in accordance with the appendix to annex 3 to the Performance
standard for the alternative means of corrosion protection for cargo
oil tanks of crude oil tankers (resolution MSC.289(87)).
2.2 Survey during the construction stage
2.2.1 The Administration's surveyor is to verify
that corrosion resistant steel has been used correctly at the appropriate
locations.
2.2.2 The verification in 2.2.1 is to be implemented
periodically, and the frequency is to be determined on assessment
of quality control feedback of each shipyard. However, if some deficiency
is found, the shipyard is to formulate the necessary remedial action
with regard to both the deficient location and counter measures to
be taken to improve inspection methods.
3 Procedure applicable to ships in service
3.1 If the repair method is described in the Technical
File, repairs are to be carried out in accordance with the said method.
3.2 If corrosion resistant steel or coated member
is to be replaced, the same corrosion protection method to the one
used during construction is recommended.
3.3 If corrosion resistant steel is to be used
during repairs, use of the corrosion resistant steel of the same brand
as that used during construction is recommended.
3.4 If conventional steel is used in a corrosion
resistant steel member that is to be replaced, coating is to be applied
to the conventional steel. In this case, it is required that the coating
complies with paragraph 3.4.3 of the Performance standard for
protective coatings for crude oil tanks of crude oil tankers (resolution MSC.288(87)), see figure 3.4.2.
3.5 The application of welding consumables to
be used is to be confirmed through the latest Type Approval Certificate
of the relevant corrosion resistant steel to ensure conformity (brands
of the welding consumables are indicated on the Type Approval Certificate).
3.6 If the welding consumables specified in the
Type Approval Certificate for the corrosion resistant steel cannot
be used, the weld is to be coated, see figure 3.4.3. In this case,
it is required that the coating complies with paragraph 3.4.3 of the Performance standard for protective coatings for cargo oil tanks
of crude oil tankers (resolution MSC.288(87)).
4.1 Welding workmanship standards accepted for
conventional steel may be used.
4.2 An approved welding procedure is to be used
for welding work as appropriate to the grades (excluding subscripts
related to corrosion resistance), welding consumables, welding position
and plate thickness, etc. of the corrosion resistant steel to be used.
Appendix – Test Procedures
For Qualification Of Corrosion Resistant Steel For Cargo Tanks In
Crude Oil Tankers
1 Test on simulated upper deck conditions
1.1 Test condition
-
(a) The chemical composition of the conventional
shipbuilding steel used for test purposes (table 1 in the annex to
the Performance standard for alternative means of corrosion
protection for cargo oil tanks of crude oil tankers (resolution MSC.289(87))) is to be based on ladle analysis
given in the mill certificate. Steel complying with a national standard
that meets the requirements of table 1 is also acceptable.
-
(b) All the base material specimens should be
located in one tank. Figure 2 in the annex to the Performance
Standard for alternative means of corrosion protection for cargo oil
tanks of crude oil tankers (resolution MSC.289(87)) only shows locations of 20 specimens. The tank can be designed
to hold 25 or more specimens; alternatively specimens can be added
and removed as necessary so that the appropriate time periods are
achieved within the total timescale of 98 days.
-
(c) Since certain factors such as control and
measurement of temperature and size of chamber may affect the corrosion
rate achieved, it should be confirmed that the corrosion rate of conventional
steel in the conditions and equipment of the test, satisfies the rate
criteria, before carrying out corrosion test for evaluation of corrosion
resistant steel.
-
(d) To remove specimens, the chamber is to be
purged with 100% nitrogen gas while the specimens are in the high
temperature region until the specimens are dry.
-
(e) The cycling pattern of specimen temperature
and temperature of distilled water should be controlled such that
each cycle is as identical as possible throughout the whole corrosion
test period. These temperatures must be recorded. See figure App 1.
-
(f) The transition time, a, a*, c and c* in figure
App 1 is the time from when the cooling and heating commences until
the lower or upper temperature is reached, see figure App 2. The transition
of each cycle is to be as identical as possible throughout the whole
corrosion test period.
-
(g) The temperature of both the specimens and
the water is to be continuously recorded throughout the test.
-
(h) Welded specimens may be tested with the parent
material tests or tested separately against 5 conventional steel specimens.
-
(i) Base material is to be prepared such that
the surface to be tested is to be taken from a position within 2 mm
of one rolled surface. This surface is to be ground to bare steel
and polished to 600 grit finish.
-
(j) For welded samples, a test assembly is to
be made from the same steel cast as the base material test in (i)
but may be from a plate of different thickness. The assembly is to
be welded using the process and consumable to be approved for use
with the base material. The surface to be tested is to be selected
such that the width of weld metal, excluding heat affected zone, is
to be between 10 and 20 mm. This surface is to be ground to bare steel
and polished to 600 grit finish.
-
(k) Specimens are to be weighed to an accuracy
of ± 1 mg.
-
(l) Where the calculated corrosion loss of conventional
steel is less than 0.05 mm/year, the concentration of H2S
may be increased in the simulated cargo oil tank gas. All tests will
be carried out at this increased level.
-
(m) At least 3 values of individual weight loss
of conventional steel should be in the range of maximum X and minimum
Y measured in grams.
-
X = (0.11 x S x D)/10
-
Y = (0.05 x S x D)/10
-
Where
-
S = surface area (cm2)
-
D = density (g/cm3)
2 Test on simulated inner bottom conditions
2.1 Test condition
-
(a) The conventional steel used should also meet
the requirements of table 1 in the annex to the Performance
standard for alternative means of corrosion protection for cargo oil
tanks of crude oil tankers (resolution MSC.289(87)) and interpretations 1.1 (a) above.
-
(b) Base material is to be prepared such that
one surface is to be taken from a position within 2 mm of one rolled
surface. All surfaces are to be ground to bare steel and polished
to 600 grit finish.
-
(c) For welded samples, a test assembly is to
be made from the same steel cast as the base material test in (e)
but may be from a plate of different thickness. The assembly is to
be welded using the process and consumable to be approved for use
with the base material. The surface to be tested is to be selected
such that the width of weld metal, excluding heat affected zone, is
to be between 10 and 20 mm. This surface is to be ground to bare steel
and polished to 600 grit finish.
-
(d) Specimens are to be weighed to an accuracy
of ± 1 mg.
-
(e) One specimen that has a corrosion rate deviating
from the average corrosion rate by more than +25% may be eliminated
from the results, provided that the cause of the accelerated corrosion
is demonstrated to be due to localized corrosion around the hanging
hole and/or stamp (e.g. crevice corrosion, pitting corrosion, etc.).
3 Interpretation of weld discontinuity
3.1 Preparation of samples after corrosion test
-
(a) All five samples are to be prepared as follows.
-
(b) Two full thickness specimens approximately
20 mm long x 5 mm wide are to be sectioned with their principle axis
perpendicular to the weld fusion line. Each specimen is to be located
such that the weld fusion line is located approximately at its mid
length. See figure App 3.
-
(c) The specimens are to be mounted in resin to
allow polishing of the cross section. The specimens are to be etched
in Nital after polishing to reveal the fusion boundary.
-
(d) A photomicrograph is to be taken at a magnification
of approximately 100 X.
3.2 Evaluation of depth step
-
(b) Construct two parallel lines C-D and E-F one
representing the higher level, the other the lower level. Each line
is to be constructed over a distance of ≥ 300 μm from line
A-B on the base metal and weld metal side, respectively.
-
(c) Measure the distance r mm between the intersection
point at line A-B and each average surface line on the photomicrograph.
-
(d) If the intersection point at line A-B and
average surface line of welded metal part is above that of base metal
part, then the existence of step should be neglected for this sample.
-
(e) Calculate the depth of discontinuous step
R in μm from the actual photomicrograph magnification M as follows:
3.3 Evaluation of step angle
-
(a) Evaluation for angle of step is unnecessary
if the depth of step calculated on both samples see paragraph 3.2,
are not greater than 30 μm or if either step exceeds 50 μm
for a single specimen. Otherwise the angle of step is to be calculated
as follows.
-
(b) Produce a photomicrograph at a magnification
of approximately 250 X, see figure App 5.
-
(c) Draw an average surface line C-D for base
metal part and E-F for weld metal part.
-
(d) Find the closest intersection point with the
step of the base metal surface profile and the constructed line C-D
and the closest intersection point with the step for weld metal constructed
line E-F respectively, and connect those two intersection points.
3.4 Acceptance criteria
-
(a) If the depth of both steps are less than or
equal to 30 μm then the measurement of angle is unnecessary, and
the sample is considered to be acceptable.
-
(b) If the depth of steps on both photomicrographs
are less than or equal to 50 μm and in addition if both the measured
angles are less than or equal to 15 degrees, then the sample is considered
to be acceptable.
-
(c) If either of the conditions described in paragraphs
a or b above are not in compliance, the sample is considered to contain
a "discontinuous surface" and fails the test.
-
(d) Welds should be evaluated as "without
discontinuous surface" when all 5 corrosion test samples are
considered acceptable.