draft uganda standard - punto focalstandard, deas 903: 2020, welded steel tanks for liquefied...

DRAFT UGANDA STANDARD

DUS DEAS 903

First Edition 2020-mm-dd

Reference number DUS DEAS 903: 2016

© UNBS 2020

Welded steel tanks for liquefied petroleum gas (LPG) — Road tankers — Design and manufacture

DUS DEAS 903: 2016

ii © UNBS 2020 - All rights reserved

Compliance with this standard does not, of itself confer immunity from legal obligations

A Uganda Standard does not purport to include all necessary provisions of a contract. Users are responsible for its correct application

© UNBS 2020

All rights reserved. Unless otherwise specified, no part of this publication may be reproduced or utilised in any form or by any means, electronic or mechanical, including photocopying and microfilm, without prior written permission from UNBS.

Requests for permission to reproduce this document should be addressed to

The Executive Director Uganda National Bureau of Standards P.O. Box 6329 Kampala Uganda Tel: +256 417 333 250/1/2 Fax: +256 414 286 123 E-mail: [email protected] Web: www.unbs.go.ug

mailto:[email protected]

DUS DEAS 903: 2016

© UNBS 2020 - All rights reserved iii

National foreword

Uganda National Bureau of Standards (UNBS) is a parastatal under the Ministry of Trade, Industry and Cooperatives established under Cap 327, of the Laws of Uganda, as amended. UNBS is mandated to co-ordinate the elaboration of standards and is

(a) a member of International Organisation for Standardisation (ISO) and

(b) a contact point for the WHO/FAO Codex Alimentarius Commission on Food Standards, and

(c) the National Enquiry Point on TBT Agreement of the World Trade Organisation (WTO).

The work of preparing Uganda Standards is carried out through Technical Committees. A Technical Committee is established to deliberate on standards in a given field or area and consists of representatives of consumers, traders, academicians, manufacturers, government and other stakeholders.

Draft Uganda Standards adopted by the Technical Committee are widely circulated to stakeholders and the general public for comments. The committee reviews the comments before recommending the draft standards for approval and declaration as Uganda Standards by the National Standards Council.

This Draft Uganda Standard, DUS DEAS 903: 2020, Welded steel tanks for liquefied petroleum gas (LPG) — Road tankers — Design and manufacture, is identical with and has been reproduced from an East African Standard, DEAS 903: 2020, Welded steel tanks for liquefied petroleum gas (LPG) — Road tankers — Design and manufacture, and is being proposed for adoption as a Uganda Standard.

The committee responsible for this document is Technical Committee UNBS/TC 16, Petroleum.

Wherever the words, “East African Standard " appear, they should be replaced by "Uganda Standard."

DEAS 903: 2016

ICS

© EAC 2016 First Edition 2016

DRAFT EAST AFRICAN STANDARD

Welded steel tanks for liquefied petroleum gas (LPG) — Road tankers — Design and manufacture

EAST AFRICAN COMMUNITY

DEAS 903: 2016

ii © EAC 2016 – All rights reserved

Copyright notice

This EAC document is copyright-protected by EAC. While the reproduction of this document by participants in the EAC standards development process is permitted without prior permission from EAC, neither this document nor any extract from it may be reproduced, stored or transmitted in any form for any other purpose without prior written permission from EAC.

Requests for permission to reproduce this document for the purpose of selling it should be addressed as shown below or to EAC’s member body in the country of the requester:

© East African Community 2013 — All rights reserved East African Community P.O. Box 1096 Arusha Tanzania Tel: +255 27 2504253/8 Fax: +255 27 2504481/2504255 E-mail: [email protected]

Web: www.eac-quality.net

Reproduction for sales purposes may be subject to royalty payments or a licensing agreement. Violators may be prosecuted.

DEAS 903: 2016

© EAC 2016 – All rights reserved iii

Foreword

Development of the East African Standards has been necessitated by the need for harmonizing requirements governing quality of products and services in the East African Community. It is envisaged that through harmonized standardization, trade barriers that are encountered when goods and services are exchanged within the Community will be removed.

In order to achieve this objective, the Community established an East African Standards Committee mandated to develop and issue East African Standards.

The Committee is composed of representatives of the National Standards Bodies in Partner States, together with the representatives from the private sectors and consumer organizations. Draft East African Standards are circulated to stakeholders through the National Standards Bodies in the Partner States. The comments received are discussed and incorporated before finalization of standards, in accordance with the procedures of the Community.

East African Standards are subject to review, to keep pace with technological advances. Users of the East African Standards are therefore expected to ensure that they always have the latest versions of

the standards they are implementing.

DEAS 903 was prepared by Technical Committee EASC/TC 038

DRAFT EAST AFRICAN STANDARD DEAS 903: 2016

© EAC 2016 – All rights reserved 1

Welded steel tanks for liquefied petroleum gas (LPG) — Road

tankers — Design and manufacture

1 Scope

This draft East Africa Standard specifies minimum requirements for materials, design, construction and workmanship procedures, and tests for welded LPG road tanker tanks and their welded attachments manufactured from carbon, carbon/manganese and micro alloy steels.

This standard does not cover tanks for ISO type containers.

2 Normative references The following referenced documents are indispensable for the application of this East Africa Standard. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including amendments) applies: ISO 6892-1, Metallic materials -- Tensile testing -- Part 1: Method of test at room temperature ISO 148-1, Metallic materials — Charpy pendulum impact test —Test method ISO 17636-2 Non-destructive testing of welds -- Radiographic testing -- Part 2: X- and gamma-ray techniques with digital detectors ISO 11484, Steel products — Employers qualification system for non-destructive testing (NDT) personnel ISO 6520-1, Welding and allied processes — Fusion welding ISO 6520-2, Welding and allied processes — Classification of geometric imperfection in metallic materials — Welding with pressure CD/K/1:2016; Inspection and testing of LPG road tankers ISO 9328-2, Steel flat products for pressure purposes -- Technical delivery conditions -- Part 2: Non-alloy and alloy steels with specified elevated temperature properties ISO 9692. 3 Terms and definitions For the purposes of this East Africa Standard, the following terms and definitions apply: 3.1 yield strength upper yield stress ReH or, for steels that do not exhibit a definite yield (non-proportional elongation), the 0.2 % proof stress

3.2 cold forming process of deforming metal plastically under conditions of temperature and strain – hardening, usually, but not necessarily conducted at room temperature

DEAS 903: 2016

2 © EAC 2016 – All rights reserved

3.3

hot forming process where metal are plastically deformed above their recrystallization temperature 3.4 sun shield shield covering not less than the upper third but not more than the upper half of the shell surface, separated from the shell by an air gap of at least 40 mm 3.5 road tanker tank assembly of the shell (the pressure-retaining enclosure including the openings and their closures) and non-pressure-retaining parts welded directly to the shell

3.6 approving authority within the scope of the relevant competent authority(ies) in the partner states

3.7 notified/designated body testing and certifying body approved by the relevant authority(ies) in the partner states

3.8 competent person person who, by qualifications, training, experience and resources, is able to make objective judgments and is duly authorised by the relevant authority(ies) in the partner states

3.9 LPG (liquefied petroleum gas) is pure propane, butane or a mixture of the propane and butane

3.10 Parent material Materials to be joined by welding to form a tank shell

4 Materials

4.1 Suitability Unless otherwise specified by the design documents, the design temperature range shall be -20

oC to

+ 50 oC. The materials of construction shall be suitable for operating within the envisaged temperature

range. If the tank could be subjected to more severe ambient or product temperatures, the design temperature range shall be -40

oC to + 50

oC. The materials of construction shall be resistant to brittle

fracture and stress corrosion cracking within the envisaged temperature range. NOTE Guidance on selection of material grades is given in Annex A.

4.2 Pressure retaining parts Pressure-retaining materials shall be of appropriate steels conforming to ISO 9328-2or shall conform to specifications agreed with the approving authority. All materials shall conform to 10.2.4.5 and the

ratio of the specified yield strength )( eHR to minimum tensile strength (Rm) shall not exceed 0.85 (i.e

0.85) meH RR . The percentage elongation at fracture shall be not less than 10 000 divided by the

actual tensile strength in N/mm2, and in any case shall be not less than 16 % for fine grained steels

and not less than 20 % for other steels.

DEAS 903: 2016


.

4.3 Non-pressure retaining parts Non-pressure retaining parts that are directly welded to pressure retaining parts shall be of suitable materials or materials with characteristics approved by a competent authority. All materials used for non-pressure retaining parts shall be compatible with the materials of pressure retaining parts, and shall conform to the impact requirements of10.2.4.5.

4.4 Welding consumables Welding consumables shall be able to provide consistent welds with properties at least equal to those specified for the parent materials in the finished tank.

4.5 Non-metallic materials (gaskets) Non-metallic materials (gaskets) shall be compatible with both phases of LPG over the range of pressures and temperatures for which the tanker is designed. (see 4.1 and Annexes B and C).

4.6 Certification of materials Pressure retaining parts and non-pressure retaining parts directly welded to the tank shall be provided with the material manufacturers’ certificates.

5 Tank design 5.1 Design conditions 5.1.1 Reference temperatures shall conform to Annex B. 5.1.2 Design calculations shall be carried out in accordance with Annex D. 5.1.3 Account shall be taken of the fatigue loading on all component parts of the tank and its attachments by conducting an assessment or through proven operating experience.

5.2 Surge plates 5.2.1 To reduce the dynamic loadings of the liquid content due to accelerations of the vehicle, tanks longer than 4 m shall be fitted with transverse surge plates at a maximum spacing of 4 m, and shall be designed to permit full internal inspection of the tank. The area of each plate shall be at least 70 % of the cross-sectional area of the tank in which the plates are fitted. 5.2.2 Surge plates shall be able to withstand the load imposed by a full capacity liquid content of the section between the plates in either direction. 5.2.3 Surge plates shall be at least 2 mm thick. 5.2.4 Provision shall be made for communication and drainage between sections. 5.2.5 For tanks over 1.8 m diameter, having a wall thickness less than 6 mm and for tanks up to 1.8 m diameter, having wall thickness less than 5 mm, the surge plates shall have the same thickness as the shell and the volume between any two plates shall not exceed 7 500 L.

5.3 Doubler plates

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5.3.1 To reduce stress concentration on the tank, load-carrying attachments shall incorporate a doubler plate between the attachment and the tank. 5.3.2 Non-circular doubler plates shall be designed with as generous as practicable corner radii, with a minimum of 25 mm to reduce stress concentrations. 5.3.3 If doubler plates are provided with test sockets they shall be closed with threaded plugs after testing.

5.4 Stresses due to motion 5.4.1 Tanks and their permanent attachments shall be able to absorb, under maximum permissible load, forces exerted by the design pressure, and the following dynamic forces: a) In the direction of travel: twice the total mass times gravity; b) At right-angles to the direction of travel: the total mass times gravity; c) Vertically upwards: the total mass times gravity; d) Vertically downwards: twice the total mass times gravity. 5.4.2 Under the forces defined above, the stresses in the tank and its fastenings shall not exceed the following: a) General membrane stress in the shell, remote from the supports which shall be calculated as

the normal design stress as defined in Clause D.1; b) Stresses local to the supports, determined either by experimental analysis or

calculation/special analysis.

5.5 Self-supporting tanks Self-supporting tanks shall be designed to carry bending stresses that would otherwise be carried by the chassis or frame.

5.6 Vacuum conditions Tanks shall be designed to withstand vacuum conditions generated by the product during operation or other operational conditions, but as a minimum, this shall be equivalent to an external pressure of at least 40 kPa.

5.7 Tanks mountings 5.7.1 Mounting structures shall be fabricated in steel and designed to limit movement of the tank in relation to the chassis. 5.7.2 Tank mountings and their method of attachment to the shell shall be of sufficient strength to support the tank when full of water. 5.7.3 The design of the tank mounts shall be co-coordinated with the design of the vehicle chassis. The designer shall assess the effect of the tank and its mountings, including the additional loadings given in 5.4.

DEAS 903: 2016


NOTE The chassis manufacturer should be notified at the tank design stage that the tank, while on the chassis, could be subjected to a hydraulic test, during which the tank can contain twice the normal weight of carrying capacity.

5.7.4 Tank mountings designed as an integral attachment to the shell shall be fitted with doubler plates as specified in 5.3. Stitch welding shall not be used.

5.8 Internal pipe work 5.8.1 The mechanical strength of internal pipe work and supports shall be strong enough to withstand the service conditions, including dynamic load as determined by the design calculations. NOTE Internal pipe work may be attached directly to a tank boss.

5.8.2 Pipe work shall be located so as to avoid inadvertent entry of liquid LPG from the liquid inlet line into other pipe work terminating in the vapour space.

6 Openings

6.1 General Valves and other accessories shall be protected against damage by external impact either by their positioning on the tank, when mounted on the vehicle, or by specific tank design. Provision in tank design shall be either by mounting and fitting valves and other accessories in a recess with the contour of the tank shell or end, or by use of a guard able to with stand a collision with another vehicle and the forces experienced in a tank roll-over.

6.2 Reinforcement of openings Openings shall be reinforced and designed in accordance with Annex D.4.

6.3 Threaded connections The maximum nominal diameter of threaded connections shall be 50 mm.

6.4 Manhole 6.4.1 Tanks over 1.5 m diameter shall be fitted with a manhole either: a) At least 500 mm in diameter; or b) At least 420 mm in diameter, if acceptable to the notified/designated body. 6.4.2 Manholes shall be of forged construction, machined from plate, or fabricated from pipe and standard flanges of the appropriate temperature and pressure rating. If plate is used for pad type manholes, it shall be ultrasonically tested for lamella defects. 6.4.3 The manhole shall be positioned for safe egress and access of an inspector.

7 Non-pressure retaining parts

7.1 Attachment welds

Attachment welds shall be continuous.

DEAS 903: 2016


7.2 Position of attachment welds Attachments shall be designed not to trap water and to permit inspection of the weld. Wherever possible, attachment welds shall be clear of vessel welds (longitudinal, circumferential and opening welds), by a minimum distance of 40 mm. Where this is not possible, attachment welds shall fully cross the main welds.

8 Workmanship and construction

8.1 General 8.1.1 Road tanker tanks shall be manufactured, inspected and approved in accordance with this standard.. 8.1.2 The manufacturer shall be responsible for the competence, training and supervision of their staff. 8.1.3 The manufacturer shall ensure, taking into account any instructions from the material supplier that the materials of the finished tank conform to this standard. 8.1.4 The manufacturer shall have defined procedures for manufacturing operations, including processes such as forming, welding and heat treatment.

8.2 Control of materials 8.2.1 The manufacturer of the tank shall maintain a system of identification for the material used in the fabrication so that all material for pressure-retaining parts and non-pressure-retaining parts directly welded to pressure-retaining parts in the completed work can be traced to origin. The system shall incorporate appropriate procedures for verifying the identity of material received from the supplier. 8.2.2 Verifying procedures shall be based on the material manufacturer’s certificates and/or acceptance tests. The system shall ensure that before cutting and forming parts of the tank, the original identification mark of the material is transferred to any parts of the tank that could be without markings after the process. The manufacturer shall ensure the material conforms to the design and/or drawing specification. 8.2.3 In laying out and cutting the material:

a) The material identification mark shall be clearly visible when the pressure part is complete; or

b) The manufacturer shall operate a documented system that ensures material traceability for all materials in the completed tanks.

8.2.4 If the materials identification mark is unavoidably cut out during manufacture of a pressure part, it shall be transferred by the pressure part manufacturer to another part of the component. Transfer of the mark shall be carried out by a person designated by the manufacturer. 8.2.5 When identification on materials is transferred, the method of marking shall not have any detrimental effect on the specified materials properties. 8.2.6 Details of welding consumables shall be retained.

8.3 Acceptable weld details 8.3.1 The manufacturer, in selecting an appropriate weld detail, shall consider:

DEAS 903: 2016


a) The method of manufacture;

b) The service condition;

c) The ability to carry out necessary non-destructive testing.

The root faces of welding preparations shall be aligned within the tolerances given in the welding procedure specification. NOTE Examples of typical welded joints used on the tank are given in Annex E.

8.3.2 If a tank is made from more than one shell strake, the longitudinal weld of adjacent strakes shall be staggered by at least 100 mm between weld edges. 8.3.3 Where the tank diameter is less than 1.5 m and no internal access is provided, joggle joints are permitted for end to shell joints. Only dished ends shall be joggled. 8.3.4 Joggles shall be sufficiently clear of the knuckle radius to ensure that the edge of the circumferential weld is at least 12 mm clear of the knuckle. NOTE A typical joggle joint detail is shown in Figure E.2

8.4 Heat treatment and forming

8.4.1 Cold forming

8.4.1.1 Heat treatment of cold formed cylindrical shells is not required.

8.4.1.2 Cold formed dished ends shall be heat treated unless the manufacturer can demonstrate that the properties of the finished products confirm to the original design.

8.4.1.3 Cold formed dished ends that have not been heat treated shall not be welded or heated locally in the knuckle area to temperatures above 55

oC without subsequent heat treatment.

8.4.2 Hot forming 8.4.2.1 For normalized steels, because of the danger of excessive grain growth, the work piece temperature during hot forming shall not exceed 1050

oC. Before the final stage of hot forming, or if

hot forming is performed only once, the work piece shall not be heated above 980 oC.

NOTE: The duration of hot forming should be kept to a minimum to avoid grain growth.

8.4.2.2 If no subsequent heat treatment is applied, hot forming shall be completed above 750 0

C, or above 700

0C if the degree of forming in the final stage does not exceed 5 %.

8.4.2.3 Cooling shall be carried out in still air. 8.4.2.4 If hot forming is carried out in conditions other than those specified in this sub clause, normalizing as specified by the steel manufacturer or supplier shall be carried out after hot forming.

8.4.2.5 A competent person shall specify the heat treatment procedure to ensure that the properties of the finished product conform to the original design.

8.4.3 Testing of formed parts

DEAS 903: 2016


8.4.3.1 For cold-formed parts not subject to heat treatment, no mechanical tests are required in respect of the forming operation. 8.4.3.2 All other formed parts shall have tests carried out after the last forming operation or any heat treatment to demonstrate conformity to the material specification. Test pieces shall be taken from an excess length or a redundant piece of the formed part or from a separate test piece formed to same procedure. The test pieces shall consist of one tensile and three impact specimens.

8.4.3.3 In case of formed ends, the test pieces shall be taken from sample ends selected as follows:

i) From initial production: 1 from 10 of each family; and

ii) From production formed ends 1 formed part in 1 000 production units, but not less than one per 2 years.

8.4.3.4 Ends with the following characteristics are considered to be a family of ends:

i) same material specification;

ii) same forming process;

iii) same heat treatment;

iv) geometrical similarity to ± 10 %.

8.4.4 Visual examination and control of dimensions Outsourced formed parts that require acceptance certificates shall be submitted by the tank manufacturer to visual examination and dimensional check in the delivery condition and the results shall be included in the tank acceptance certificate. 8.4.5 Marking Formed parts of pressure tanks shall be marked so that the material and the manufacturer of the part can be identified as specified in 8.2. For batch testing the relationship to the batch shall be evident.

8.5 Welding 8.5.1 General Welding of the joints of the component parts of a tank shall be carried out only if all the following apply: i) a welding procedure specification is compiled by the manufacturer; ii) the welding procedures selected by the manufacturer are qualified for the field of application.

If the design is based on material specifications agreed by a competent authority, the welding procedure shall be qualified using material with the higher properties;

iii) the welders and welding operators are qualified for the work and their approval (8.5.5). 8.5.2 Longitudinal welds There shall be not more than one longitudinal weld on any strake. Longitudinal welds shall be full penetration butt welds

8.5.3 Welding procedure specification (WPS)

DEAS 903: 2016


The manufacturer shall compile a welding procedure specification for each joint or family of joints. 8.5.4 Qualification of WPS 8.5.4.1 Welding procedures shall be qualified by welding procedure tests. 8.5.4.2 Production and testing of test pieces shall be certified by an independent body. 8.5.4.3 Welds shall be subjected to impact testing as specified in10.2.4.5 . 8.5.5 Qualification of welders and welding operators 8.5.5.1 Welders and welding operators shall all be approved. 8.5.5.2 Production and testing of test pieces shall be certified by an independent body. 8.5.5.3 A list of welders and welding operators and records of approval tests shall be maintained by the manufacturer. 8.5.6 Preparation of edges Preparation of edges shall be done in accordance with ISO 9692. Material may be cut to size and shape by any mechanical or thermal cutting process or by combination of these. Cutting may be carried out before or after forming.

The surface to be welded shall be cleaned of oxide scale, oil, grease, or other foreign substance that could have a detrimental effect on weld quality. Edges to be welded shall be kept in position, either by mechanical means or by tack welds or by a combination of these. Tack welds shall be removed or fused again in the weld bead. The manufacturer shall ensure that tack welding does not generate metallurgical or homogeneity defects. The manufacturer shall ensure that for welds without a sealing run (single sided welds), the edges are sufficiently aligned and spaced to ensure the required penetration at the weld root. NOTE A joggle may be used on circumferential welds (8.3.3.) to act as an integral backing trip.

8.5.7 Attachments of fastenings Welding of attachments (temporary or otherwise), including supports, to a pressure retaining part shall follow a qualified procedure. Temporary attachments shall be removed by a technique that does not affect the properties of the metal or pressure part to which they are welded. Care shall be taken to ensure that the area of a removed attachment is free from surface cracks. The area shall be dressed smooth and subjected to magnetic particle (10.4.4.) or penetrant (10.4.5) testing. Any cracks detected shall be repaired as appropriate. 8.5.8 Preheat

DEAS 903: 2016


8.5.8.1 The manufacturer shall include the preheating temperature in the WPS. The preheating temperature shall depend on the composition of the metal to be welded, the weld process, and the arc energy. 8.5.8.2 Welding shall not be carried out if the temperature of the parent metal near the joint is less than + 5

oC.

8.6 Post-weld heat treatment If required, post-weld heat treatment shall be carried out in accordance with Annex G. NOTE 1 Post-weld heat treatment is not required for the material types and weld thicknesses used on tanks build in accordance with this Standard. Post-weld heat treatment may be carried out on tanks by agreement between the purchaser and the manufacturer. NOTE 2 Tanks contain many fillet welds that cannot be tested. Where residual stresses and pressure plus dynamic stresses apply, there is a greater risk of crack initiation and crack growth. Lowering the residual stresses with post-weld heat treatment lowers the risk of cracking.

8.7 Manufacturing tolerances Tolerances on the tank shape shall conform to Annex F. NOTE Annex H gives a conservative method of measuring peaking (including ovality).

8.8 Repairs to pressure envelope and direct attachment welds 8.8.1 General requirements Imperfections shall be repaired by a mechanical or thermal process or combination of these. The thickness of the material, after repair is completed, shall be within the tolerances of the design and not less than the minimum thickness specified in Clause 5. After the repair, the material shall be subjected to the non-destructive testing originally applied. For welding repairs, after any specified post-weld heat treatment has been carried out, the repaired vessel shall be subjected to further post-weld heat treatment in accordance with the original specification. 8.8.2 Repair of surface imperfections in the parent metal 8.8.2.1 Minor surface imperfections (arc strikes, tool marks, cutting marks etc.) shall be removed by grinding. 8.8.2.2 The ground-out area shall have a smooth transition into the surrounding areas. 8.8.2.3 Repairs that involve depositing of a weld metal shall be carried out in accordance with a qualified welding procedure. 8.8.3 Repair of weld imperfections 8.8.3.1 The extent of repairs of weld imperfections shall be determined by the position, size and type of defect. Repairs may cover only the defect and surrounding area or may involve complete removal of the weld containing the defect. Repairs by grinding or other processes involving removal of material and that do not include welding shall be finished with a smooth transition into the surrounding areas.

DEAS 903: 2016


8.8.3.2 Thermal gouging shall be carried out using an electrode that minimizes contamination of remaining material surfaces. 8.8.3.3 Repairs shall be carried out in accordance with a qualified welding procedure and the welders shall be qualified.

9 Construction and workmanship of internal pipe work Welding of internal pipe work shall be to the same quality as for the pressure retaining parts.

10 Inspection and testing

10.1 General All tests shall be carried out after any heat treatment process and prior to any external corrosion protection and finishing.

10.2 Mechanical testing 10.2.1 Production test plates To control the continuing quality of welded joints and to ensure their mechanical properties conform to the specification, production test plates shall be welded and tested. 10.2.2 Longitudinal welds 10.2.2.1 For tanks that include one or more longitudinal welds, the test plates, if practicable, shall be attached to the shell plate on one end of the weld so that the edges to be welded in the test plate are a continuation and duplication of the longitudinal weld. 10.2.2.2 The weld metal shall be deposited in the test plates continuously with the welding of the corresponding longitudinal weld, so that the welding process, procedure and technique are the same. One test plate shall be produced per tank. 10.2.3 Circumferential welds If circumferential welds are welded by a different procedure to the longitudinal weld, the manufacturer shall produce two further test plates per year or one test plate per tank, whichever is the fewer. Test plates shall be produced by the same procedure as used in construction of the tank. 10.2.4 Mechanical tests Each production test plate shall be tested on specimens as required by Annex I.

10.2.4.1 Test requirements

The test specimens shall be prepared and tested as follows: 10.2.4.2 Bend test Bend testing and test requirements shall be carried out. 10.2.4.3 Tensile test

DEAS 903: 2016


Test shall be carried out in accordance with ISO 6892-1. The tensile strength of the test specimen shall be not less than the corresponding specified minimum value used for the design. 10.2.4.4 Macro-examination Macro-examinations shall be carried out and shall show sound build-up of weld beads and sound penetration. 10.2.4.5 Impact tests 10.2.4.5.1 Tests shall be carried out in accordance with ISO 148-1 with a V-shaped notch perpendicular to the surface of the test specimen. 10.2.4.5.2 Impact-strength tests are not required on welds with a parent plate thickness less than 5 mm. 10.2.4.5.3 For plates below 10 mm but not less than 5 mm thick, test specimens with a cross section of 10 mm wide by the thickness of the parent plate shall be used. NOTE Machining to either 7.5 mm or 5 mm may be permitted if required.

10.2.4.5.4 If the thickness of the parent plate is ≤ 10 mm, tests shall be carried out on three test

specimens with the notch at the centre of the weld and three test specimens with the notch at the centre of the heat affected zone (with the V-notch crossing the fusion boundary at the centre of the specimen). 10.2.4.5.5 If the thickness of the parent plate is > 10 mm, tests shall be carried out on three test specimens from the centre of the weld and three test specimens from the heat affected zone (with the V-notch crossing the fusion boundary at the centre of the specimen). 10.2.4.5.6 The average value obtained from each set of three test specimens shall be not less than 34 J/cm

2. Not more than one of the individual values shall be below 34 J/cm

2 and shall, in no case be

less than 24 J/cm2. This shall apply to specimens taken at the centre of the weld and in the heat-

affected zone. 10.2.4.5.7 The normal test temperature shall be -20

oC but for tanks that may be subjected to

temperatures below -20 oC, as defined in 4.1, impact testing shall be carried out at a temperature of

-40 oC.

10.2.4.6 Retests 10.2.4.6.1 Production factors can result in a scatter of mechanical test results that occasionally fall below the agreed specification level. If the results of tests do not conform to 10.2.4.1 to 10.2.4.5, the following re-tests shall be carried out: a) Two tensile tests; b) Two bend tests; c) One impact test (with three specimens). 10.2.4.6.2 In a repeated impact test, on the weld deposit or the heat affected zone, none of the individual values shall be below 34 J/cm

2. The average value of all results of the original test and the

DEAS 903: 2016


retests shall be a minimum of 34 J/cm2. If the retests fail these requirements then the welds

represented by the test specimens shall be deemed not to conform to this Standard. 10.2.4.7 Record of test results A test record shall be prepared indicating conformity of the test results to the specified requirements.

10.3 Non-destructive testing 10.3.1 Internal imperfections Examination for internal flaws shall comprise 100 % radiographic and/or ultrasonic examination of shell longitudinal and circumferential welds in accordance with 10.4.1 and 10.4.2 or 10.4.3 as applicable. 10.3.2 Surface imperfections Examination for surface imperfections shall comprise 100 % magnetic particle and/or penetrant testing of all welds that attach nozzles, branches and doubler plates to the shell and end plates and all other attachment welds to pressure components in accordance with 10.4.4 and 10.4.5 as applicable.

10.4 Non-destructive testing techniques for welds 10.4.1 Visual examination of welds All welds shall be visually examined on completion. The examined surface shall be well illuminated and free from grease, dirt, scale, residue, or protective coating of any kind. The examination shall apply to both sides of the welded joint as far as possible. 10.4.2 Radiographic techniques Radiographic examinations shall be carried out in accordance with ISO 17636-2. NOTE Other radiographic techniques may be used by agreement between the purchaser, the manufacturer and the competent person, provided it can be demonstrated that comparable sensitivities can be achieved.

10.4.3 Marking and identification of radiographs Each section of weld shall have suitable symbols affixed to identify the following: a) The job or workplace serial number, order number or similar distinctive reference number; b) The weld location; c) The section of the weld; d) Arrows or other symbols, alongside but clear of the outer edges of the weld to clearly identify the position. NOTE The weld location reference may be identified e.g. with a letter “L” for a longitudinal weld and a “C” for a circumferential weld, with addition of 1, 2, 3 etc, to indicate whether the weld was the first, second, third, etc, of the type.

10.4.3.1 Symbols consisting of lead arrows, letters and/or numerals shall be positioned so that their images appear on the radiograph of the section.

DEAS 903: 2016


10.4.3.2 Sufficient overlap shall be provided to ensure that radiographs cover the whole of the weld. Each radiograph shall exhibit a number near each end. 10.4.3.3 Radiographs of repair welds shall be clearly identified R1, R2, etc., for the first repair, second repair,

etc.

10.4.4 Ultrasonic techniques

Ultrasonic examination shall be carried out.

10.4.5 Magnetic particle techniques Magnetic particle inspection techniques shall be carried out. Particular care shall be taken to avoid damage to surfaces by misuse of magnetic equipment. Any damage that occurs shall be repaired. 10.4.5 Penetrant techniques

Dye or fluorescent penetrant examination of welds shall be carried out. NOTE Guidance on the selection of non-destructive test methods for welds is given in Annex J.

10.5 Qualification of non-destructive testing personnel

Personnel performing and evaluating non-destructive examinations shall be qualified and certified in accordance with ISO 11484. Non-destructive testing personnel and supervisors shall have adequate knowledge of the job and basic knowledge of welding. Testing personnel shall be independent of the personnel responsible for manufacture.

10.7 Acceptance test criteria

Acceptance criteria for non-destructive and visual examinations shall conform to Annex I. Unacceptable imperfections shall be repaired in accordance with 8.8 or the component shall be rejected. Imperfections shall be as defined in ISO 6520-1 and ISO 6520-2.

10.8 Pressure test

10.8.1 On completion of construction, tanks shall be subjected to a hydraulic pressure test at a test pressure of 1.3 times the design pressure specified in Annex D.

10.8.2 The general membrane stress occurring at the actual test pressure shall not exceed 90 % of the specified minimum yield stress of the material.

10.8.3 The test pressure required by this standard is higher than the minimum test pressure specified in other pressure vessel manufacturing standards. This higher test pressure shall not be used to allow marking of the tank for other substances or LPG mixtures than those used as a basis for the design. 10.8.4 The first pressurization shall be carried out under controlled conditions with appropriate safety precautions. NOTE A recommended procedure is given in Annex K.

10.9 Capacity

DEAS 903: 2016


Following the pressure test the water capacity of each tank shall be checked by suitable method to an accuracy of at least 1 % and recorded. The capacity shall be corrected to 20

oC.

11 External corrosion protection and finishing

11.1 External protection Tanks shall have sufficient external protection against corrosion arising from atmospheric effects.

11.2 Finishing operations

The tank shall be protected from the ingress of foreign matter during transportation, handling and fixing to the chassis, and other finishing operations.

12 Marking

As a minimum, markings conforming to Annex L shall be permanently placed on a nameplate permanently attached to the tank or supports.

13 Records and documentation

13.1 Documentation obtained by the manufacturer The following documentation shall be obtained by the manufacturer: a) Certificates showing chemical analysis and details of the mechanical properties of the steel used in construction of the pressure retaining parts of the tanks (see 4.6); b) A certificate for formed parts (see 8.4.4);and c) acceptance certificate for outsourced parts.

13.2 Records prepared by the manufacturer The manufacturer shall prepare the following records: a) Fully dimensioned drawings including material specification and design criteria; b) Records of heat treatment, if applicable; c) Records of mechanical tests; d) Records of visual examination and dimensional checks on formed parts; e) Welding procedure specifications and qualification certificates f) A list of the welders and records of their approval tests g) Records of any weld repairs; h) A certificate of the hydraulic pressure test; i) Radiographs and results of non-destructive tests;

DEAS 903: 2016


j) A certificate of water capacity measurement; and k) A certificate of conformity to this standard, endorsed by a notified/designated body.

13.3 Retention and supply of documents The manufacturer or agent shall retain copies of all documentation in accordance with the relevant national legislations of the Partner States. Documentation shall be supplied to the purchaser or operator on request.

DEAS 903: 2016


Annex A (normative)

Guidance on selection of material grades

A.1 This Annex lists material grades from the standards specified in Clause 4 that may be used for fabricating the tank. NOTE Not all of the grades listed have guaranteed mechanical properties that conform to Clause 4. Some grades may require special testing to demonstrate conformity.

The steel group is listed for each of the grades or equivalent. The grouping shall be in accordance with ISO 9328-2.

DEAS 903: 2016


Annex B (normative)

Reference temperatures for design

B.1 Introduction The liquid volume and developed pressure of LPG in a closed system are a function of the ambient temperature.

B.2 General . The reference temperatures designated in this Annex shall be applicable for the design of all road tankers operating within the jurisdiction of the EAC Partner States , unless the competent authority under special consideration and permit given in writing, authorizes for transport designated type of LP Gas, the reference temperature designated in Annex C.

B.3 Developed pressure The reference temperature for developed pressure shall be as specified in Table B.1. The developed pressure shall be the pressure of commercial propane at the reference temperature. The corresponding pressure value shall be not less than the minimum test pressure specified in KS CD/K/1;2016.

Table B.1 — Reference temperature for developed pressure

Sun shield Tank diameter

m 1.5 D oC

Tank diameter

D < 1.5 m oC

Without sun shield 65

70

With sun shield 65

70

B.4 Filling The reference temperature used for calculation of maximum allowable fill shall be 55

o C.

Tanks shall be designed to be filled in accordance with the following formula: Degree of filling (kg/L) = 0.95 x density of the liquid phase at the reference temperature (55

oC).

Tanks shall not become 100 % liquid full at 60

oC.

DEAS 903: 2016


Annex C (informative)

Alternative reference temperatures for design

C.1 Introduction The liquid volume and developed pressure of LPG in a closed system are a function of the ambient temperature.

C.2 General The reference temperatures designated in this Annex shall be applicable for the design of road tankers when authorized by a competent authority for use within specified terms that are given in writing.

C.3 Developed pressure The reference temperature for developed pressure shall be as specified in Table C.1.

Table C.1 — Reference temperatures for developed pressure

Sun shield Tank diameter D ≥ 1.5 m

oC

Tank diameter

D < 1.5 m oC

Without sun shield 50 55

With sun shield 50a)

55a)

a) Lower values of temperature with a sun shield may be used if justified by

experience or experimental testing.

C.4 Filling The reference temperature used for calculation of maximum allowable fill shall be 32.5

oC.

Tanks shall be designed to be filled in accordance with the following formula: Degree of filling (kg/l) = 0.95 x density of the liquid phase at the reference temperature (32.5

oC).

Tanks shall not become 100 % liquid full at 40

oC.

DEAS 903: 2016


Annex D (normative)

Design

D.1 Design stresses

The nominal design stress f shall be the lesser of 2.4R and 5.1 meHR where:

eHR is the yield strength specified in the material standard or specification;

mR is the tensile strength specified in the material standard or specification

The following units shall be used in the formulae in this Annex: — Pressure and stress – N/mm

2

— Dimensions - mm

D.2 Design pressure

D.2.1 Rigid single tankers and semi-trailers P = Pd (D1)

D.2.2 Tanker plus full trailer combinations P = Pd K (D2)

where, p is the design pressure; Pd is the highest developed gauge pressure for the products to be carried, at the reference

temperature given in Table B.1 or Table C.1;

K is the greater of 1.0;or 65/T-650.6 1 r

Tr is the reference temperature for developed pressure given in Table B.1 or Table C.1.

D.3 Design formula

D.3.1 cylindrical shell calculation The minimum required thickness shall be the greater of:

p2fz

pD o

min

e (D3)

DEAS 903: 2016


and

5.1500

min oDe (D4)

where,

Do is the outside diameter of the shell; P is the design pressure specified in D.2; z is the joint efficiency = 0.85

f is the nominal design stress.

D.3.2 Dished ends D.3.2.1 Minimum thickness Dished ends can be torispherical, ellipsoidal or hemispherical. For tanker plus full trailer combinations, the following minimum thicknesses shall apply;

a) for tank diameter 5.1D m, end thickness = 7 mm;

b) for tank diameter D < 1.5 m, end thickness = 6 mm. D.3.2.2 Torispherical end calculation The following rules are limited in application to ends for which:

Dr 06.0 i (D.5)

r > 3e (D.6)

iDe 08.0 (D.7)

oDR (D.8)

The required thickness e is the greatest of es, ey and eb, where:

pfz

pRes

5.02 (D.9)

f

DRCpe i

y

2.075.0 (D.10)

and

DEAS 903: 2016


5.1

1

825,0

1112.075.0

r

D

f

pDRe i

b

ib (D.11)

where,

5.1ehb Rf for all materials

and C or (β) factor determined from Figure D.1 or by calculation (see D.3.2.5); Di inside diameter of end; Do outside diameter of shell; e required thickness of the end; eb minimum thickness of knuckle to avoid buckling; es minimum thickness of end to limit membrane stress in central part; ey minimum thickness of knuckle to avoid axisymetric yielding; f nominal design stress; fo design stress for buckling calculation; p design pressure; R inside radius of curvature of central part of torispherical end; r inside radius of knuckle; z joint efficiency = 0.85 The thickness of the spherical part of the end may be reduced to the value es over a circular area that

shall not come closer to the knuckle than the distance Re

Any straight cylindrical flange shall conform to D.3.1 for a cylinder, unless the length is not greater

than eDi2,0 , in which case the flange may be the same thickness as the knuckle.

D.3.2.3 Ellipsoidal end calculation An ellipsoidal end is defined as able to produce a truly semi-ellipsoidal shape without distinct spherical knuckle radii. The design method converts these ends to equivalent torispheres that are calculated in accordance with D.3.2.2.

DEAS 903: 2016


NOTE These rules apply only to ends for which 1,7 < K < 2.2 and z = 0.85.

Ellipsoidal ends shall be designed as nominally equivalent torispherical ends with:

iD

Kr

08.0

5.0 (D12)

iDKR 02.044.0 (D13)

where

K is the shape factor for an ellipsoidal end, and

ih is the inside height of the ellipsoidal end.

K will be calculated as follows;

ii hDK 2

D.3.2.4 Hemispherical ends The required thickness of a hemispherical end is given by equation Clause D.14. The thickness of the cylinder to which the end attaches shall be kept at or above the minimum determined by D.3.1 for the cylinder up to the tangent line.

This method is valid for :16.0oDe

pfz

pRes

5.02 (D14)

D.3.2.5 Equations for calculating C

R;0.04e minY (D15)

Y1 logZ (D16)

iDrX (D17)

4902.6

1006.1

YN (D18)

For X = 0,2;

5.0;95.05.8294.156.0.max 2

2,0 YYC (D19)

For X = 0,1:

NZZZC 837.02943.10383.11833.0 23

1,0 (D20)

DEAS 903: 2016


For X = 0,06:

NZZZC 8873.12937.32124.23635.0 23

06,0 (D21)

For 0.1 < X < 0.2:

2.01.0 1.02.010 CXCXC (D22)

For 0,06 < X < 0.1:

1.006.0 06.01.025 CXCXC (D23)

NOTE The equations for C (β), given above, lead to an iterative calculation. A computer procedure is recommended.

Figure D.1 — Parameter β for torispherical end — Design

D.3.3 Conical shell calculations D.3.3.1 General requirements This calculation is for offset cones between two cylinders (see Figure D.2). The cylinders shall have parallel centre lines offset from each other by a distance not greater than the difference between their radii.

DEAS 903: 2016


A thickness shall be calculated in accordance with D.3.3.3 for the junction at the large end. A thickness shall be calculated in accordance with D.3.3.4 for the junction at the small end. The greater of these shall apply to the whole cone. The calculations do not apply to cones for which the half angle at the apex of the cone is greater than

60o, or for which 001.0Da cos c e where cD is the mean diameter of the cylinder at the junction

with the cone. D.3.3.2 Thickness of conical shell The minimum permissible thickness of a cone, at any point along its length, shall be the greater of

: where,e and jse

a

xpfz

pDe i

cos

1

2 (D.24)

or

a

xpfz

pDe e

cos

1

2 (D.25)

where;

lD is the inside diameter of the cone at the point under consideration;

eD is the outside diameter of the cone at the point under consideration’

cD is the mean diameter of the cone at the section under consideration, generally at the large end;

e is the required thickness of the cone;

f is the nominal design stress;

p is the design pressure;

z is the joint efficiency = 0.85; a is the greatest semi-angle of the cone at the apex in degrees.

The thickness of the cone may be increased locally or generally to provide reinforcement at branches or openings or to carry non-pressure loads. D.3.3.3 Junction between large end of a cone and a cylinder without a knuckle This sub clause applies provided that the joint is a butt weld in which the inside and outside surfaces merge smoothly with the adjacent cone and cylinder without local reduction in thickness.

DEAS 903: 2016


NOTE 1 The junction is the intersection of shell centre-lines D.2b Figure see

15.0cos11

tan

3

1

x

e

D

j

c (D.26)

f

pDe c

j2

(D.27)

where:

is a factor defined above;

je is a required thickness at a junction at the large end of a cone;

1e is the required thickness of the cylinder at the junction;

2e is the required thickness at the cone at the junction.

NOTE 2 Equations D.26 and D.27 are a trial and error calculation for je . The answer is acceptable if the value is not less

than that assumed to calculate . Figure D.3 gives directly as a function of fp and .

The minimum thickness 1e of the cylinder adjacent to the junction is the greater of

jj e wheree and ce is the thickness calculated using equation (D.27), and ce is the required

thickness of the cylinder as specified in D.3.1.

Thickness shall be maintained for a distance of at least

1

4.1

l from the junction along the cylinder,

where 11 eDl c is the length along the cylinder.

The minimum thickness, 2e , of the cone adjacent to the junction is the greater of je and e , where e is

the thickness of the cone specified in D.3.3.2 and je is the thickness calculated using equation

(D.28).

This thickness shall be maintained for a distance of at least

2

4.1

lfrom the function along the cone

where

cos22 eDl c

D.3.3.4 Junction between the small end of a cone and a cylinder This subclause applies provided the thicknesses conform to D.3.1 and D.3.3.2

DEAS 903: 2016


The required thicknesses 2e for the cone are determined by applying the following procedure.

Assume initial values of :21 e and e

12 eeS

(D.28)

5.0tan

4.01

x

e

Dc

H

(D.29) If S< 1:

2

1

cos

2SSS

(D.30)

If S ≥ 1:

xSS

cos2

11

2 (D.31)

NOTE Equations D.28 and D.29 do not provide values for 2 1 e and e separately. These may require adjustment relative

to each other to suit the design. If:

HcD

fzep

22

then 21 e and e are acceptable, where H is a factor defined in equation D.29. If:

p >

HcD

fze

22

repeat with increased values of 21 e and e . The final derived thickness for 21 e and e shall be

maintained for a distance 21 l and l from the junction, respectively, where 2l and l are determined in

accordance with D.3.3.3.

DEAS 903: 2016


a) Offset cone

b) Cone/cylinder intersection without knuckle: large end

c) Cone/cylinder intersection: small end

Figure D.2 — Conical shells

DEAS 903: 2016


Figure D.3 — Values of coefficient for cone / cylinder without knuckle

D.4 Nozzle reinforcement D.4.1 The design method specified in D.4.2 to D.4.10 shall only apply to cylindrical shells and dished ends with circular or elliptical openings, with which the conditions specified in D.4.1 and D.4.2 apply. The size of openings shall be limited as follows:

—cylindrical shells: ;1ii Dd

—dished ends: .6.02 imi rd

where,

id is the inside diameter of the opening or branch;

imr is the inside radius of the main body (shell or dished end).

DEAS 903: 2016


The ratio of branch thickness to main body thickness mb ee shall conform to the limits of Figure D.4.

D.4.2 The distance between openings or branches, measured from the outside of the branches or

pads, shall be not less than ml2 , where:

mmimm eerl 2 (D32)

where:

for shells 2iim Dr (D.33)

for torispherical ends ihim rr (D.34)

and for ellipsoidal ends

02.0

22.0

i

iiim

h

DDr (D.35)

where:

iD is the inside diameter of shell or straight flange of dished end;

me is the analysis thickness of main body (shell or dished end) maintained within the length

:ml

ih is the inside height of an ellipsoidal dished end;

ml is the length of main body considered as effective compensation, measured along the

material centerline from the edge of the opening without a branch or outside of the branch (or pad) see equation D.32);

imr is the inside radius of main body (shell or dished end) as specified in D.4.2;

ihr is the inside radius of hemispherical dished end or spherical portion of torispherical head.

D.4.3 Openings and branches and their reinforcements in dished heads shall be located entirely within the spherical portion of the torisphere. D.4.4 Cylindrical shells and dished ends with openings shall be reinforced where required. Reinforcement of the main body may be obtained by the following measures: a) by set-in welded pads (see Figure D.5a); b) by set-on or set-in welded branches as shown in Figure D.5b). D.4.5 The reinforcement area of the main body with openings cannot be calculated directly but shall be assumed in the first instance. The assumption may be verified by means of the method given in D.4.6 to D.4.10.The applied method is based on basic pressure thicknesses derived from equation D.3 for cylindrical shells and from the equations in D.3.2 for dished ends, and leads to relationships

DEAS 903: 2016


between a pressure loaded area A and a stress loaded cross sectional area that is given by

fbfpfm AAA (see Figure D.5). The calculation may be repeated using a corrected assumption of

the reinforcement area. D.4.6 Where required sufficient reinforcement shall be provided in all planes through the axis of the opening branch. D.4.7 For elliptical openings the ratio between the major and the minor axis shall not exceed 1.5. For elliptical openings in cylindrical shells and dished ends, the opening axis parallel to the longitudinal axis of the cylinder shall be considered as the diameter for design purposes. For elliptical openings in dished ends the major axis shall be considered as the diameter. D.4.8 Set-on or set-in welded branches, fillet welded only, may be considered as reinforcement if they conform to Figure D.5. Each fillet shall have a throat thickness not less than 0.7 times the tank wall thickness. D.4.9 Reinforcement of openings by compensating plates shall not be permitted. D.4.10 All openings shall conform to the following general relationship:

fbbfppfmfpfbfmp AfAffAAAAAp 5.0 (D36)

where: p is the design pressure;

pA is the pressure loaded area as shown in Figure D.5, calculated using internal dimensions;

fbA is the cross-sectional area of branch within the compensation limits;

fmA is the cross-sectional area of main body (shell or head) within the compensation limits;

fpA is the cross-sectional area of pad within the compensation limits;

f is the nominal design stress of either the shell or dished end;

bf is the lower of the nominal design stress of the branch and f;

pf is the lower of the nominal design stress of the pad and f.

NOTE Simplified formulae for calculation of fb , A and fpfm AA for various geometries are given in Figure D.5. These

formulae give acceptable results within the accuracy of the method. However, the designer can choose to calculate more precise values, based on the true geometry, if required.

D.5 Nozzle reinforcement by pads or flanges Only pads of the set-in welded type conforming to Figure D.5a) shall be used.

DEAS 903: 2016


The width of the pads pl considered as contributing to the reinforcement shall not exceed .ml

The value of pe used in determination of fpA in equation in D.4.10 shall not exceed .2 me

pl is the maximum length of pad considered to be effective as compensation, measured from the

inside surface of the main body;

ml is as defined in equation D.32;

pe is the thickness of pad;

me is the actual thickness of main body (shell or head), minus any thinning allowance.

D.6 Nozzle reinforcement by branches D.6.1 The wall thickness of branches (nozzles) shall, if required, exceed the thickness calculated to

withstand internal pressure for a length oh measured from the exterior wall of the main body.

D.6.2 Areas fpfbfm,, A and A A pA shall be determined in accordance with Figure D.5b, where the

lengths contributing to the reinforcement shall be not more than ml for the shell (see equation D.32),

and:

bbob eedl (D.37)

for the branch.

DEAS 903: 2016


Figure D.6 – Maximium branch to body thickness ratio The maximum value used in calculation of the part extending inside, it any, in the case of set-through

branches (see Figure D.5b) shall be .5,0 bbi ll

bl is the length of external branch considered as effective compensation measured from the outside

of the main body.

od is the outside diameter of branch;

be is the analysis thickness of the branch maintained within the length bl

DEAS 903: 2016


a) Reinforcement by pads

Figure D.5 — Design of openings: Cylindrical shells with isolated openings

DEAS 903: 2016


b) Reinforcement by welded branches

Figure D.5 (continued) — Design of openings: Cylindrical shells with isolated openings

DEAS 903: 2016


bimbfb

mmfm

o

m

im

p

leeA

leA

dl

rA

22

c) Intruded branch in a dished end

Figure D.5 (concluded) — Design of openings: Cylindrical shells with isolated openings

DEAS 903: 2016


Annex E (informative)

Example of joints

NOTE 1: The dimension limits (i.e.≥ e, ≤ 2,5e) apply to weld preparation only. NOTE 2: The finished weld should have a smooth profile and should completely fill the grooves to the full thickness of the plates being jointed. 8.3.3 specifies where joggle joints can be applied.

Figure E.2 — Joggle Joint

DEAS 903: 2016


The offset section that forms the weld backing should be a close fit within the mating section round its entire circumference. This can be achieved by machining the spigot of the offset section, provided the thickness remaining as backing material is not less than 75 % of the original thickness.

3eL minimum but not less than 6 mm

Figure E.3 — Nozzle joints: set on

DEAS 903: 2016


Figure E.4 — Nozzle joints: set in

DEAS 903: 2016


Figure E.5 — Nozzle joints: integral backing

DEAS 903: 2016


Annex F (normative)

Allowable tolerances

F.1 Tanks F.1.1 External diameter The mean external diameter derived from the circumference shall not deviate by more than 1.5 % from the external diameter shown on the manufacturer’s design drawing. F.1.2 Out of roundness Out of roundness, O, the ratio of the difference between the maximum and minimum diameter and the mean diameter as defined by:

minmax

minmax2

DD

DD

Shall not exceed 1.5 % of the specified external diameter, with a maximum (in millimeters) of:

200

1250D

These tolerances shall apply to the shell, including the straight flange length on the dished ends. At nozzle positions, a greater out of roundness may be permitted if justified by calculation or strain gauge measurement. Single dents or knuckles shall be within tolerance. Dents shall be smooth and their depth (i.e. the deviation from the surface of the shell) shall not exceed 1 % of their length or 2 % of their width. Greater dents and knuckles are permissible if they are proven acceptable by calculation or strain gauge measurements. The cylindrical shell tolerance on tanks designed for vacuum conditions, where the thickness of the tank is governed by the vacuum criterion, shall be circular to within 0.5 % of radius (i.e. 0.005R)- measured from the true centre. F.1.3 Deviation of straightness The deviation from straightness shall not exceed 0.5 % of the total length of the tank. F.1.4 Irregularities in profile Irregularities in profile shall not exceed the following: — 2 % of the gauge length (checked by a 20

o gauge); or

— 2.5 % of the gauge length (checked by a 20

o gauge) where the length of the irregularities does not

exceed one quarter of the tangential length of the shell strake part between two circumferential seams, with a maximum of 1.0 m; or

Figure E.4 — Nozzle joints: set in

DEAS 903: 2016


— if either of the above are exceeded, proof by calculation or strain gauge measurement shall be required to show that the stresses are permissible. If irregularity in the profile occurs at the welded seam and is associated with “flats” adjacent to the

weld, the irregularity in profile or “peaking” shall not exceed 3e (see Figure F.1), where e is the wall

thickness. NOTE 1 A conservative method of measurement (covering peaking and ovality) is given in Annex H. NOTE 2 Other types of gauges (e.g. bridge gauges, needle gauges) may be acceptable for measurements.

F.2 Dished end tolerance F.2.1 Thickness of material The thickness of the material after forming shall at no point be less than the thickness determined in accordance with Annex D. F.2.2 Profile Dished ends shall be within the tolerances specified in Table F.1. The crown radius shall be not greater than the value specified in the design, and the knuckle radius shall be not less than the value specified in the design.

DEAS 903: 2016


Key R Crown radius r Knuckle radius H Dish height h Straight flange e Wall thickness D External diameter

C Circumference D

O Out of roundness (see F.1)

i Deviation of the bore from cylindrical shape: inner side

o Deviation of the bore from cylindrical shape: outer side

Figure F.1 — Example of a dished end profile

Table F.1 — Dished end tolerances

DEAS 903: 2016


Feature Tolerance of the

feature

Notes

C D = 1 000 mm ±0.4 % Special manufacturing conditions may require smaller

tolerances D > 1 000 mm ±0.3 %

O 1 % of D Special manufacturing conditions may require smaller

tolerances

H + 0.015 D or 10 mm

whichever is the greater

The tolerance shall not fall below zero

mm 10e – 0.3 mm The actual wall thickness shall not fall below the

minimum value calculated in Annex D e >10 mm – 0.5 mm

i

5o

For dished ends where the outer side angle is

influenced by an upsetting due to the forming process,

the deviation of the straight flange from the cylindrical

shape shall be measured only on the inside of the

dished end.

o

2

o

F.3 Assembly tolerances

F.3.1 Middle line alignment F.3.1.1 For longitudinal joints in the cylindrical shells, the middle lines of adjacent plates shall be aligned within the following tolerances: — 1 mm for plate thickness e up to and including 10 mm; — 10 % of thickness for plate thickness e above 10 mm. F.3.1.2 For circumferential joints, the middle lines of adjacent plates shall be in alignment with the following tolerances: — 1 mm for plate thickness e up to and including 10 mm; — 10 % of the thinner part + 1 mm for plate thickness e above 10 mm.

F.3.2 Surface alignment The misalignment at the surface of the plates for plate thickness e shall either be as specified in a ) and b), or if this misalignment is exceeded, the surface shall be tapered with a slope of 1:4 over a width that includes the width of the weld, with the lower surfaces built up with added weld metal, if required, to provide the required taper. Trimming of plate surfaces shall not be permitted if this reduces the thickness below the required minimum. a) For longitudinal joints in shells the surfaces of adjacent plates shall be aligned within the following tolerances:

DEAS 903: 2016


— 4e for thickness e up to and including 12 mm,

— 3 mm for plate thickness e over 12 mm.

b) For circumferential joints the surface of adjacent plates shall be aligned within the following tolerances:

— 4e for plate thickness e up to and including 20 mm;

— 5 mm for plate thickness e over 20 mm.

F.4 Attachments, nozzles and fittings Pads, doubler plates, lugs, brackets, supports, and other attachments shall lift closely to the shell. The gap at all exposed edges to be welded shall not exceed 2 mm. Except where specific dimensions are shown on the fully dimensioned drawing, the maximum gap between the outside of any branch or shell and the inside edge of the hole in the shell, flange, reinforcing ring, or backing ring shall not exceed 1.5 mm for openings up to 300 mm in diameter and 3 mm for openings over 300 mm. To achieve this gap it may be permissible to machine over a sufficient length of the outside diameter of the tank or nozzle to accommodate the attachment to be welded. The machined length shall not extend beyond the toes or edges of the attachment welds, and shall not reduce the nozzle wall thickness to a value less than the design thickness.

F.5 Overall length The length of the finished tank shall conform to the nominal length shown on the manufacturing drawing (see 8.1).

DEAS 903: 2016


Annex G (normative)

Heat treatment

G.1 Method of post-weld heat treatment G.1.1 For post-weld heat treatment the tank shall be heated as a whole in an enclosed furnace within the limits of 550

oC to 600

oC and heldfor 30 min.

G.1.2 Localized post-weld heat treatment can be used to accomplish local heating of the weld using the either of the following methods; Low/high voltage electric resistance heaters or combustion burners (high velocity gas, luminescent flame, infrared burners) or induction coil or quartz lamps. When conducting local post-weld heat treatment the following area shall be considered see figure below;

DEAS 903: 2016


Nomenclature

W = Widest width of weld.

HAZ = Heat affected zone.

SB = Soak band (width of the volume of the material where the holding temperature equals or exceeds the minimum and equals

or is below the maximum required. The minimum width is typically specified as W plus a multiple of t on each side of the weld).

L = Minimum distance over which the temperature may drop to a percentage of that at the edge of the soak band.

HB = Heated band (width of heat source).

GCB = Gradient control band (minimum width of insulation and/or gradient heat source).

t = Nominal thickness.

R = Inside radius.

DEAS 903: 2016


Figure G.1 — Schematic diagram for description of local Circumferential

heating.

Figure G.3 —Minimum number of thermocouples (monitoring & control) recommended for circumferential PWHT of a horizontal pipe butt weld for pipe greater than 12 NPS but less than or equal to 24 NPS (4 zones of control).

DEAS 903: 2016


Note: The soak band (SB) is the volume of metal which should be heated to the minimum but not exceed the maximum required temperature. As a minimum, it should consist of the weld, HAZ, and a portion of the base metal adjacent to the weld being heated The heated band (HB) is the surface area over which the heat source is applied to achieve the required temperature in the soak band and limit induced stresses in the vicinity of the weldment. It should consist of the soak band plus any adjacent base metal necessary to both control the temperature and limit induced stress within the soak band. The gradient control band (GCB) is the surface area over which insulation and/or supplementary heat source (s) are placed. It should encompass the soak band, heated band, and sufficient adjacent base metal such that the maximum permissible axial temperature gradient within the heated band is not exceeded.

G.2 Temperature control During heating and cooling periods, variation in temperature throughout the tank or component shall not exceed 150

oC within 4 500 mm and the temperature gradient shall be gradual. Above 500

oC the

variation shall not exceed 100 oC.

During the heating and holding periods, the furnace atmosphere shall be controlled to avoid excessive oxidization of the surface of the tank or component.

G.3 Temperature limit The temperature of the furnace when the tank is placed in or taken out shall not exceed 400

oC.

The rate for heating or cooling the furnace temperature shall not exceed 220

oC/h.

G.4 Temperature measurement The specified temperature shall be the actual temperature of any part of the tank or heated zone and shall be determined by thermocouples in effective contact with the tank. A sufficient number of temperatures shall be recorded continuously and automatically. Several thermocouples shall be applied to ensure that the whole tank or treated zone is within the range specified. Additional pyrometers shall be utilized to check that undesirable thermal gradients do not occur. The heat treatment record shall be available. Thermocouples shall be calibrated at regular intervals.

DEAS 903: 2016


Annex H (informative)

Typical method for measurement of shell peaking

H.1 Profile gauge To measure peaking a profile gauge (see Figure H.1) should be made for each size of tank. The minimum inner arc length of the gauge should be 0.175Do (20

o of arc), where Do is the external

diameter of the tank. This diameter should be checked by measurement of the tank. NOTE For some tanks the calculated arc length may not extend beyond the flats. Because of this, the minimum arc length of the gauge should be sufficient to clear the flats. The width of the weld cut should be 28 mm but this may be longer to ensure that the cut out is clear of the weld (see Figure H.1).

H.2 Peaking survey The approximate zone of maximum peaking should be determined by taking readings at intervals of approximately 250 mm along the longitudinal welds. When the maximum zone has been found, the maximum peaking P should be determined by accurate measurement of P1 and P2 (see Figure H.1). Care should be taken to ensure that the gauge makes contact with the shell at the points indicated in the note to Figure H.1. NOTE It may be beneficial to make a taper gauge as shown in Figure H.2, for checking P1 and P2.

Approximate dimensions of the flats should be measured at the point of maximum peaking and recorded. If there is a significant high spot between points A and B or between points D and C in Figure H.1b) then this method may overestimate the peaking. A plaster cast should be made to verify the amount of peaking. Points A and D should be clear of any flats.

DEAS 903: 2016


Key

a) 20° gauge details P1 + P2 b) Measurement of outward peaking – maximum peaking, P = 4 c) Measurement of inward peaking

NOTE For Figure H.1 b) the gauge should touch the shell at point A and as near to point B as possible. When

the gauge touches point D it should be as near as possible to point C.

Figure H.1 — Measurement of shell peaking

DEAS 903: 2016


Figure H.2 — Taper gauge

DEAS 903: 2016


Annex l (normative)

Welding imperfections and test specimens

l.1 Imperfections Acceptance levels for internal and surface weld imperfections shall conform to Tables I.1 and I.2 respectively, and the maximum reinforcement for welds shall conform to Table I.3. The following symbols are used in Tables I.1 to I.3: a nominal fillet weld throat thickness

b width of weld reinforcement

d diameter of pore

h height of imperfection

w width of imperfection

l length of imperfection

t wall or plate thickness

Table I.1 — Acceptance levels for internal imperfections detected by NDT methods

Imperfection ISO 6520-1

ISO 6520-2

Reference a)

Limit for detectable imperfection

Cracks and lamellar tears 100 Not permitted.

Porosity 2011 d = 0.3t, maximum 4 mm.

Uniformly distributed porosity

2012 For any individual gas pore, see 2011. Not permitted if the total projected surface porosity exceeds 2 % of the considered projected surface of weld.

Localized (clustered) porosity.

2013 For any individual gas pore, see 2011. Not permitted if the total projected surface porosity exceeds 4 % of the considered projected surface of the weld, which is the greatest of the following areas

b.

— area 1: an envelope surrounding all the pores; — area 2: a circle with a diameter corresponding to the weld width.

Linear porosity 2014 Same as for uniformly distributed pores, see 2012, but the distance between two pores shall be greater than twice the diameter of the larger pore, and not less than 4 mm, to ensure there

1 inner edge of gauge to match the nominal outside diameter (Do) of shell (to be checked)

DEAS 903: 2016


is no lack of fusion.

Elongated cavity 2015 l = 0,3t, maximum 5 mm; and w = 2 mm. Not permitted if occurring at a stop or restart.

Wormhole 2016 Same as for elongated cavity, see 2015.

Imperfection ISO 6520-1:1998

ISO 6520-2:1999 reference


Shrinkage cavity 202.00 l = 0,3t, maximum 4 mm; and w = 2 mm. Not permitted if occurring at a stop or restart.

Slag and flux inclusions and oxide inclusions (parallel to the weld axis)

301 302 303

Not permitted if occurring at a stop or restart.

Slag and flux inclusions (random, not parallel to weld axis)

3012 3013 3022 3023

Individual length, maximum 0,3t.

Tungsten inclusions 3041 Same as porosity, see 2011.

Copper inclusions 3042 Not permitted.

Lack of fusion (side, root or inter-run)

401 Not permitted.

Incomplete penetration 402 Not permitted a

the reference numbers in column 2 are for imperfections as illustrated in the diagrams in the ISO 6520, parts 1 and 2

b area = maximum length of weld affected times local width of weld.

DEAS 903: 2016


Table I.2 — Acceptance levels of surface imperfections in welds found by visual

examination and/or NDT methods

Imperfection ISO 6520-1:1998 ISO 6520-2:1999

reference


Cracks and lamellar tears 100 Not permitted.

Slag inclusions (all) Flux inclusions (all) Oxide inclusions (all) Metallic inclusions (all)

301 302 303 304

Not permitted if occurring at the surface (shall be removed e.g. by grinding).

Lack of fusion (side, root or inter-run)

401 Not permitted.

Lack of penetration 402 Not permitted.

Imperfect shape

500 These imperfections are normally accepted or rejected by visual examination and the same acceptance criteria shall be applied. These imperfections can occur on surfaces with not access for visual examination (e.g. internal tubes). In these cases other techniques should be considered as a basis for acceptance.

Undercut 5011 5012

t ≥ 16 mm: h = 0.5 mm long imperfections.

6 mm ≤ t < 16 mm: h = 0.3 mm for long imperfections;

H = 0,5mm for short imperfections. t < 6 mm: h = 0.3 mm for short imperfections.

Local protrusion 5041 Occasional local protrusion exceeding h (see 504) is permitted with a maximum that shall be related to the operating conditions.

Shrinkage groove 5013 Long imperfections: not permitted. Short imperfections: h = 1 mm.

Root concavity 515 A smooth transition is required.

Excessive penetration 504 h = 1 mm + 0.6b, maximum 4 mm.

Excessive convexity 503 h = 1 mm + 0.15b, smooth transition required.

Excess weld metal 502 h = 1 mm + 0.15b, smooth transition required.

Excessive asymmetry of fillet weld

512 h = 2 mm + 0.15a.

Imperfection ISO 6520-1:1998

ISO 6520-2:1999 reference


Irregular surface 514 509 511 513 517

Reinforcement shall be of continuous and regular shape with complete filling of groove.

Overlap 506 Not permitted.

Surface misalignment 507 See Annex F.

Spatter 602 Normally, shall be removed from all pressure parts and from both load carrying/attachment welds. Isolated, non-systematic spatter may be permitted on components made from steel St. 1 (see Table A.1).

DEAS 903: 2016


Arc strike Spatter Tungsten spatter Torn surface Grinding mark Chipping mark

610 602

6021 603 604 605

Grind smooth, accept subject to thickness and crack detection test.

Under flushing 606 Not permitted, any local under flushing shall be related to the design characteristics (calculated thickness = minimum thickness for base material). Thickness shall be measured by ultrasonic method in case of doubt.

NOTE Short imperfections: one or more imperfections of length not greater than 25 mm in any 100 mm length of weld, or a minimum of 25% of the weld length for a weld shorter than 100 mm. Long imperfections: one or more imperfections of total length greater than 25 mm in any 100 mm length of the weld, or a maximum of 25 % for a weld shorter than 100 mm.

Table I.3 — Maximum reinforcement thickness for finished butt welds in plates

Thicker plate thickness mm

Maximum reinforcement thickness mm

B ≤ 12 2.5

B > 12 3

The weld reinforcement shall be weld metal in excess of the quantity required to fill a joint as indicated in the figure below. .

Figure I. 1 — Maximum reinforcement thickness for finished butt welds in plates l.2 Test specimens Table I.4 gives the number of test specimens that shall be produced and tested from each test plate.

DEAS 903: 2016


Table I.4—Test specimens

Steel group

a

Parent metal thickness e

Face bend test

Root bend test

Macro-examination

Impact test: weld deposit

Impact test: heat

affected zone

Longitudinal weld tensile

test

Transverse tensile test

St. 1 ≤ 12 1 1 1 3b 3

b — —

12 — — 1 3 3 — —

St .2 ≤ 12 1 1 1 3b 3

b — —

12 — — — 3 3 1c 1

NOTE Non-destructive testing may be applied on the test plate prior to cutting the test specimens so that they are selected from sound areas. a The grouping system is based on chemical analysis and material properties in relation to manufacture. The groupings are

as defined and shall apply regardless of production form (i.e. plate, forging, piping, etc.). Groupings for typical steels are shown in Annex A. The groupings shall be assessed on the guaranteed properties used in the design. The steel groupings are the groupings normally used in construction of road tanker tanks. b Not required for thicknesses less than 5 mm.

c If difficulty is experienced in obtaining an all weld metal test, a full chemical analysis of the weld metal may be carried out.

DEAS 903: 2016


Annex J (informative)

Choice of non-destructive test methods for welds

J.1 Internal imperfections Radiographic and ultrasonic methods both have advantages and disadvantages in flaw detection, identification and sizing. Radiography is particularly suitable for detection and identification of “volume” imperfections such as cavities and solid inclusions and incomplete penetration where a gap exists. Ultrasonic flaw detection is very suitable for detection and sizing of planar defects such as cracks, lack of fusion and “tight” incomplete penetration in ferritic steels. The two techniques should be regarded as complementary, and the most suitable method for the particular application and material should be chosen in each case. Joint geometry may have an overriding influence on choice of method. If ultrasonic testing is used to determine the length of imperfections such as slag inclusions, sensitive techniques can result in indications of length greatly in excess of indications that would be obtained by radiography. If ultrasonic testing is chosen, care shall be taken to limit the sensitivity to avoid detection of indications within the limits for acceptable imperfections (see Annex I).

J.2 Surface imperfections Magnetic particle and penetrant testing indicate surface imperfections but do not indicate the depth of surface imperfections. These tests should be used to ensure that no unacceptable surface imperfections are present. Other suitable methods may also be required.

DEAS 903: 2016


Annex K (normative)

Hydraulic pressure test

K.1 Temporary fittings Temporary pipes and connections and blanking devices shall be designed to withstand the standard test pressure. Jointing materials for flanged joints shall be the same as used in service.

K.2 Pressure gauges Pressure gauges shall be selected in accordance with EN 837-2. Pressure gauges shall have an accuracy at least equal to 4 % of the reading. The test pressure of the tank shall give a reading on the gauge between 50 % and 90 % of full scale deflection. NOTE Alternative methods of pressure measurement (e.g. by transducer) may be used if they achieve equivalent accuracy.

K.3 Pressurizing agent Water shall normally be used as the pressuring agent. Ensure that the tank is positioned so that entrapped air is vented. NOTE To avoid risk of freezing, the temperature of the water during the test should be not less than 7

oC.

K.4 Avoidance of shock Tanks undergoing pressure testing shall not be subjected to any form of impact or pulsation loading.

K.5 Applied pressure Gradually increase the pressure in the tank to test pressure which shall be maintained for not less than 30 min. There shall be no signs of leakage or yield and no pressure drop when the tank is isolated. On completion of the test, gradually release the pressure. There shall be sufficient venting to ensure that no vacuum is created during draining. After the test the tank shall exhibit no sign of permanent distortion.

DEAS 903: 2016


Annex L (normative)

Name plate

Each tank shall be fitted with a corrosion-resistant metal plate conforming to Table L.1 permanently attached in a place readily accessible for inspection. Markings on the plate shall be stamped or similar. To avoid any linguistic misunderstanding, the lines of the plates shall be numbered as shown in Table L.1. The minimum height of the letters shall be 3 mm. The wording shall be in one of the official languages of the country of registration, and in English for international transport. The content of the name plate shall conform to Table L.2.

Table L.1 — Name plate

Design standard: CD/K/5

1 Manufacturer

2 Approval number

3 Manufacturer’s serial number

4 Year of manufacture

5 Test pressure bar MPa

6 Capacity of the tank (total) litres

7 Design pressure

8 Design temperatures max/min oC

9 Material tank

10 Material protective lining/coating

11 Insulation

12 Maximum allowable working pressure MPa

13 Name(s) of dangerous goods

14 Maximum mass

15 Stamps of expert (initial and periodic inspection)

16 Stamps of expert (intermediate inspection)a

a If required, otherwise shall be omitted.

DEAS 903: 2016


Table L.2— Content of name plate

No Content

1 Manufacturer’s name or mark

2 Approval number given by the competent authority or body designated by this authority

3 Serial or production number issued by the manufacturer

4 Year of manufacture

5 Test pressure (gauge) in bar and/or Mpa. The test pressure marked on the plate shall not exceed the ADR test pressure for the mixtures authorized.

6 Water capacity in litres

7 ADR for tanks in accordance with Annex B, or country name(s) for tanks in accordance with Annex C.

Design pressure in bar and/or Mpa

8 Design temperatures in oC (if above 50

oC or below-20

oC)

9 Materials of the shell and of the ends if different

10 Material of protective lining or coating, if applicable. Brand names may be used if they are in common use.

11 Type of insulation of the tank in words, e.g. “vacuum” or “foam”, if applicable

12 Maximum (allowable) working pressure (gauge) in bar and/or MPa

13 Full names of the LPG mixtures approved for transport in the tank, as applicable. These shall be the technical names used in scientific handbooks, journals and texts. Trade names shall not be used for this purpose

14 Maximum allowable mass of substance given in non.13

15 Month and year of the initial inspection and of each subsequent periodic inspection, and stamp of the expert who carried out the inspection

16 Month and year of intermediate inspection and stamp of the expert who carried out the test

DEAS 903: 2016

© EAC 2016 – All rights reserved

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DEAS 903: 2016


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