Rules For The Certification and Construction

IV
Rules for the Certification and Construction

Industrial Services
Offshore Substations
Structural Design
Edition 2013
The following Rules come into force on 1 October 2013.

Germanischer Lloyd SE
Head Office
Brooktorkai 18, 20457 Hamburg, Germany
Phone: +49 40 36149-0
Fax: +49 40 36149-200
headoffice@gl-group.com
www.gl-group.com
"General Terms and Conditions" of the respective latest edition will be applicable
(see Rules for Classification and Construction, I - Ship Technology, Part 0 - Classification and Surveys).
Reproduction by printing or photostatic means is only permissible with the consent of
Germanischer Lloyd SE.
Published by: Germanischer Lloyd SE, Hamburg
Rules
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Chapter
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Structural Design
Table of Contents
Table of Contents
Section 1
A
B
C
D
E
F
G
H
I
Environmental Conditions
Basic Considerations ........................................................................................................
Wind..................................................................................................................................
Sea Currents .....................................................................................................................
Sea Waves........................................................................................................................
Sea Level ..........................................................................................................................
Tsunamis ..........................................................................................................................
Climatic Conditions, Temperature and Marine Growth.....................................................
Sea Ice and Icebergs ........................................................................................................
Sea Bed ............................................................................................................................
Section 2
A
B
C
D
E
F
G
Design Loads
Basic Considerations ........................................................................................................
Environmental Loads ........................................................................................................
Permanent Loads..............................................................................................................
Functional Loads...............................................................................................................
Accidental Loads...............................................................................................................
Transportation and Installation Loads...............................................................................
Earthquake Loads.............................................................................................................
Section 3
A
B
C
D
E
F
G
H
I
J
2- 1
2- 1
2- 14
2- 14
2- 15
2- 17
2- 18
Principles for Structural Design

General .............................................................................................................................
Design Methods and Criteria ............................................................................................
Loading Conditions ...........................................................................................................
Dynamic Analysis..............................................................................................................
Effective Width of Plating ..................................................................................................
Beam Member Design ......................................................................................................
Tubular Joint Design .........................................................................................................
Buckling of Plates .............................................................................................................
Fatigue Strength ...............................................................................................................
Application of BSH Requirements ....................................................................................
Section 4
A
B
C
D
E
F
G
H
I
J
K
1- 1
1- 3
1- 5
1- 8
1- 15
1- 15
1- 15
1- 16
1- 17
3- 1
3- 2
3- 5
3- 11
3- 13
3- 14
3- 15
3- 18
3- 18
3- 24
Steel Structures
Materials ...........................................................................................................................
Fabrication ........................................................................................................................
Welding .............................................................................................................................
Survey, Inspection and Testing ........................................................................................
Survey and Inspection Scheme ........................................................................................
Non-Destructive Testing ...................................................................................................
Visual Inspection...............................................................................................................
Magnetic Particle Inspection.............................................................................................
Penetrant Testing..............................................................................................................
Radiographic Testing ........................................................................................................
Ultrasonic Testing .............................................................................................................
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4- 39
4- 66
4- 68
4- 69
4- 74
4- 75
4- 77
4- 78
4- 80
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Table of Contents
Section 5
A
B
C
D
Corrosion Protection
General ............................................................................................................................
Material Selection.............................................................................................................
Coating Selection .............................................................................................................
Cathodic Protection..........................................................................................................
Section 6
A
B
C
D
E
Foundations
General ............................................................................................................................
Geotechnical Investigations .............................................................................................
General Design Considerations .......................................................................................
Steel Pile Foundations .....................................................................................................
Shallow Foundations........................................................................................................
Section 7
A
General ............................................................................................................................
Structure of the Helicopter Deck ......................................................................................
7- 1
8- 1
8- 2
Marine Operations
General ............................................................................................................................
Standards and Guidelines................................................................................................
Lifting Operations .............................................................................................................
Section 10
A
B
C
D
E
F
G
H
I
1
1
2
4
8
Helicopter Deck Structures
Section 9
A
B
C
66666-
Crane and Crane Support Structures

Cranes..............................................................................................................................
Section 8
A
B
5- 1
5- 6
5- 11
5- 14
Containers
Scope ...............................................................................................................................
Certification for Offshore Service Containers ..................................................................
Structural Parts ................................................................................................................
Materials and Production .................................................................................................
Electrical Requirements ...................................................................................................
Heating, Ventilation and Air Conditioning ........................................................................
Public Address and Main Alarm Systems ........................................................................
Portable Offshore Unit .....................................................................................................
Certification Procedure ....................................................................................................
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9- 2
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10- 2
10- 6
10- 7
10- 8
10- 10
10- 10
10- 11
10- 12
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Section 1
A
B
C
D
E
F
G
H
I
Basic Considerations ....................................................................................................

Wind ..............................................................................................................................
Sea Currents .................................................................................................................
Sea Waves ....................................................................................................................
Sea Level ......................................................................................................................
Tsunamis ......................................................................................................................
Climatic Conditions, Temperature and Marine Growth .................................................
Sea Ice and Icebergs ....................................................................................................
Sea Bed ........................................................................................................................
1- 1
1- 3
1- 5
1- 8
1- 15
1- 15
1- 15
1- 16
1- 17
Basic Considerations
Environmental conditions give rise to loads imposed on the structure by natural phenomena including
wind, current, waves, earthquake, snow, ice, and earth movement. Environmental loads also include the
variation in hydrostatic pressure and buoyancy on structural components caused by changes in the water
level due to waves and tides. Environmental loads shall be anticipated from any direction unless knowledge of specific conditions makes a different assumption more reasonable.
The unit/installation shall be designed for the appropriate loading conditions that will produce the most
severe effects on the structure. Environmental loads, with the exception of earthquake load, shall be
combined in a manner consistent with the probability of their simultaneous occurrence.
A.1
Determination
Pertinent meteorological and oceanographic conditions affecting a unit/installations operating site shall
be defined. The corresponding environmental design data should be prepared to develop the descriptions
of normal and extreme environmental conditions. Environmental conditions may be determined by wind,
sea currents, sea waves, sea level, climatic conditions, temperature and fouling, sea ice, sea bed conditions, and other influences as applicable.
A.2
Normal environmental design conditions
Normal environmental conditions are those conditions that are expected to occur frequently during the life
of the unit. Normal environmental conditions, important both during the construction and the service life of
a unit/installation, consider the most adverse possible effect during the erection and the operation of the
unit/installation.
A.3
Extreme environmental design conditions
A.3.1
Extreme environmental conditions occur rarely during the life of the unit/installation. Extreme
design conditions are important in formulating design loads for the unit when out of operation, while resting on its site with all equipment secured in a seaworthy condition. Design loads may be specified on the
basis of statistical observations if available. Probabilistic estimations, if not specified in the Rules, are to
be approved by Germanischer Lloyd.
A.3.2
Fixed offshore installations shall be designed to meet limiting environmental conditions valid
for the designated operating area.
A.3.3
Mobile offshore units shall be designed and operated to meet limiting environmental conditions
as specified in the operating manual.
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Estimation of design parameters
Estimation of design parameters on the basis of environmental design conditions, e.g., estimation of wave
particle velocity or acceleration on the basis of wave height and period, if not carried out as specified in
the Rules, is to be approved by Germanischer Lloyd.
A.5
Superposition of parameters
Superposition of different environmental design parameters is to be based on physical relations or on

stochastic correlations between these parameters or between the environmental phenomena to which
they belong.
A.6
Simplifying assumptions
Simplifying assumptions in these Rules are made in accordance with the specification of related safety
factors for structural design. If estimates of environmental design parameters are based on assumptions
that are more appropriate for the design case than those specified in the Rules, a reduction of the safety
factor may be approved by Germanischer Lloyd, see also Section 3, C.
A.7
General definitions
In the following paragraphs the general designations used are (see also Fig. 1.1):
x
: horizontal coordinate axis in the direction of the wave propagation [m]
: vertical coordinate axis above still water level [m]
: water depth [m]
: wave height, crest to trough [m]
: wave period [s]
: wave length [m]

z
still water line
seabed
Fig. 1.1
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Wind
Although wind loads are dynamic in nature, offshore structures respond to them in a nearly static fashion.
However, a dynamic analysis of the unit/installation is indicated when the wind field contains energy at
frequencies near the natural frequencies of the unit/installation (be it fixed or moored to the ocean bottom). Sustained wind speeds should be used to determine global loads acting on the unit/installation, and
gust speeds should be used for the design of individual structural elements.
B.1
Wind properties
Wind speed changes with both time and height above sea level. Therefore, the averaging time and height
shall be specified. Common reference times are one minute, ten minutes, or one hour. The common reference height is ten (10) meters. Wind forces should be computed using the one (1) minute mean wind
speed, and appropriate formulas and coefficients may be derived from applicable wind tunnel tests.
B.2
Mean wind speed
The mean wind speed at the reference height of 10 m, averaged over time t, may be estimated by the
formula
u10(t) = Ct u10(tr)
where
u10(t)
: mean wind speed at a reference height of 10 m [m/s]
Ct
: wind speed averaging time factor

: [1 0.047 ln (t / tr)]
u10(tr)
: mean wind speed at a reference height of 10 m for the reference averaging time [m/s]
: averaging time [minutes]
tr
: reference averaging time

: 10 [minutes]
Wind speed averaging time factors Ct for selected averaging times t are given in Table 1.1:
Table 1.1
Wind speed averaging time factors Ct related to reference time tr = 10min
Averaging time t
Ct
3 seconds
1.249
5 seconds
1.225
15 seconds
1.173
1 minute
1.108
10 minutes
1.000
1 hour
0.916
B.3
Minimum wind speed for stability calculations of mobile offshore units
For the requirements for stability calculations of mobile offshore units please refer to GL Rules for Mobile
Offshore Units (IV-6-2), Section 7, B.4.
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Sustained wind speed
The greatest one (1) minute mean wind speed, expected to occur over a return period of 100 years and
related to a reference level of 10 m above sea level, is generally referred to as the sustained wind speed,
uS. This sustained wind speed is to be used for the determination of global loads.
B.5
Gust wind speed
The greatest three (3) second mean wind speed, expected to occur over a return period of 100 years, is
referred to as the gust wind speed, uG. This gust wind speed is to be used for the determination of local
loads. The gust wind speed is related to the sustained wind speed as follows:
uG = 1.137 uS
The gust wind component may be considered as a zero mean random wind component which, when superimposed on the constant, average wind component yields the short-term wind speed.
The wind in a 3 second gust is appropriate to determine the maximum static wind load on individual
members; 5 second gusts are appropriate for maximum total loads on structures whose maximum horizontal dimension is less than 50 m; and 15 second gusts are appropriate for the maximum total static
wind load on larger structures. The one minute sustained wind is appropriate for total static superstructure
wind loads associated with maximum wave forces for structures.
B.6
Design wind speeds
A design value of wind speed at height z above still-water level may be calculated according to the following formula:
1
z 10
u(z, t) = u10 (t)
[m / s]
10m
where
u10(t)
: mean wind speed, averaged over time t for the reference height of 10 m see(3.) [m/s]
: vertical coordinate axis above mean still water level [m]
u(z,t)
u10(t)
10 m
still water line

x
Fig. 1.2
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Statistics of wind speed
The Weibull distribution may be used to describe the statistical behavior of the average wind speed
u(z,t).
Sea Currents
C.1
Sea currents are characterized as:
near-surface currents, i.e., wind/wave generated currents, see C.2

sub-surface currents, i.e., tidal currents and thermosaline currents, see C.3
near-shore currents, i.e., wave induced surf currents, see C.4
C.2
Near-surface currents
Near-surface currents are typically wind induced.

For near-surface currents, the design velocity may be estimated as follows (see Fig. 1.3):
uw(z) = k(z) uS
where
uw(z)
: near surface current velocity [m/s]
k(z)
: factor depending linearly on the vertical coordinate z

: 0.01
for z = 0 m
: 0
for z 15 m
: to be obtained by linear interpolation for 0 > z > 15 m

z
: vertical coordinate axis above mean sea level [m]
uS
: sustained wind speed used for design [m/s]

: one (1) minute mean at z = 10 m as defined under B.5 [m/s]
C.3
Sub-surface currents
For sub-surface currents the design velocity is to be based on the current velocity at sea level (z = 0),
which shall be based on observed values provided by competent institutions. The data are subject to
approval by Germanischer Lloyd. The vertical velocity distribution for 0 z d may be determined as
follows (see Fig. 1.3):
uSS(z) = [(z + d) / d] 1/7 uS0
where
uSS(z)
: sub-surface current velocity [m/s]
: water depth [m]
: vertical coordinate axis [m]
uS0
: current velocity at sea level [m/s]
Linear superposition of uSS(z) and uw(z) is applicable.
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z
sub-surface
x
near-surface
uS0
0.01uS
15 m
uw(z)
d
uSS(z)
seabed
Fig. 1.3
C.4
Current profiles
Near-shore currents
For near-shore currents, which have a direction parallel to the shore line, the design velocity at the location of breaking waves may be estimated as follows:
u nS = 2 s g H B
where
unS
: near-shore current velocity [m/s]
: beach slope
: tan
: inclination of beach
: 9.81 m/s2
HB
: breaking wave height [m]

: b / [1 / dB + a / (g TB2)]
: 44 [1 exp(19 s)]
: 1.6 / [1 + exp(19 s)]
dB
: water depth at the location of the breaking wave [m]
TB
: period of the breaking wave [s]
For very small beach slopes, HB may be estimated from
HB = 0.8 dB [m]
C.5
Combined wave and current kinematics
Wave kinematics, adjusted for directional spreading and irregularity, should be combined vectorial with
the current profile, adjusted for blockage.
C.5.1
Wave kinematics
C.5.1.1
Jackets
For deterministic/regular wave load calculations on jackets a directional spreading factor of 0.95 down
to 0.87 can be applied on wave horizontal particle velocities and accelerations. Guidelines can be found
in ISO 19901-1. The applied factor shall be agreed upon case by case early in the design phase.
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C.5.1.2
Jack-ups
For deterministic/regular wave load calculations on jack-ups a kinematic reduction factor of 0.86 on max.
wave height HD can be applied. This factor considers wave spreading and the irregular nature of the Sea.
No further reduction on wave particle velocities or accelerations is permitted.
For stochastic or random time-domain analysis a wave kinematics factor according to C.5.1.1 can be
applied.
C.5.2
Current blockage
For structures that are more or less transparent, the current velocity in the vicinity of a structure is reduced by blockage. The presence of the structure causes the incident flow to diverge, with some of the
incident flow going around the structure rather than through it.
The degree of blockage depends on the kind of structure. For dense fixed space frame structures it will
be large, while for some kinds of transparent floaters it will be small. Approximate current blockage factors for typical jacket-type structures are given in Table 1.2.
For structures with other configurations, a current factor can be calculated according to C.2.3.1 b4 of API
RP 2A-WSD. Factors less than 0.7 should not be used unless empirical evidence supports them.
Current blockage for lattice legs of self-elevating units can be considered according to SNAME, Rev. 3,
C4.5.3 by formula (4.5.2).
Table 1.2
Current blockage factors
Number of
legs
Current
heading
Blockage
factor
All
0.90
End-on
0.80
Diagonal
0.85
Broadside
0.80
End-on
0.75
Diagonal
0.85
Broadside
0.80
End-on
0.70
Diagonal
0.85
Broadside
0.80
C.5.3
Stretching of current profile and linear wave kinematics
As the current profile is specified only to storm mean water level, it shall be stretched or compressed to
the local wave elevation. For slab current profiles, simple vertical extension of the current profile from
storm mean water level to the wave elevation is acceptable. For other current profiles, linear stretching is
acceptable. In linear stretching (Wheeler), the current at a point with elevation z, above which the wave
surface elevation is , is obtained from the specified current profile at elevation z.
The elevations z and z are related as follows:
(z + z ') =
(z + z ') d
(d + )
where d is the water depth. Points z and are both positive above and negative below storm mean water
level.
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In case linear wave theory is applied the wave particle velocity and acceleration needs also to be
stretched to the instantaneous free surface elevation. Wheeler stretching (see above) or delta stretching
(see ISO 19901-1) can be used.
For the calculation of wave kinematics the intrinsic wave period (or frequency) should be applied. The
intrinsic wave period is based on a reference coordinate system that travels with the current speed in its
direction. Please refer to ISO 19901-1.
Sea Waves
D.1
Design criteria
The design environmental criteria shall be developed from the environmental information. These criteria
may be based on risk analysis where prior experience is limited. For new and relocated structures that
are manned during the design event, or where the loss of or severe damage to the structure could result
in severe damage, a 100-year recurrence interval should be used for oceanographic design criteria. Consideration may be given to reduced design requirements for the design or relocation of other structures
that are unmanned or evacuated during the design event, that have either a shorter design life than the
typical 20 years, or where the loss of or severe damage to the structure would not result in a high consequence of failure.
D.2
Design conditions
Two alternative methods may be used to specify design conditions for sea waves, namely, the deterministic method based on the use of an equivalent design wave or the stochastic method based on the application of wave spectra.
The deterministic method describes the seaway as regular periodic waves, characterized by wave period
(or wave length), wave height, wave direction, and possible shape parameters.
The deterministic wave parameters may be based on statistical methods.
D.3
Two-dimensional wave kinematics of regular waves
Analytical or numerical wave theories may describe the wave kinematics. For a specified wave period T,
wave height H, and water depth d, two-dimensional regular wave kinematics can be calculated using appropriate wave theory. The following theories are mentioned:
linear (Airy) wave theory, where a sine function describes the wave profile
Stokes 5th order wave theory, appropriate for high waves
stream function theory, where wave kinematics are accurately described over a broad range of water depths
solitary wave theory for shallow waters
Other wave theories, such as Chappelear, may be used, provided an adequate order of the solution is
selected.
In the (H/gT2, d/gT2) plane, regions of applicability of various theories are shown in Fig. 1.4 as functions of
wave period T, wave height H, and storm water depth d (g = acceleration of gravity).
D.3.1
Equivalent design wave
Wave loads on a platform are dynamic in nature. For most design water depths presently encountered,
these loads may be adequately represented by their static equivalents. For deeper waters or where platforms tend to be more flexible, a load analysis involving the dynamic action of the structure is required.
D.3.2
Design wave period and design wave height
The design wave period TD, is associated with the highest wave. In any given storm, there is only one
maximum wave, and the associated period is the most probable period of the maximum wave. For this
reason it is common to give a range of wave periods for TD that are independent of the peak period Tp.
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The peak period is the value associated with the peak of the wave spectrum. A range of design wave
periods is specified as follows:
3.5 H1/3 < TD < 4.5 H1/3
where
TD
: design wave period [s]
H1/3
: significant wave height [m]
HD
: design wave height [m]
The design wave period TD shall not exceed 25 s.

The design wave height HD, may be estimated with the following relations:
TD
HD / H1/3
09s
10 15 s
16 25 s
1.86
1.95
2.23
This method generally applies to deep water waves, i.e. waves of periods T that satisfy the following condition:
d / g T 2 > 0.06
where
: water depth [m]
Design wave parameters for wind-induced transitional water waves, i.e. water waves of periods T that
satisfy the condition
0.002 < d / g T 2 < 0.06

may be defined from information on extreme wind speed and fetch, using relevant theories subject to
approval by Germanischer Lloyd.
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Deep Water
Breaking Limit
H/L = 0.14
0.02
Hb
0.01
0.005
H
gT2
0.002
Stokes 5th order

or Stream Function 3
Shallow Water
Breaking Limit
H/d = 0.78
0.001
>11 11
9
7 5
0.0005
Linear/Airy
or Stream Function 3
Stream Function
0.0002
0.0001
Shallow
Water Waves
0.00005
0.001
Deep
Water
Waves
Intermediate Depth Waves
0.002
0.005
0.01
0.02
0.05
0.1
0.2
d
gT2
H/gT2 :
d/gT2 :
H:
Hb :
n :
Dimensionless wave steepness

d : Mean water depth
T : Wave period
Dimensionless wave depth
g : Acceleration of gravity
Wave height
L : Wave length
Breaking wave height
Minimum order of solutions for stream function theory
Fig. 1.4
D.4
Regions of applicability of wave theories
Short-term wave conditions
The principal natural sea state parameters are as follows:

The significant wave height H1/3 is defined as the average of the one-third highest wave heights in a
record of stationary sea surface elevations.
The characteristic wave period T1 is defined as the mean wave period in a record of stationary sea
surface elevations.
The visually observed wave height Hv and the visually observed wave period Tv may be considered approximately equal to H1/3 and T1, respectively.
Short-term stationary natural sea states may be described by a wave spectrum, i.e. by the power spectral
density function of the vertical sea surface elevation. Short-term wave conditions are defined as seaways
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whose representative spectrum does not change for a brief but not closely specified duration. Wave spectra may be given in tabular form, as measured data, or in analytic form.
The two parameter modified Pierson-Moskowitz spectrum and the JONSWAP spectrum are most frequently applied. Both spectra describe sea conditions relevant for the most severe sea states. Application
of other wave spectrum formulations is to be approved by Germanischer Lloyd.
D.4.1
Spectral density
The following expression describes the wave energy spectral density:

2
H1/3
S() = f ( )
4p
5
5
p
exp
4
( p ) 2
4 exp
2 2
2 p
where
S()
: spectral density [m2s]
: circular wave frequency [s1]

: 2/T
: wave period [s]
f()
0.0624
0.23 + 0.0336
0.185
1.9 +
: peakedness parameter (see D.4.4)
: circular spectral peak frequency [s-1]

: 2/Tp
: modal period or peak period [s]
Tp
: period at which the spectrum is a maximum
: spectral shape parameter (see D.4.4)
D.4.2
Spectral moments
The spectral moments, mn, of order n are defined as follows:
m n ( ) = S ( ) d
0
for n = 0, 1, 2,
where
S()
: wave energy spectral density [m2s], see D.4.1
The following quantities may be defined in terms of the spectral moments:

Significant wave height:
H1/3 = 4 m 0
[m]
Mean wave period (center of gravity of the wave spectrum):

T1 = 2
m0
m1
[s]
Zero-up-crossing period (average period between successive up- crossings):

Tz = 2
m0
m2
[s]
Crest period (average period between successive wave crests):

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TC = 2
m2
m4
[s]
Significant wave slope:

s=
D.4.3
m
2
2
g m0
Spectral density and moments in terms of wave frequency
The wave spectral density may also be given in terms of wave frequency f in [Hz]. The relationship is
S(f ) = 2 S()
The moments of the wave energy spectral density may also be given in terms of the wave frequency f
[Hz]. The relationship is
m n (f ) = 0 f n S(f ) df = (2) n m n
D.4.4
Wave spectra
D.4.4.1
The Pierson-Moskowitz spectrum
The parameters for the spectral density of the Pierson-Moskowitz spectrum are defined as follows:
: peakedness parameter
: 1.0 for a mean spectrum
: spectral shape parameter is not defined as it is not relevant if = 1.0
D.4.4.2
The JONSWAP spectrum
The JONSWAP spectrum is also frequently applied. In addition to the significant wave height H1/3 parameters are needed to describe the spectral shape, namely, the peakedness parameter and the spectral shape parameter :
: peakedness parameter
: 3.30 for a mean spectrum
: spectral shape parameter

: 0.07 if 2/Tp
: 0.09 if 2/Tp
D.4.5
Wave spreading and short-crested sea states
The wave spectra given above are uni-directional. However, real waves travel in many different directions. Directional short-crested wave spectra may be derived from a uni-directional wave spectrum as
follows:
S(, ) = S(). W ()
where
S(,)
: directional short-crested wave energy spectral density
: angle between direction of elementary wave trains and primary wave direction
W()
: directionality function
: const coss
The value of the power constant s shall reflect an accurate correlation to the actual sea state. For typically
occurring conditions in the open ocean s = 2 is appropriate.
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For design purposes it is usual to assume that the secondary wave directions are spread over 90 < <
+ 90. Energy conservation requires that the directionality function fulfils the requirement
max
min
D.4.6
W () = 1
Wave period relationships
The following wave periods are in use:
Tp
is the period at which the spectrum is a maximum (modal period or peak period)
Tz
is the average period between successive up- crossings (Zero-up-crossing period)
T1/3
is the average period of the 1/3 highest wave periods
Tmax
is the associated period of the wave with maximum height
D.4.6.1
For the Pierson-Moskowitz spectrum, wave periods are related to each other as follows:
Tp
: 1.40 Tz
T1
: 0.77 Tp
T1/3
: 0.88 Tp
Tmax
: 1.04 Tp
D.4.6.2
For the JONSWAP spectrum, wave periods are related to each other as follows:
Tp
: 1.28 Tz
T1
: 0.83 Tp
D.5
Response in natural seas
D.5.1
Response from different wave components
A useful consequence of linearly predicted response is that results from regular waves of different amplitudes, wave lengths and propagation directions can be superimposed to obtain the response in natural
seaways made up of a large number N of regular waves of different length and height. Thus, the response R from different wave components can be written as
N
R=
an
H( n ) sin [ n t + ( n ) + n ]
n =1
where
H(n)
: response amplitude per unit wave amplitude (transfer function)
(n)
: a phase angle associated with the response
BothH(n)and (n) are functions of the frequency of oscillation n. The response can be any linear
wave-induced motion of or load on the structure.
D.5.2
Variance of the response
In the limit, as N approaches infinity, the variance of the response, r, is found as follows:
2r = S() H 2 () d
0
The Rayleigh probability function may be used to approximate the probability density function for the
maxima (peak values) of the response, p(R):
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p(R) =
D.5.3
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R
2r
exp (0.5 R 2 / 2r )
Most probable largest value during a short-term seastate
During a short-term seastate of significant wave height H1/3 and mean wave period of the sea spectrum
T1 the most probable largest value Rmax over time t is then
R max = 2 2r ln(t/T1 )
Strictly speaking, the mean period of the response variable should be used instead of the average mean
wave period T1. However, for linear wave-induced motions and loads the difference when estimating Rmax
is small and can be neglected.
D.5.4
Long-term probability of the response
Short-term response predictions are sometimes considered inadequate for the design and reliability
analysis of offshore structures, because the assumption of stationarity (of a statistically invariant record)
restricts the validity of the analysis. A long-term probability defines events and extreme value statistics for
a period on the order of 20 to 100 years, as opposed to a few hours for the short-term probability.
The long-term prediction considers all sea states the structure is expected to encounter during its design
lifetime. This may be accomplished in the form of the frequency of occurrences of all possible sea states
or the long-term wave data over the entire life of the structure, i.e. in the form of a wave scatter diagram
that conveniently describes a family of sea states, each characterized by the wave spectrum parameters
(H1/3, T1) or (H1/3, T1, ) as defined in D.4.1 and D.4.2, respectively.
The long-term method provides a rational criterion of acceptability in the form of a uniform likelihood that
a given response level will be exceeded during the lifetime of the structure.
The long-term prediction can be performed in the frequency domain for a linear system or in the time
domain for a nonlinear system.
Combining the Rayleigh distribution and a joint probability (H1/3, T1) from a wave scatter diagram listing M
significant wave height intervals and K spectral peak periods yields the long-term probability of the response:
M K
R2
P(R) = 1 exp
2 2rjk
j=1 k =1
p jk
where
: number of significant wave height intervals
: number of spectral peak periods listed in the wave scatter diagram
P(R)
: long-term probability that the peak value of the response does not exceed R
rjk
: standard deviation of the response in the seastate (H1/3, T1) of interval j and mean period k
pjk
: probability of occurrence of seastate (H1/3, T1) of interval numbers j and k
D.6
Derived wave parameters
Derived wave parameters, such as wave particle velocities and accelerations, may be used to determine
drag and inertial forces on underwater portions of offshore drilling units or structures that are operating or
situated in locations where the water depth is considered deep. Subject to approval by Germanischer
Lloyd, other appropriate methods to determine these forces will be considered, provided they are referenced and supported by calculations
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Sea Level
E.1
The highest still water level to be used for design is defined by the water depth d at the highest
astronomical tide plus the water level elevations due to storm surge.
E.2
The smallest still water level to be used for design is defined by the smaller value of either the
water depth d due to the lowest astronomical tide minus the water level decline due to storm surge or the
chart datum, whichever is applicable.
The highest wave elevation above still water level * defined in E.1. or E.2. is given as
E.3
* = HD [m]
where
HD
: wave height (see D.3.2) [m]
: wave elevation coefficient
The wave elevation coefficient is a function of the wave period TD (see D.3.2) and the water depth d as
given in Table 1.3.
Wave elevation coefficient
Table 1.3
d/(gTD2)
HD/(gTD2)
0.02
0.01
0.005
0.001 0.0005 0.0001
0.2
0.60
0.55
0.50
0.50
0.50
0.50
0.02
0.68
0.58
0.52
0.50
0.50
0.002
0.87
0.80
0.68
E.4
Water depth and statistical wave data shall be provided by a competent Authority. The application of the data is subject to approval by Germanischer Lloyd.
Tsunamis
Tsunamis are generated by large and sometimes distant earthquakes or undersea fault movements or by
large sea floor slides triggered by earthquakes or by volcanic eruptions. Traveling through deep water,
tsunamis are long surface waves with low height and pose little hazard to floating or fixed offshore structures. When they reach shallow water, the wave form pushes upward from the bottom to make a rise and
fall of water that can break in shallow water and wash inland with great power. Tsunamis travel great
distances very quickly and can affect regions not normally associated with such events. The likelihood of
tsunamis affecting the location of the structure shall be considered.
The greatest hazard to offshore structures results from inflow and outflow of water in the form of waves
and currents. These waves can be significant in shallow water, causing substantial actions on structures.
Currents caused by the inflow and outflow of water can cause excessive scour problems.
Climatic Conditions, Temperature and Marine Growth
G.1
Design temperature
G.1.1
Estimates of design temperatures of air and water shall be based on relevant data that are
provided by competent institutions. Preferably, 1 percent and 99 percent fractiles shall be used as lowest
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and highest design temperatures, respectively. Least square fits of the data may be used to obtain a stochastic model.
G.1.2
If design air temperatures are less than 0 C, the amount of snow and rain turning to ice on
exposed surfaces is to be specified.
G.1.3
If design air temperatures are less than -2 C, the amount of ice accretion on free surfaces,
e.g., lattice structures, as result of seawater spray is to be specified.
G.2
Other environmental factors
Depending on circumstances, other environmental factors can effect operations and can consequently
influence the design of structures. Appropriate data shall be compiled, including, where appropriate, records and or predictions of
precipitation
humidity
fog
wind chill
salinity of sea water
oxygen content of sea water
G.3
Marine growth
G.3.1
The thickness and kind of marine growth depends on location, age of structure, and the maintenance regime. Experience in one area of the world cannot necessarily be applied to another. Sitespecific studies shall be conducted where necessary to establish the likely thickness and the water depth
dependence of marine growth.
G.3.2
The influence of marine growth on hydrodynamic actions is caused by increased dimensions
and increased drag coefficients of rough surfaces. Components with circular cross sections shall be
classed as either smooth or rough, depending on the thickness and kind of marine growth expected to
accumulate on them.
Structural components can be considered hydrodynamically smooth if they are either above the highest
still-water level or sufficiently deep, such that marine growth is sparse enough to ignore the effect of
roughness. Site-specific data should be used to establish the extent of the hydrodynamically rough zones.
Sea Ice and Icebergs
H.1
lished.
The probability of occurrence of sea ice and icebergs in the operating area shall be estab-
H.2
If seasonal sea ice is probable in the operating area, the modes of occurrence and the mechanical properties of the ice shall be determined by a competent Authority upon agreement with Germanischer Lloyd.
H.3
If permanent sea ice is probable in the operating area, thickness and extension as well as
mechanical properties and drifting characteristics shall be determined by a competent Authority upon
agreement with Germanischer Lloyd.
H.4
This data shall be used to determine design characteristics of the installation as well as possible evacuation procedures.
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Sea Bed
I.1
Structures founded on the sea bed may be affected by gradual or transient changes of the sea
bed. These changes shall be accounted for because they influence the validity of design parameters
(compare E) and affect the structural integrity.
I.2
Sea bed stability
As outlined in Section 6, it will have to be determined whether, owing to topography and soil configuration, the possibility of slope failure or slides, cavity failure, or erosion phenomena have to be considered.
Settlement and soil liquefaction generally have to be taken into account for gravity foundations.
I.3
Seismic activities
Where seismic activity is to be expected, two different earthquake levels have to be distinguished:
A strength level earthquake (SLE) represents a level not unlikely to happen in the region of the
planned installation. For this level the strength of the structure is used up to the minimum nominal
upper yield stress ReH, but the main functions of the offshore installation can still be fulfilled and, after a sufficient checking operation, can be continued.
A ductility level earthquake (DLE) represents an extreme level that normally puts the offshore installation out of operation, but still allows the main elements of the installation to keep their position, and
the structure is thus able to survive. This should make it possible for the crew to save themselves or
to be evacuated and should avoid extreme damage of the installation and to the environment.
The characteristics of these two earthquake levels (acceleration intensity, duration) shall be established
by a competent Authority and agreed upon with Germanischer Lloyd, compare Section 2, G and Section
3, C.
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Design Loads
Section 2
A
B
C
D
E
F
G
Design Loads
Basic Considerations .................................................................................................. 2-1

Environmental Loads .................................................................................................. 2-1
Permanent Loads...................................................................................................... 2-14
Functional Loads....................................................................................................... 2-14
Accidental Loads....................................................................................................... 2-15
Transportation and Installation Loads....................................................................... 2-17
Earthquake Loads..................................................................................................... 2-18
Basic Considerations
A.1.1
Design loads for marine structures include environmental loads, permanent loads, functional
loads, and accidental loads.
A.1.2
Loads, or load effects such as stresses, may result from direct action (imposed forces) or indirect action (imposed or constrained deformations, such as settling or temperature gradients). Loads of the
latter category are usually termed deformation loads.
In the context of these Rules (Loading Conditions, Section 3, C), such loads may generally be grouped
into one of the categories listed in A.1.1.
A.2
analysis.
These Rules specify - explicitly or implicitly - nominal or design loads to be used in structural
A.3
Design values of permanent loads shall be vectorially added to the design values of other
loads as listed in A.1.1.
Environmental Loads
B.1
Environmental loads include all loads attributable to environmental conditions as specified in
Section 1:
wind loads, see B.2.
sea current loads, see B.3
wave loads, see B.5
vibratory loads caused by vortex shedding, see B.6
loads caused by climatic conditions, see B.7
loads caused by sea ice, see B.8
mooring loads, see D.2
Other environmental loads, such as loads caused by sea bed movements, earthquakes, etc., as applicable.
B.2
Wind loads
B.2.1
Wind pressure
A design value of wind pressure on structural elements at height z above still-water level may be calculated according to the following formula:
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q = u2 CS
where
q
: wind pressure [kPa]
: design wind speed at the height z, averaged over time t [m/s]

: u(z,t), see Section 1, B.2 and Section 1, B.6
: density of air
: 0.001224 for dry air [kN s2/m4]
: coordinate for height above sea level [m]
CS
: shape coefficient from Table 2.1
In the absence of data indicating otherwise, the following shape coefficients (CS) are recommended for
perpendicular wind approach angles with respect to each projected area.
Table 2.1
Wind pressure shape coefficients CS

Shape
CS
Spherical shapes
0.4
Cylindrical shapes (all sizes)
0.5
Large flat surfaces (hull, deckhouses, smooth

deck areas)
1.0
Drilling derrick
1.25
Wires
1.2
Exposed beams and girders under deck
1.3
Small parts
1.4
Isolated shapes (cranes, beams, etc.)
1.5
Clustered deckhouses and similar structures
1.1
Shape coefficients for shapes or combination of shapes that do not readily fall into the specified categories are subject to special consideration or may be provided by competent institutions. These values are
to be approved by Germanischer Lloyd.
In calculating the wind overturning moment for fixed platforms and jack-up rigs in elevated mode, the
lever for the wind overturning force is to be taken vertically from the seabed to the centre of pressure of
all wind exposed surfaces.
In calculating the wind overturning (heeling) moment for mobile offshore units, the lever for the wind overturning force is to be taken vertically from the centre of lateral resistance of the underwater body of the
unit to the centre of pressure of all wind exposed surfaces. (The unit shall be assumed floating free of
mooring restraints.)
Wind heeling moments derived from wind tunnel tests on a representative scale model of the structure
may be considered as alternatives. The determination of such heeling moments shall include lift and drag
effects.
B.2.2
Shielding
Shielding may be considered when the object lies close enough behind another object. In such a case,
shielding factors listed in Table 2.2 may be used.
B.2.3
Wind force
The design wind load may be calculated according to the following formula:
F = qA
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where
F
: wind force [kN]
: wind pressure [kPa]
: wind projected area of all exposed surfaces in either upright or heeled condition [m2]
The exposed surfaces are to be taken in either the upright or heeled condition.
The wind load calculation for stability calculations for floating units is to be done according to GL Rules for
Mobile Offshore Units (IV-6-2), Section 7, Table 7.2
B.2.4
Wind force directions
Wind forces shall be considered from any direction relative to the structure.
The wind direction shall generally be assumed to be identical with the dominant direction of wave propagation.
B.2.5
Recommendations
For units with columns, the projected areas of all columns are to be included without shielding.
Areas exposed because of heel, such as underdecks, are to be included using the appropriate
shape coefficients.
Cranes, isolated houses, structural shapes, etc., are to be calculated individually, using the appropriate shape coefficients of Table 2.1.
Open truss structural components, such as lattice structures, derrick towers, crane booms, and certain kinds of masts may be approximated by taking 60 % of the projected area of one side, using the
shape coefficient of 1.25.
B.2.6
Design wind loads on the whole structure may be estimated by superposition of all design
wind loads on individual structural elements, or by wind tunnel tests with a model of the entire structure.
B.3
Sea current loads
B.3.1
Where current is acting alone (i.e., no waves), a design value of sea current pressure on structural elements at depth z below the still-water level is defined as follows:
qD(z) = uD2 (z)
for 0 z d
where
qD(z)
: sea current pressure [kPa]
uD(z)
: design sea current speed [m/s]
uD(z) is either uW(z), uSS(z) or unS(z), as defined in Section 1, C.2, C.3 or C.4, or a superposition of these
values, as applicable.
: density of seawater
: 1.025 [kN s2/m4]
: coordinate for height above sea level [m]
: depth from still-water to bottom [m]
B.3.2
Using qD(z) as defined above, design sea current loads F(z) may be calculated according to
the following formula:
F = qD(z) A
where
F
: current force [kN]
qD(z)
: current pressure [kPa]
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: current projected area [m2]
Values of the current projected area A may need to be corrected for effects of marine growth, as applicable, compare Section 1, F.3
B.3.3
Consideration shall be given to the possible superposition of current and waves. In those
cases where this superposition is deemed necessary, the current velocity shall be added vectorially to the
wave particle velocity. The resultant velocity is to be used to compute the total force.
B.4
Conductor shielding
The hydrodynamic forces on conductor arrays can be reduced by applying a conductor shielding factor
KS.
The shielding depends on the spacing of the conductors and the amplitude of oscillation.
A shielding factor for the steady flow or oscillating flow with high amplitudes KSS can be estimated according to Table 2.2, in which:
S
: center-to-center spacing of the conductors in the current direction [m]
: diameter of the conductors, including marine growth [m]
Table 2.2
Shielding factor KSS

S/D
KSS
2.00
0.50
4.00 and larger
1.00
For other values of S/D, linear interpolation may be applied.

The shielding factor KS can be calculated as follows:
: KSS KA
KS
where
: factor for adjusting the amplitude of oscillatory flow according to Table 2.3.
KA
Table 2.3
Adjustment factor KA
Amp/S
KSS
2.5
Amp
0.5
< 2.5
S
1
1 Amp
1
2.5 + 1
2 KSS S
1
K SS
< 0.5
Amp
: Amplitude of oscillation
:
U m0 Ti
[m]
2
Um0
: max. wave induced orbital velocity [m/s]
Ti
: intrinsic wave period [s], please refer to Section 1, C.5.3
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B.5
Wave loads
B.5.1
General
B.5.1.1
The design wave criteria have to be specified by the Owner / Designer. A design value of
wave load on a structural element (local wave load) or on the entire structure (global wave load) may be
estimated by either using a design wave method, as outlined in B.5.2 to B.5.6, or a spectral method, as
outlined in B.5.7.
B.5.1.2
Consideration is to be given to waves of less than maximum height where, due to their period,
the effects on various structural elements may be greater.
B.5.1.3
Forces caused by the action of waves on the installation/unit are to be taken into account in
the structural design, with regard to forces produced directly on the immersed elements and forces resulting from heeled positions or accelerations due to motions. Theories used to calculate wave forces and to
select relevant force coefficients are to be acceptable to Germanischer Lloyd.
B.5.1.4
Forces on appurtenances such as boat landings, fenders or bumpers, J-tubes, walkways,
stairways, grout lines, anodes, etc. shall be considered for inclusion in the hydrodynamic model of the
structure. Forces on some appurtenances may be important for local member design. Appurtenances are
generally modeled by non-structural members that contribute equivalent wave forces.
B.5.2
Design wave methods
Methods to estimate design wave loads depend on the hydrodynamic characteristics of the structure and
on the way the structure is held on location, as outlined in Table 2.4.
B.5.3
Method I.1: Rigidly positioned, hydrodynamically transparent structures
B.5.3.1
The Morison formula may be used to calculate the force exerted by waves on a cylindrical
object, such as a structural member. The wave force can be considered as the sum of a drag force and
an inertia force, as follows:
F = FD + FI = CD A U |U | + CM V (U/t)
Table 2.4
Summary of design wave methods

Hydrodynamic characteristics
Kind of positioning
I. Transparent 1
II. Compact 2
1. Rigid 3
Method I.1 (see 4.3)
Method II.1 (see 4.5)
2. Flexible 4
Method I.2 (see 4.4)
Method II.2 (see 4.6)
1 A structure is considered hydrodynamically transparent if wave scattering can be neglected, i.e., if the structure does not
significantly modify the incident wave. This condition is satisfied if D/L < 0.2, where D is a characteristic dimension of the
structure (e.g., diameter of structural members, such as platform legs) in the direction of wave propagation, and L is the
wave length.
2 A structure is considered hydrodynamically compact if scattering of sea waves cannot be neglected. This condition occurs if
D/L > 0.2. If D/L is about 0.2, a design value may be defined as the smaller one of the design values obtained from the alternative application of methods I and II.
3 A structure is considered rigidly positioned if the wave-induced deviation from its equilibrium position in still-water is negligi-
bly small when compared to the wave height.

4 A structure is considered flexibly positioned if the wave-induced deviation from its still-water equilibrium position is of the
order of the wave height or more.
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where
F
: hydrodynamic force vector per unit length acting normal to the axis of the member [kN/m]
FD
: drag force vector per unit length acting on the member in the plane of the member axis and
U [kN/m]
FI
: inertia force vector per unit length acting normal to the axis of the member in the plane of the
member axis and U/t [kN/m]
CD
: drag coefficient
: density of water [kNs2/m4]
: projected area normal to the cylinder axis per unit length

: D for circular cylinders [m]
: displaced volume of the cylinder per unit length
: D2/4 for circular cylinders [m2]

D
: effective diameter of circular cylindrical member, including marine growth [m]
: component of the velocity vector (due to wave and/or current) of the water normal to the axis
of the member [m/s]
|U|
: absolute value of U [m/s]
CM
: inertia coefficient
U/t
: component of the local acceleration vector of the water normal to the axis of the member
[m/s2]
Note that the Morison equation, as stated here, ignores the convective acceleration component in the
inertia force calculation as well as lift forces, impact related slam forces, and axial Froude-Krylov forces.
B.5.3.2
The vectorial superposition of local wave loads in a phase correct manner defines global wave
loads on the structure. Total base shear and overturning moment are calculated by a vector summation of
local drag and inertia forces due to waves and currents, dynamic amplification of wave and current forces
(see Section 3, D), and wind forces on the exposed portions of the structure (see B.2).
Slam forces can be neglected because they are nearly vertical. Lift forces can be neglected for jackettype structures because they are not correlated from member to member. Axial Froude-Krylov forces can
also be neglected.
The wave crest shall be positioned relative to the structure so that the total base shear and overturning
moment have their maximum values. The following aspects need to be considered:
The maximum base shear may not occur at the same wave position as the maximum overturning
moment.
In special cases of waves with low steepness and an opposing current, maximum global structure
force may occur near the wave trough rather than near the wave crest.
Maximum local member stresses may occur for a wave position other than that causing the maximum global structure force.
B.5.3.3
If the Morison equation is used to calculate hydrodynamic loads on a structure, the variation of
CD as a function of Reynolds number, Keulegan-Carpender number, and roughness shall be taken into
account in addition to the variation of the cross-sectional geometry:
Reynolds number
Rn
: UmaxD/
Keulegan-Carpenter number
KC
: UmaxT/D
Relative roughness
: k/D
where
D
: diameter [m]
: wave period [s]
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: maximum of velocity U defined in 4.3.1 [m/s]
: kinematic viscosity of water

-6
1.4 10
at 10 C [m2/s]
: roughness height [m]
B.5.3.4
As guidance in determining drag coefficients, surface roughness values listed in Table 2.5
may be used.
Table 2.5
Surface roughness
Surface
Steel, new uncoated
5 10-6
Steel, painted
5 10-6
Steel, highly rusted
3 10-3
Concrete
3 10-3
Marine growth
5 10-3 to 5 10-2
B.5.3.5
For smooth circular cylinders in steady flow, where the cylinder length is significantly larger
than the cylinder diameter, Table 2.6 lists design values of hydrodynamic coefficients CD and CM for two
classes of Reynolds number.
Table 2.6
Hydrodynamic coefficients CD and CM for circular cylinders in steady flow conditions
Reynolds number
(Rn)
CD
CM
< 10
-5
1.2
2.0
> 10
-5
0.7
1.5
1.
Corrections due to marine growth have to be made,

as applicable.
2.
CD and CM values for more complicated structural

elements shall be provided by competent institutions.
These values are to be approved by Germanischer
Lloyd.
B.5.3.6
For circular cylinders in supercritical oscillatory flow at high values of KC, with in-service marine roughness, Table 2.7 lists design values of hydrodynamic coefficients CD and CM.
Table 2.7
Hydrodynamic coefficients CD and CM for circular cylinders in oscillatory flow conditions
Surface condition
CD
CM
Multiyear roughness, k/D >

1/100
1.05
1.8
Mobile unit (cleaned), k/D <

1/100
1.0
1.8
Smooth member, k/D < 1/10000
0.65
2.0
The smooth values will normally apply 2 m above the mean

water level and the rough values 2 m below the mean water level.
The roughness for a mobile unit applies when marine
growth is removed between submersions of members.
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B.5.3.7
For several cylinders close together, group effects may be taken into account. If no adequate
documentation of group effects for the specific case is available, the drag coefficients for the individual
cylinder may be used.
B.5.3.8
The hydrodynamic modeling of jack-up legs may be carried out by utilizing the detailed or the
equivalent technique. The detailed technique models all relevant members with their own unique descriptions for the Morison term values and with the correct orientation to determine relative normal velocities and accelerations and the corresponding drag and inertia coefficients, as defined in B.5.3.6. The hydrodynamic model of the equivalent technique comprises one equivalent vertical tubular located at the
geometric center of the actual leg. The corresponding (horizontal) relative velocities and accelerations are
applied together with equivalent hydrodynamic coefficients (CD and CM) and equivalent diameters (D).
The model shall be varied with elevation, as necessary, to account for changes in dimensions, marine
growth thickness, etc.
For non-tubular geometries, such as split tube and triangular leg chords, the appropriate hydrodynamic
coefficients may, in lieu of more detailed information, be assessed from relevant literature and/or appropriate interpretation of (model) tests. The SNAME (2002) Technical & Research Bulletin 5-5A Guidelines
for Site Specific Assessment of Mobile Jack-Up Platforms is an example of a document that provides
such information.
B.5.4
Method I.2: Flexibly positioned, hydrodynamically transparent structures
B.5.4.1
Depending on the kind of structural elements considered in a strength analysis, this method
requires calculation of wave-induced first order motions (see B.5.4.2) as well as second order motions of
the moored structure (see B.5.4.3).
B.5.4.2
Loads on structural elements not belonging to the mooring system
Wave-induced design loads used for strength analysis of structural elements that do not belong to the
mooring system may be estimated by a phase correct vectorial superposition of all local wave loads acting on the rigidly positioned (fixed) structure according to B.5.3, Method I.1. The corresponding design
loads for all motion-induced loads may be calculated on the basis of a linear motion analysis. Such an
analysis shall account for all relevant degrees of freedom of the structure being considered. Typical offshore structures may be classified according to the number of degrees of freedom of rigid-body motions
as listed in Table 2.8:
Table 2.8
Degrees of freedom of different kinds of offshore structures
Degrees
of freedom
Kind of structure
Drill ships, supply vessels, tugs

Anchored or dynamically positioned
semisubmersibles
Loading buoys, storage tanks
Floating cranes, pipelaying vessels
Tension-leg platforms
Guyed towers
Articulated towers
For a six degree-of-freedom system the motion analysis may generally be based on the following linear
motion equations:
6
2
D .(M jk + A jk ) + i.D .B jk + C jk s Dk = Fj
j=1
for j = 1, 2 ... 6
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where
j
: index denoting the direction of the force
: index denoting the direction of the motion
: circular frequency of motion

: 2 / TD
TD
: period of the design wave
Mjk
: generalized mass matrix
Ajk
: generalized added mass matrix
Bjk
: generalized damping matrix
Cjk
: generalized restoring force matrix
sDk
: generalized vector of motion amplitudes
Fj
: generalized global wave-induced load vector, determined according to B.5.4.3
To solve these equations for the motion components sDk, the generalized masses Mjk of the structure
(including mass moments of inertia for i, j > 3), the respective global hydrodynamic added masses Ajk,
the global damping coefficients Bjk (viscous damping for hydrodynamically transparent structures), and
the global hydrostatic (restoring) coefficients Cjk need to be defined. These global hydromechanic coefficients may be obtained from calculation of local loads on all structural elements below the still-water line.
Linear superposition of all local hydromechanic coefficients determines the required global hydromechanic coefficients. Details can be found in related text books. Appropriate computer codes or a compatible procedure may be applied upon agreement with Germanischer Lloyd.
After determination of the motion components, motion induced local loads on all structural elements can
be estimated and added to the local wave loads as determined for the rigidly positioned (fixed) structure,
as applicable, finally yielding the resulting wave induced (first order) local design loads on structural elements.
B.5.4.3
Loads on structural elements belonging to the mooring system
Wave-induced design loads used for strength analyses of structural elements that belong to the mooring
system shall be estimated by superposition of wave loads due to first and second order (drift) motions.
The second order motion analyses shall include restoring forces of the mooring system, which may be
linearized upon agreement with Germanischer Lloyd. Simulation techniques with statistical evaluation or
equivalent spectral analysis methods are acceptable. Details are subject to approval by Germanischer
Lloyd.
Selected model tests are recommended to determine (validate) the influence of damping.
B.5.5
Method II.1: Rigidly positioned, hydrodynamically compact structures
B.5.5.1
Linear wave-induced loads on large body, hydrodynamically compact structure shall be determined by diffraction theory. Diffraction theories may be based on sink-source methods or finite fluid
volume methods. For simple geometric shapes, analytical solutions may be used. For surface piercing
bodies, results from sink-source methods shall be checked to avoid unreliable predictions in the
neighborhood of irregular frequencies. Details can be found in related text books. Appropriate computer
codes or a compatible procedure may be applied upon agreement with Germanischer Lloyd.
Model experiments are recommended if a new structural concept is to be analyzed and the loads cannot
be adequately predicted by state of the art methods.
B.5.5.2
Wave-induced loads on structures comprising large volume parts and slender members may
be obtained by combining the use of the wave diffraction theory and the Morrison equation. The modified
velocities and accelerations caused by the large volume parts, however, should be accounted for when
using the Morrison equation.
B.5.5.3
Hydrodynamic interaction between large volume parts should be accounted for.
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B.5.5.4
In the vicinity of large bodies the free surface elevation (i.e., wave height) may be increased.
This increase shall be accounted for not only in the wave-induced load calculation, but also when estimating the under deck clearance.
B.5.5.5
In many cases second order wave-induced loads may be important for the design of hydrodynamically compact structures.
In addition to first order (linear) loads, mean (nonlinear) second order wave (drift) loads and nonlinear loads varying in time with twice the first order (wave) frequency act on the structure. Waveinduced load effects of higher order than two are usually neglected.
In a natural (irregular) seaway, composed of an infinite number of elementary regular wave components, the resulting second order wave-induced loads contain three components, namely, the mean
(drift) loads, loads varying in time with the difference frequencies of component waves (slowly varying drift loads), and loads varying in time with the sum frequencies of component waves (high frequency loads).
The sum frequency loads may be important in considering wave load effects on certain offshore
structures, such as deep water gravity structures.
Second order loads shall be determined by a consistent second order theory or by appropriate
model tests.
B.5.6
Method II.2: Flexibly positioned, hydrodynamically compact structures
B.5.6.1
Depending on the kind of structural elements considered in a strength analysis, this method
requires calculation of wave-induced first order motions (see B.5.5.1) as well as second order motions of
the moored structure (see B.5.5.5).
B.5.6.2
Wave induced local design loads used for strength analysis of structural elements that do not
belong to the mooring system may be estimated on the basis of the linear motion analysis as outlined in
B.5.4.2, with Fj representing the components of the global wave load vector determined according to
B.5.5.
Contrary to B.5.4.2, global hydrodynamic coefficients Ajk and Bjk may be determined directly by diffraction
theory based methods. Details can be found in related text books. Appropriate computer programs or
compatible procedures may be used upon agreement with Germanischer Lloyd.
B.5.6.3
The second order (slowly varying) difference frequency wave-induced loads (see B.5.5.5) may
be important for the design of mooring or dynamic positioning systems as well as for offshore loading
systems. For hydrodynamically compact structures with a small waterplane area, the slow drift forces may
cause large vertical motions.
Second order loads shall be determined by a consistent second order theory or by appropriate model
tests.
B.5.7
Spectral methods may be used to obtain the response in natural (irregular) seas by linearly
superposing results from regular wave components of different amplitudes, wave lengths, and propagation directions, assuming the natural seaway is made up of a large number of regular waves of different
length and height. The procedure to follow is outlined in Section 1, D.5.
B.5.8
Wave impact loads
Structural members in the splash zone are susceptible to loads caused by wave-induced impact (slamming) when the member is submerged. These loads are difficult to estimate accurately and should generally be avoided by structural design measures. Long horizontal members in the splash zone are particularly susceptible to impact related loads.
B.5.9
For a cylindrical shaped structural member the slamming force per unit length may be calculated as follows:
FS = CS D v2
where
FS
: slamming force per unit length in the direction of the velocity v [kN/m]
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: density of water [kNs2/m4]
CS
: slamming coefficient
: member diameter [m]
: relative velocity normal to member surface [m/s]
For a smooth circular cylinder the slamming coefficient shall be at least CS = 3.0.
B.5.9.1
The slamming pressure space averaged over a broader area (several plate fields) may be
obtained as follows:
pS = Cps v2
where
pS
: space averaged slamming pressure [kPa]
: density of water [kNs/m ]
Cps
: space averaged slamming pressure coefficient
: relative velocity normal to member surface [m/s]
For a smooth circular cylinder the space averaged slamming pressure coefficient shall be at least
Cps = 3.0. For a flat bottom the slamming pressure coefficient shall be at least Cps = 6.3.
B.5.9.2
Space averaged slamming pressure coefficients for other shapes shall be determined using
recognized numerical and/or experimental methods, taking into account three-dimensional effects. Interface capturing techniques of the volume-of-fluid (VOF) type, for example, are appropriate numerical
methods as they take into account viscosity, flow turbulence, and deformation of the free surface.
B.5.9.3
Fatigue damage caused by wave slamming shall be taken into account. The fatigue damage
caused by slamming has to be added to the fatigue contribution from other viable loads.
B.5.10
Impact related pressure from breaking waves
Breaking waves causing impact pressures on vertical surfaces shall be considered. In the absence of
more reliable methods, the procedure described in B.5.8 may be used to calculate this impact pressure.
The coefficient CS depends on the configuration of the area exposed to this impact related pressure. The
impact velocity v shall correspond to the most probable largest wave height.
B.5.11
Air gap
B.5.11.1
Air gap for units
The air gap is defined as the minimum clearance between the underside of the unit in the elevated position and the calculated crest of the design wave with adequate allowance for safety. It is usually not practical to change the air gap in preparation for a storm and, therefore, the air gap for an intended operation
shall be determined based on a suitable return period. Omnidirectional guideline wave heights with a return period of 100 years are recommended to compute wave crest elevations above storm water level,
even if a lower return period is used for other purposes.
For jack-up platforms, the air gap shall be 1.20 m or 10 percent of the combined storm tide, astronomical
tide, and height of the maximum wave crest above mean low water level, whichever is less. An additional
air gap shall be provided for any known or predicted long-term seafloor subsidence.
B.5.11.2
Air gap for installations
The air gap is the clearance between the highest water surface that occurs during the extreme environmental conditions and the lowest part not designed to withstand wave impingement. For fixed platforms,
the air gap to be maintained shall be at least 1.5 m.
B.6
Vibratory loads due to vortex shedding
Flow past a structural member may cause unsteady flow patterns from vortex shedding, leading to vibrations of the member normal or in line to its longitudinal axis. Such vibrations shall be investigated.
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At certain critical flow conditions, the vortex shedding frequency may coincide with or be a multiple of the
natural frequency of motion of the member, resulting in harmonic or subharmonic resonance vibrations.
The vortex shedding frequency in steady flow with Keulegan-Carpender number KC (see B.5.3.3) greater
than 40, such as in a current, may be obtained as follows:
f = Sn (U / D)
where
f
: vortex shedding frequency [HZ]
Sn
: Strouhal number
: local flow velocity normal to the member axis [m/s]
: diameter of the member [m]
At certain critical velocity ranges, the vortex shedding will be such as to lock-in to the natural frequency of
the member. This lock-in to the natural frequency can occur for flows in line as well as transverse to the
member.
Vortex shedding on structural members may also be generated in waves. Vortex shedding occurs in that
part of the wave motion where the acceleration is small. Vortex shedding in waves falls into two categories. For KC > 40, the vortex shedding is of the same kind as in a steady current. For 6 < KC < 40, vortex
shedding frequency depends on the type of wave motion. One distinguishes between two limiting cases:
If the wave motion can be considered regular, the vortex shedding frequency is a multiple of the
wave frequency.
If the wave motion is irregular, the vortex shedding frequency is the same as the in a steady current,
and the frequency depends on Sn.
For irregular waves characterized by a narrow band spectrum, the vortex shedding frequencies are a
combination of these two limiting cases.
To reduce the severity of flow-induced oscillations caused by vortex shedding, either the members shape
or its structural properties should be changed. This can be achieved by altering the members mass or the
members damping characteristics. As a result, its natural frequency will be changed so as to lie outside
the range for the onset of resonant vortex shedding.
Spoiling devices are often used to suppress vortex shedding lock-on. The underlying principle is to either
reduce drag on the member or to cause the shed vortices to become uneven over the length of the member. Drag can be reduced by adding streamlined fins and splitter plates that break the oscillating flow
pattern. Uneven vortex shedding can be induced by making the member irregular, i.e., by adding spoiling
devices, such twisted fins, helical strakes, or ropes wrapped around the member. Tests should determine
the efficiency of the spoiling device to be used.
B.7
Loads due to climatic conditions
B.7.1
Snow and ice accretion
B.7.1.1
If icing is possible, and ice or snow covers parts of the structure, the weight of ice or snow
shall be added to the permanent load under any loading conditions.
B.7.1.2
Snow can settle on both horizontal surfaces and, if the snow is sufficiently wet, on nonhorizontal windward parts of installations or units. On horizontal surfaces, dry snow is blown off as soon
as any thickness accumulates, while wet snow can remain in position for several hours. Snow covering
on surfaces inclined more than 60 to the horizontal can be disregarded. Snow covering on surfaces inclined between 0 and 60 can be reduced linearly. Snow can freeze and remain as ice only on vertical
surfaces.
B.7.1.3
Ice on the topsides of installations or units can accumulate through a number of mechanisms:
freezing of old wet snow

freezing sea spray
freezing fog and super cooled cloud droplets
freezing rain
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Where ice covering is caused mainly by sea water spray, it may be taken to decrease linearly to zero
from a level corresponding to the highest wave elevation to a level corresponding to 60 m above the highest wave elevation.
The effects of topside icing on the stability of floating structures and on the operation of emergency equipment are particular aspects that shall be considered when designing for operations in cold climates.
B.7.1.4
Loads caused by ice and/or snow on open decks and externally exposed walls are to be
specified according to recommendations of competent independent authorities/institutions. In absence of
specific information, new snow may be assumed to have a density of 100 kg/m3, and the average density
of ice formed on the structure may be taken as having a density of 900 kg/m3.
B.7.2
Temperature influences
Stresses in and deformations of the structure or parts of it, which are induced by extreme temperature
gradients in the structure, shall be added to the permanent load induced stresses and deformations under
operating conditions, where they are deemed to be relevant.
B.7.3
Marine growth
B.7.3.1
Marine growth may be considerable in some areas and shall be taken into account, e.g., when
assessing the wave and current loads acting on submerged parts of the structure. Relevant information
shall be submitted to Germanischer Lloyd for verification, see also Section 1, G.3.
B.7.3.2
Thickness of marine growth shall be assessed according to local experience. If no relevant
data are available, a thickness of 50 mm may be chosen for normal climatic conditions.
B.8
Loads due to sea ice
B.8.1
Forces exerted on a structure by ice are to be evaluated for their effect on local structural elements and for global effects on the structure as a whole.
B.8.2
Ice loads are to be evaluated for a range of ice-structure interactions. The range of interactions is determined by the ice environment of the area of operations, see Section 1, G, and may include
the following aspects:
ice pressure loads from continuous first or multi-year level ice
loads from collision with first and/or multi-year ridges within the ice field
impact loads caused by drifting ice floes (sea ice or glacial ice)
impact loads caused by icebergs
B.8.3
Ice load evaluations are to include the forces exerted by ice on rubble ice or other ice pieces
that are in firm contact with or held by the structure. This is of particular concern for multi-legged structures and for structures designed to cause ice failure in modes other than crushing.
B.8.4
The brittle nature of ice can lead to periodic dynamic loading, even during ice-structure interactions where this is not initially apparent. Dynamic amplification of the structures response in its natural
vibratory modes shall be evaluated.
B.8.5
When calculating ice loads, the following parameters specifying the condition of the ice have
to be considered:
thickness of a level ice sheet
temperature or temperature gradient in the ice
orientation of the ice crystals
bulk salinity
total porosity of the ice (brine volume, gas pockets, voids)
density
ice strength
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loading rate
scale effects (size of structure/ice thickness)
B.8.6
Any attempt to determine ice loads on offshore structures shall be based on probabilistic
methods. Ice parameters and corresponding forces shall be analyzed over the entire range of possible
parameter values by using simulation techniques, such as the Monte Carlo simulation.
B.8.7
Exclusively using deterministic methods for ice loads, only considering a maximum ice thickness, introduces uncertainties of the following kind:
randomness of every natural process
incomplete ability to describe natural processes in engineering models
human participation in engineering processes
In case of ice-structure interaction, the most significant uncertainties arise from the available models. It
should always be considered that none of the publicly available methods delivers reliable results.
B.8.8
Model tests are recommended for evaluation of global loads and confirmation of expected ice
failure modes.
B.8.9
Further details are described in GL Guideline for the Construction of Fixed Offshore Installations in Ice Infested Waters (IV-6-7).
Permanent Loads
C.1
Permanent loads are loads acting throughout the lifetime of the unit/installation or during prolonged operating periods. Such loads may comprise the weight of structures (dead load), equipment,
permanent ballast, and effects of hydrostatic pressure exerted on parts of the submerged structure (buoyancy).
C.2
Permanent Loads shall be clearly stated and accounted for in the design documents and calculations.
C.3
In cases where loads/weights may be acting over longer periods, but not necessarily at all
times (e.g., when using certain kinds of equipment), these cases may have to be investigated to account
for the most unfavorable condition.
Functional Loads
D.1
lows:
Functional loads are variable loads caused by normal operations in a variable manner as fol-
weight of tools and mobile equipment

stores, frequently varying ballast, fuel, wastes
loads from operations of cranes and other conveyance equipment
loads from transport operations, e.g., helicopters
mooring/fendering loads from vessels serving the unit/installation
operational boat impact on the boat landing structure
D.2
Loads on windlasses, etc., exerted by mooring lines on mobile units, shall generally be regarded as functional loads, although they are mainly due to environmental influence. Regarding permissible stresses, these mooring loads shall be attributed to loading conditions 2 or 3 as applicable, see
Section 3, C and GL Rules for Mobile Offshore Units (IV-6-2), Section 8.
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D.3
Deck loads, weight of equipment, etc. shall be specified by the Owner/Designer. The specification shall also contain indications of permissible load combinations and limitations regarding the overall
weight of the structure or installation.
D.4
If not otherwise specified, the following minimum loading on deck surfaces is to be taken:
crew spaces, walkways, etc.:
4.5 kN/m
access platforms:
3 kN/m
working areas:
9 kN/m
storage areas:
13 kN/m
helicopter platform:
2 kN/m
For railings and foot rails, a horizontal load in form of a moving single load of 0.3 kN/m has to be assumed.
The above loads on walkways, stairs, access platforms, and similar areas shall be fully considered for the
local design; but for the overall design of the installation/unit, a minimum of 50 % of the live loads on
these areas shall be considered.
D.5
Layout plan for loads
A layout plot plan, including weights, shall be prepared for each design. This plan is to show the permanent design loads, see C, and functional maximum design loads (uniform loads as well as concentrated
loads) for all areas and for each mode of operation. Compare also GL Rules for Certification and Surveys
(IV-7-1), Section 3, B.2.6.1.
Accidental Loads
E.1
General
E.1.1
Accidental loads are loads not normally occurring during the installation and operating phases,
but which shall be taken into account, depending on location, type of operations, and possible consequences of failure. Causes for accidental loads within this context may be the following:
collisions (other than normal mooring impacts referred to under D.1)
falling or dropped objects
failing or inadequate crane operations
explosions, fire
strength level earthquakes according to Section 1, I.3
E.1.2
The installation/unit shall be so designed and, if necessary, protected that the consequences
of damage are acceptable and that an adequate margin of safety against collapse is maintained.
E.2
Collision of vessels with offshore installations
E.2.1
Collision zone
Accidental damage shall be considered for all exposed elements of an installation in the collision zone.
The vertical extent of the collision zone shall be assessed on the basis of visiting vessel draft, maximum
operational wave height, and tidal elevation.
E.2.2
Accidental impact energy
E.2.2.1
Total kinetic energy
The total kinetic energy involved in accidental collisions can be expressed as follows:
E = a v2
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where
E
: total kinetic energy [kJ]
: displacement of the vessel [t]
: vessel added mass coefficient

: 1.4 for sideways collision
: 1.1 for bow or stern collision
: impact speed [m/s]
The minimum value for E shall be as follows:

14 MJ for sideways collisions and
11 MJ for bow or stern collisions
These minimum values correspond to a vessel of 5000 t displacement with an impact speed of 2 m/s. A
reduced impact energy may be acceptable if the size of the visiting vessels and/or their operations near
the offshore installation are restricted. In this instance, a reduced vessel size and/or a reduced impact
speed may be considered.
E.2.2.2
Impact speed
The reduced impact speed may be estimated from the following empirical relationship:
v = HS
where
v
HS
: significant wave height [m]
Here the significant wave height HS is to be taken equal to the maximum permissible significant wave
height for vessel operations near to the installation.
E.2.2.3
Energy absorbed by the structure
The energy absorbed by the installation during the collision impact will be less than or equal to the impact
kinetic energy, depending on the relative stiffness of the relevant parts of the installation and the impacting vessel that the installation comes in contact with, the mode shape of the collision, and the vessels
operation. These factors may be taken into account when considering the energy absorbed by the installation.
For a fixed steel jacket structure, it is recommended that the energy absorbed by the installation should
not be taken less than 4 MJ unless a study of the collision hazards and consequences specific to the
installation demonstrates that a lower value is appropriate. Examples of such structures are small, occasionally manned and infrequently supplied installations, or structures where there is a restriction on the
size of the visiting vessel.
For vessels of less than 5000 t displacement, the minimum energy to be absorbed by the installation may
be reduced to a value given by the following relationship:
Ea = 0.5 + 2 (4.2 10-7 5.6 x 10-11 )
Ea
: energy absorbed by the installation [MJ]
The energy absorbed by the installation may be taken less than this value if the stiffness of the impacted
part of the installation is large compared to the stiffness of the impacting part of the vessel, as for example in collisions involving concrete installations or fully grouted installation elements. In such cases the
effects of impact loading shall be considered in detail as in the following.
E.2.3
Accidental impact loading
In cases where the stiffness of the impacted part of the installation is large compared to stiffness of the
impacting part of the vessel, as for example in collisions involving concrete installations or fully grouted
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elements, the impact energy absorbed locally by the installation may be low. In such cases, it is important
to examine damage caused by the impact force.
The impact force may be calculated as follows:
F = P0
or
F = v ca
whichever is the less, where
: impact force [kN]
P0
: minimum crushing strength or punching shear, as appropriate, of the impacting part of the
vessel and the impacted part of the installation [kN]
: total spring stiffness of the vessel and installation related to the impact point [kN/m]
: vessel added mass coefficient, see E.2.2.1
E.3
The regulations of competent Authorities and/or Administrations have to be observed, particularly regarding collisions.
E.4
According to Section 3, C.2.2.1, loading condition 4 Accidental loads, the choice of accident
cases and the determination of loads will be considered on a case to case basis.
E.5
Consequences of damage
The primary structure shall be designed to ensure that accidental damage does not cause complete collapse. Damaged members shall be considered to be totally ineffective unless it can be shown by analysis
or tests that they retain residual load-carrying capacity.
Transportation and Installation Loads
F.1
General
Marine operations for transportation and installation are routine operations of limited duration. Such operations depend on the type of the offshore installation and shall include all the transient movements and
other activities where the structure or operation is at risk in the marine environment. Samples of such
operations are the following:
load-out from shore to barge or vessel
float-out from drydock
construction and outfitting afloat
wet or dry towage and other marine transportation
installation
jacket launching
float-over of topsides
piling, grouting, connection to permanent moorings
modifications to an existing structure
total or partial decommissioning and removal of the structure
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Loads
The loads for these phases have to be defined on a case by case basis according to the type of installation and the situation on site. In determining these loads in an actual case, the following aspects shall be
considered:
The required equipment, vessels, and other means involved are to be designed and checked for
adequate performance with respect to their intended use.
Redundancy in the equipment shall cover possible breakdown situations.
Operating weather conditions, chosen at values smaller than the specified design criteria, are to be
forecasted for a period long enough to complete the required marine operations.
The marine operations are planned, in nature and in duration, such that accidental situations, breakdowns, or delays have a low probability of occurrence and are covered by detailed contingency actions.
Adequate documentation has been prepared for a safe step-by-step execution of the operation, with
clear indications of the organization and adopted chain of command.
Marine operations are to be conducted by suitably experienced and qualified personnel.
Earthquake Loads
G.1
Seismic actions
The characteristics of earthquake levels (acceleration intensity, duration, etc.) shall be established by a
competent Authority and agreed upon with Germanischer Lloyd.
G.2
Seismic analysis
G.2.1
General
Two levels of seismic loading on a structure shall be considered in accordance with G.1:
G.2.1.1
Strength level earthquake
Strength level earthquakes (SLE) shall be assessed as an ultimate strength condition (ULS). In zones
with low to moderate seismic activity, the action effects obtained from an analysis in which the structure is
modeled as linear and elastic will normally be such that the structural design can be performed based on
conventional linear elastic strength analyses, employing normal design and detailing rules for the reinforcement design.
G.2.1.2
Ductility level earthquake
Provided the structure survives, it is permissible to assess ductility level earthquakes (DLE) with ductile
behavior of the structure, assuming extensive plastic deformation occurs.
If, under the DLE event, ductile response of specific components of the structure is predicted or considered
in the analysis, such components shall be carefully detailed to ensure appropriate ductility characteristics
and structural constraints. Expected best estimate of stress/strain parameters associated with ductile behavior may be adopted in the analysis. Due consideration shall be given to the effects of excessive strength
with respect to the transfer of forces acting at adjoining members as well as to the design of those failure
modes of such members that are not ductile, such as shear failure. For those cases where the structure can
be designed to the DLE event by applying normal ULS criteria, no special detailing for ductility is required.
G.2.1.3
Seismic response
Seismic events may be represented by input response spectra or by time histories of significant ground
motion. Where the global response of the structure is essentially linear, a dynamic spectral analysis shall
normally be appropriate. Where nonlinear response of the structure is significant, a transient dynamic
analysis shall be performed.
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Section 3
A
B
C
D
E
F
G
H
I
J
General ....................................................................................................................... 3-1

Design Methods and Criteria ...................................................................................... 3-2
Loading Conditions ..................................................................................................... 3-5
Dynamic Analysis...................................................................................................... 3-11
Effective Width of Plating .......................................................................................... 3-13
Beam Member Design .............................................................................................. 3-14
Tubular Joint Design ................................................................................................. 3-15
Buckling of Plates ..................................................................................................... 3-18
Fatigue Strength ....................................................................................................... 3-18
Application of BSH Requirements ............................................................................ 3-24
General
A.1
Scope
This Section defines the principles for structural design of fixed steel offshore installations. Subsections A
- C are applicable to structures in general. Subsections D - I refer to steel structures. If structures made of
aluminium alloys shall be provided, the design should follow the GL Rules for Hull Structures (I-1-1) or
Eurocode. Fixed Concrete Structures shall be designed according to ISO 19903. The design principles for
mobile offshore units are defined in GL Rules for Mobile Offshore Units (IV-6-2)
The following rules are based on and mostly refer to:
API Recommended Practice 2A-WSD (RP 2A-WSD) for jacket and topside
ISO 19902:2007 (same as DIN EN ISO 19902:2008-07) for jacket
ISO 19901-3:2010 (same as DIN EN ISO 19903:2010) for topside
The requirements in the following paragraphs B I of this Section are to be read together with the cited
ISO standards for analysis performed based on the Load and Resistance Factor Design method (LRFD)
and together with the cited API standard for analysis performed based on the Allowable Stress Design
method (ASD)
J provides recommendations on how to use Eurocode 3 to fulfil BSH regulations for offshore installations
in the German Exclusive Economic Zone.
Eurocode 3 consists of the following documents:
DIN EN 1990:2002 + A1:2005 + A12005/AC:2010 (including German National Annex)
DIN EN 1993-1-1:2005 + AC:2009 (including German National Annex)
DIN EN 1993-1-8:2005 + AC:2009 (including German National Annex)
A.2
General design considerations
A.2.1
Structural integrity throughout the lifetime of an offshore installation depends on the thoroughness of design investigations, on the quality of materials and manufacture, and on the in-service inspection and maintenance. This Section deals with the required level of design investigations.
A.2.2
Serviceability and functional considerations may have influence on the structural design. They
will generally be specified by the Owner/Operator of the installation, but will be taken into account in the
design review by GL where relevant.
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A.2.3
Loads and loading conditions should generally be treated in accordance with Sections 1 and
2. More specific or especially adapted load criteria/ values shall be well documented and agreed upon.
The load cases and combinations to be considered in the design calculations shall cover the most unfavourable conditions likely to occur.
A.2.4
The dynamic nature of some loads acting on the structure has to be taken into account by
suitable calculation methods where these loads are considered important, e.g. because they produce
considerable accelerations of (parts of) the structure. In some cases dynamic forces can be accounted for
quasi-statically, i.e. using adequate increments on static forces acting simultaneously, see D.
A.2.5
Strength/stress analysis may be carried through according to different, recognized methods
and standards, see B, and GL Rules for Certification and Surveys (IV-7-1), Section 1, E. However, it shall
be ascertained in every case that the design fundamentals and standards used are consistent and compatible for one structure or installation, regarding the considerations stated in A.2.1.
A.2.6
Structural redundancy shall be considered at an early stage. As redundancy is not explicitly
taken account of in the all design methods currently in use, with the exception of the categories grouping
of structural elements (special, primary, secondary - see Section 4, A), the consequence of a failure of
individual structural elements will have to be specially considered. Aspects of reparability, especially of inwater structures should be taken into account.
A.3
Avoidance of wave impact
Where structures are not or cannot be suitably designed to resist wave impact, the latter shall be avoided
by providing sufficient distance between the probable highest wave elevation and the lower edge of the
structure (e.g. lowest closed deck). A clearance - "air gap" - of 1.5 m is recommended. In case of structures not connected rigidly to the sea floor, their vertical motions shall be accounted for. For mobile units,
see also GL Rules for Mobile Offshore Units (IV-6-2), Section 2 and 3.
A.4
Corrosion and wear allowances
Determination of scantlings, using the following indications or equivalent design methods, is based on the
assumption that an accepted corrosion protection system is provided for, see Section 5. Otherwise adequate corrosion allowances are to be agreed upon, depending on the environmental and operating conditions as well as the design lifetime. The same applies to structural elements prone to wear, e.g. by chafing of cables or chains.
A.5
Loading conditions
Loading conditions occurring during construction, transport or sea installation may have to be considered
in the design, see also C and Section 9.
Design Methods and Criteria
B.1
Choice of design concept/methods
B.1.1
Structural strength calculations is generally to be based on linear elastic theory. However,
non-linear relations between loads and load effects shall be properly accounted for, where they are found
to be important
B.1.2
ASD ("allowable stress design")
Where deterministic methods incorporating global safety factors are used, they shall comply with the requirements given in this section. This method is also known as WSD (working stress design)
B.1.3
LRFD ("load and resistance factor design")
A semi-probabilistic design method in association with limit state and partial safety factor design, see B.2
and B.3, may be applied alternatively.
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B.2

Design criteria, limit states
B.2.1
A structure may become unsafe or unfit for use by damage or other changes of state according to different criteria. They may be defined by "Limit States", i.e. states of loading, straining (deformation) or other impairment, at which a structure, or structural component, looses its planned operability or
function. The limit states are usually classified as follows.
B.2.2
Ultimate limit states (ULS)
Ultimate limit states are related to the maximum load carrying capacity of a structure or structural component, which may be reached by:
loss of equilibrium (e.g. toppling) of the structure, considered as a rigid body
yielding and/or fracture of material, see F. and G
local and global buckling (structural instability)
fatigue (formation of cracks after repeated loading), see I
B.2.3
Serviceability limit states (SLS)
Serviceability limit states refer to the impairment of normal use or operation by changes or effects other
than structural failure, such as
excessive deformation or displacement
unacceptable vibrations
leakage (loss of tightness)
B.2.4
Accidental limit state (ALS)
The limit state of progressive collapse is related to a collapse of a structural system after accidental damage such as:
dropped objects
collisions
explosions
This limit state may also be considered for the evaluation of the "strength level earthquake (SLE)", see
Section 1, I.3.
B.2.5
Fatigue limit state (FLS)
Fatigue limit states address structural failure due to permanent cyclic loading, see I.
B.2.6
Corrosion allowance
Corrosion allowance should be defined by the designer/operator of the platform and agreed upon with GL
and should considered in member design (reduced wall thickness and diameter).
B.3
Definition of safety format
B.3.1
In connection with deterministic as well as semi-probabilistic design methods the safety condition is based on statistically representative "characteristic values" of the loading effects and of the resistance of the structure, as well as on safety factors as defined below.
B.3.2
In deterministic design (ASD) the safety condition may be expressed as follows:

g SC / RC 1
characteristic loading effect (e.g. a stress) resulting from loads/load combinations as defined
in these Rules, see C and Section 2.
SC
RC
: characteristic resistance (for instance, the yield strength, the ultimate strength or the critical
buckling force or stress)
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: numerical values are given in F and G
B.3.3
lows:
In semi-probabilistic design methods (LRFD) the safety condition may be expressed as folSd / Rd 1
Sd
: S(F)
: function, e.g. stress, of the total design loading effect
: (Fi fi)
: total design loading effect consisting of various characteristic loads Fi, multiplied by individually defined load factors fi which take account of the uncertainties of the loads and the probability of their simultaneous occurrence
Rd
: RC / m
RC
: characteristic resistance, see B.3.2
B.4
Modelling of the structure
partial safety factor for materials (covering the possible deviations of material properties for
characteristic, statistically determined values)
B.4.1
The calculation model ("idealization") used has to take account of all main load bearing and
stiffening components, and of the relevant supporting and constraining effects.
The degree of subdivision (detailing) should take account of the geometry of the structure and its influence on the load distribution and introduction, of the distribution of external loads, and of the expected
stress pattern.
Elements or members considered as being of "secondary" importance may nevertheless have to be accounted for where they have an influence on stress distribution or dynamical properties of the structure.
Appurtenances need to be taken into account if they contribute to the overall weight or attract aerodynamic or hydrodynamic forces as boatlandings, conductors or risers do.
B.4.2
Where modelling is made by means of beam elements, the actual rigidities are to be accounted for as precisely as practicable, particularly in way of connections (joints). The effective width of
associated plating may be chosen according to accepted standards, see also E.
The nodes of the model shall be the intersection points (working points) of the centre lines of the braces
with the centre line of the chord. The offset is the distance between brace working points. For global
analyses, only offsets larger than chord diameter D/4 shall be included in the model.
Depending on the diameter of the chord, the length between the physical end of the brace stub and the
centre line of the chord can be significant. In such cases the length of braces between the outer surface
of the chord and its centre line should be modelled as rigid connections with a stiffness at least one order
of magnitude (10 times) greater than that of the brace. Rigid links shall not contribute to the mass and
shall not attract direct hydrodynamic or aerodynamic forces.
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3
1
Key
1 chord can
2 brace stub
3 brace member
4 rigid link
Fig. 3.1
Definition of member rigid links
B.4.3
Stress concentration effects shall be carefully investigated, either by using adequate calculation methods (e.g. finite elements), or by applying stress concentration factors where proven and applicable design data exist.
B.4.4
The soil stiffness is to be represented as precisely as practicable when designing structures
resting on or penetrating into the sea floor, see also Section 6.
B.4.5
For calculations analysing the dynamic behaviour of the whole structure (global behaviour),
the mass distribution may generally be simulated in a simplified form, using equivalent or lumped masses
under consideration of its center of gravity and moments of inertia. Details may have to be agreed upon,
see also D.
B.5
Model tests
Model investigations (tests) may be accepted as a supplement to structural analysis provided that a recognized institution is involved and the particulars have been agreed. In special cases model tests may be
required.
B.6
Superposition of load effect components
Stresses or other load effects resulting from relevant global and local effects shall be added according to
their degree of simultaneousness, see also C and Section 2, A.3 Stresses of different type (e.g. tension,
shear) and different direction shall be combined according to recognized criteria (equivalent stress,
v. Mises).
Loading Conditions
C.1
General
C.1.1
Global or partial safety factors as defined in B and F to G. are related to specified loading conditions and load combinations, see Table 3.1. For kinds and definition of loads see Section 2.
C.1.2
In case of predominant compression stresses, the possibility of buckling is to be investigated,
see F. and H
C.1.3
Where calculations are carried through, e.g. using finite element methods, in order to determine stress concentrations, see B.4, values up to the yield strength may be admitted for loading condition
3, provided that the material employed at such points corresponds to category "special steel member"
(see Section 4) and that fatigue considerations (see I) are explicitly proven or not essential.
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C.1.4
In case of loading repeated with great frequency (fatigue) it must be ensured that no damage
ratio exceeds 1.0, see I.
C.1.5
A reduction of admissible stresses may be necessary (ASD only)
in case of unfavourable inspection and testing conditions

in case of not sufficiently well known loads
where the consequences of a possible failure are deemed to be extremely negative
(lack of redundancy, A.2.6)
For LRFD checks instead of reducing the design load the relevant partial load factor will be increased.
C.1.6
A higher stress level may be admitted in exceptional cases where the calculations have a high
degree of accuracy and the load prediction is extremely conservative.
C.1.7
The design check for elements of special purposes such as cranes or drilling rigs may be
taken according to acknowledged regulations relating to such equipment (GL Rules for Loading Gear on
Seagoing Ships and Offshore Installations (VI-2-2)). The applicability of relevant loading conditions, in
comparison with those defined in this subsection, shall be carefully checked.
C.1.8
Limiting operating conditions
The limiting operating conditions, i.e. environmental conditions tolerable during specified operations, and
the kind of (limited) operations to continue during extreme environmental conditions, will generally be
defined by the Owner or Operator, checked by GL within the design review, and established in the operating instructions.
C.2
2 ASD - Definition of loading conditions
C.2.1
Six loading conditions as summarized in Table 3.1 and defined in the following are generally to
be considered:
C.2.1.1
Loading condition 1: Permanent loads
This (still water) loading condition covers all gravity, buoyancy and hydrostatic loads which would normally act continuously, and shall also take care of variable gravity loads which may be assumed to be in
existence during a prolonged period of time, such as ballast and weight of equipment.
For fixed structures this loading condition is generally not relevant and needs to be investigated only in
combination with variable design loads.
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Table 3.1
Loading conditions, load combinations

Type of load
Loading
condition
Deadload/
1. Permanent loads
2. Operating loads
3. Extreme
environmental
loads
4. Accidental
loads
5. Marine
Operations
6. Ductility
level earthquake
Equip- Variable
ment / funct. Buoyancy
Loads
EnviDuctilEnviStrengt
ron- Impact
ity
ronDyn.
h level
level
Load
mental mental / colliearthloads
sion
earth- (see D)
loads
quake
5
(extr.)
quake
(red.)
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
if applicable
functional loads may be reduced
alternatively impact collision or strength level earthquake
maximum permissible environmental conditions to be defined
recurrence period to be defined individually, typically 1 year
impact during normal operations, e.g. mooring of attending vessels
dynamic amplification for lifting see Section 9, C.2.2

in case of earthquake analysis 75 % of supply and storage loads to be considered
C.2.1.2
Loading condition 2: Operating loads
This condition includes the loads as specified in C.2.1.1, plus other variable functional loads such as from
crane or drilling operations, supply vessels operating around the installation and those environmental
loads which, according to C.1.8, are to be taken into account during normal, unrestricted use of the installation. If not specified individually, a 1 year recurrence period is considered to be acceptable for the environmental loads.
C.2.1.3
Loading condition 3: Extreme environmental loads
C.2.2
This loading condition includes the loads as specified in C.2.1.1, the most unfavourable (100
years recurrence period) environmental loads and those functional loads which, according to C.1.8, are
assumed to be also acting in such environment. According to the principle mentioned in Section 1, A.3,
several possible load combinations or cases may have to be considered.
C.2.2.1
Loading condition 4: Accidental loads
This loading condition is intended to cover unusual loads and damage resulting from accidents, such as
collisions or fire, in addition to permanent loads, to be defined in the individual case. The kinds of accidents and extent of damages will also have to be agreed upon, possibly together with the competent Administration(s), depending on local conditions. The general philosophy is that immediate total failure of the
structure is prevented so that emergency and rescue operations are possible.
An acceptable supposition as to the assessment of associated environmental loads prevailing after the
accident is a recurrence period of one year.
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In earthquake regions, a "strength level earthquake" (see Section 1, I.3) shall be considered under this
loading condition as an alternative to an impact or collision. The associated environmental and functional
loads shall be agreed upon in the individual case.
C.2.2.2
Loading condition 5: Marine operations
This loading condition is only temporary and covers operations associated with moving or transporting an
offshore structure or part thereof during the construction, installation or abandonment process, compare
Section 9.
The situation during transport and installation or de-installation has to be investigated individually case by
case.
C.2.2.3
Loading condition 6: Ductility level earthquake
This loading condition covers an extreme level of earthquake, defined in Section 1, I.3 The earthquake
forms the excitation for the dynamic loads to be investigated according to D. This loading condition requires suitable (nonlinear) analysis methods. See ISO 19902 Recommendations for ductile design.
C.2.3
2.3 Code Checks
The code checks for the jacket are to be carried out according to formula stipulated in API RP 2A-WSD,
latest edition. For the topside structure API RP 2A is also applicable in conjunction with ANSI/AISC 36010 (Specification for Structural Steel Buildings)
C.3
LRFD - Definition of loading conditions
Several load cases are multiplied by an individual partial load factor and then added up to yield load combinations that are to be investigated. The load combinations and the factors are given in Table 3.2.
Table 3.2
Load Factors for LRFD Design

f,G1
f,G2
f,Q1
f,Q2
1.3
1.3
1.5
1.5
operating
loads
1.3
1.3
1.5
1.5
extreme
environmental
additive loads
1.1
1.1
1.1
fE
extreme environmental
opposing
loads
0.9
0.9
0.8
fE
accidental
1.0
1.0
1.0
loading condition
permanent
and
variable Loads
f,Eo
f,Ee
ac
f,GT
f,QT
1.3
1.3
1.0
1.1
1.35
0.9
1.35
1.0
1.0
marine operations (*2)

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0.9
1.1
1.1
0.9
0.9
eq
0.9 fE
earthquake
adding to
gravity
earthquake
opposing
gravity
f,T
0.9
0.8
0.9
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Permanent and variable loads
Four kinds of permanent loads are distinguished depending on the time the structure is exposed to them.
If any of them are movable, their position causing the most severe effect has to be chosen.
The loads are comprised of: (ISO 19902)
C.3.1.1
Permanent loads G1
These are the loads that never change over time, e.g. structural weight, ballast or weight of equipment
that will never be moved during the operation time. Hydrostatic loads (buoyancy and water enclosed in
the structure) are also part of G1.
C.3.1.2
Permanent loads G2
Loads that remain constant over a long period and vary only with the mode of operation, e.g. if the platform is refitted (end of commissioning phase with additional living quarters, begin of production)
C.3.1.3
Variable Loads Q1
Q1 includes varying loads that are moved frequently over free spaces on the platform like personal effects, containers, etc., but also ice loads and fluids in pipes and tanks.
C.3.1.4
Variable Loads Q2
Q2 covers all loads that happen during operation over a short period, like crane lifts, boat impacts or helicopter landings.
C.3.2
Environmental Loads due to wind and waves
Wind and wave forces acting on all sides of a structure have to be considered. If not specified otherwise a
recurrence period of
1 year is acceptable for operating conditions Eo
100 years is acceptable for extreme conditions Ee
Spacing of wave directions to be considered must not be larger than 45. For fixed platforms a more accurate distribution of wave parameters (height, period, etc.) depending on the different directions may be
used as site specific topographic features might be of influence.
Calculation of wave forces under consideration of marine growth, current blockage, conductor shielding,
etc. is shown in Section 2.
Forces due to wind, wave and current have to be combined in a way that maximal loading is caused. Two
separate cases, maximum shear force and maximum overturning moment, shall be investigated. Both
depend on water depth (highest or lowest tide) and wave crest position.
For long and slender structural appurtenances (e.g. risers or flare booms) dynamic effects due to vortex
shedding need to be considered.
Equivalent quasi-static loads D from dynamic response are added to the static loads S
E = fE (S + fD D)
fE and fD are partial factors for the environmental loads that have to be agreed between GL and the
owner. Both are discussed in ISO 19902 annex 9.9.
The value of fE depends principally on:
the target safety level represented by the exposure levels L1, L2 and L3, see 6.6,
the characteristics of the long-term environment at the offshore location of the structure, specifically
the local climate of waves, current and wind at the geographical location (the wave climate usually
being the most influential, in particular its sensitivity to return period)
the geometrical and structural properties of the structure considered.
Additionally, the value will generally be affected by the method(s) used to derive the extreme wind, wave
and current parameters and the corresponding extreme environmental action.
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The partial load factor for environmental actions fE shall be 1.35, unless rational analysis demonstrates
an alternative value is appropriate.
C.3.3
Accidental loads / Temporary loading conditions, ac
This loading condition is intended to cover unusual loads and damage resulting from accidents, such as
collisions
fire, or explosion
dropped objects
abnormal environmental conditions (10000 years wave, abnormal level earthquake)
The kinds of accidents and extent of damages will have to be agreed upon, possibly together with the
competent Administration(s), depending on local conditions. The general philosophy is that immediate
total failure of the structure is prevented so that emergency and rescue operations are possible.
All partial load factors are set to 1.0 when establishing accidental load combinations.
C.3.4
Marine operations, GT, QT, T
These loads comprise all loadings during

loadout
transportation
launching and uprighting
relocation after a certain service time
final removal
Marine operations (*1) governs for components in which permanent and variable load effects are dominant. Marine operations (*2) governs for components in which transient loads are dominant and in which
the permanent and variable loads increase the magnitudes of the internal forces. (*3) governs for components in which transient load effects are dominant but in which the permanent and variable actions decrease the magnitudes of the internal forces.
Fd = f ,GT G T + f ,GT QT + f ,T T
Where:
GT is the load imposed either by the weight of the structure in air, or by the submerged weight of the
structure in water, during the transient situation being considered, including any permanent equipment or
other objects and any piles or conductors installed on the structure, as well as any ballast installed in or
carried by the structure.
QT is the load imposed by the weight of the temporary equipment or other objects, including any rigging
installed or carried by the structure, during the transient situation being considered.
T represents the loads from the transient situation being considered, including:
when appropriate, environmental loads,
when appropriate, a suitable representation of dynamic effects
for lifting, the effects of fabrication tolerances and variances in sling length
for loadout, allowances for misalignment
for transportation, any hydrostatic and hydrodynamic loads on the structure, including any inertial
loads resulting from accelerations of the structure
for installation, the lifting loads and hydrostatic pressure on the structure
For more information refer to ISO 19902 Chapter 8, for lifting operations see also Section 9.
During launching and upending every relevant time step of the procedure has to be calculated individually.
C.3.5
Seismic Loads
Seismic loads are determined by a dynamic analysis (see D).

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Earthquake analyses are outlined in Subsection D.6.

C.3.6
Code Checks
The code checks for the jacket are to be carried out according to formula stipulated in ISO 19902, latest
edition.
In principle the design of the topside has to be checked against the standard ISO 19901-3, latest edition.
This standard does not define explicitly code checks but references instead to any national or international civil or building code. However, a so called correspondence factor Kc has to be applied to account
for any differences between the ISO 19902 standard and the applied civil or building standard. This factor
is to be multiplied on the design value of resistance calculated according to the applied building and civil
code to obtain the final design value of resistance according to ISO 19901-3. The design value of the
actions is to be taken from the ISO 19900 series and is not to be modified.
Please refer to ISO 19901-3 for details and requirements on how to apply and calculate the correspondence factor Kc.
Dynamic Analysis
D.1
General
An investigation of the dynamic behaviour of the structure is required in case of risk of resonance of
global or local structural vibration modes with energyrich dynamic loads (periodical excitation forces).
D.2
Sources of excitation
Dynamic loads may be imposed by

environmental loads such as waves, wind, currents, earthquake
by variable functional loads from drilling, process or other rotating equipment
from the propulsion system in case of mobile units
D.3
Global design
D.3.1
Fixed structures
For fixed structures a dynamic analysis will be necessary in case of a platform natural frequency close to
the frequency of energy-rich design sea states.
The global dynamic behaviour will generally have to be accounted for in case of eigenperiods larger than
3 seconds.
D.3.2
Special structures
Dynamic analyses will generally be necessary for structures with large motions, e.g. articulated towers or
guyed ("compliant") structures.
Also for structures installed in seismically active areas a dynamic investigation is required to know the
inertia induced forces.
D.4
Local design
D.4.1
Larger structural components
The design of larger structural components, e.g. flareboom, helicopter deck, and of local structural members shall take account of possible dynamic loads, e.g. due to wind, wave, current, ice-flow or wave
slamming.
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Slender structures
Due regard shall be given to dynamic loads on slender structures such as radio towers and flare booms.
Wind induced vortex shedding and also variable wind speeds (gusts) may cause dynamic stress amplifications and reduce the fatigue life.
D.4.3
Rotating equipment
For structural components supporting rotating equipment with free excitation forces and moments resonance shall be avoided. If this is not possible, the dynamic stress level shall be proven in a forced vibration investigation.
D.4.4
Earthquake loading
For structures which are subject to earthquake loading the eigen-frequencies of appurtenances or equipment supports should be substantially larger than the frequencies of the basic structure modes, see also
D.6
D.5
Structural analysis
D.5.1
Structural modelling
The structural modeling shall take account of the requirements outlined in B.4
D.5.2
Structure/foundation interaction
Special regard shall be given to the structure / foundation interaction. Compared to dynamic fatigue investigation for extreme environmental response a possible reduction of the foundation stiffness has to be
considered. When an equivalent linear foundation model is used, the stiffness of the pile foundation
should be compatible with the expected level of non-linearity in the axial and lateral foundation response.
See ISO 19901-4 for guidance.
D.5.3
Hydrodynamic masses
Besides all effective structural masses, the hydrodynamic masses, accounting for increased member
thickness due to marine growth, and water enclosed in submerged members are to be considered.
D.5.4
Viscous damping
Equivalent viscous damping may be used for dynamic investigations of fixed steel structures. As an estimate two to three percent of critical damping may be applicable.
D.5.5
Method of analysis
D.5.5.1
sponse.
The analysis method to be used will depend on the type of loading and the structural re-
D.5.5.2
Response spectral analysis will be used for structures with a linear elastic response to random
loading, e.g. due to non-deterministic wave loads, provided a linearization of the non-linear load effects is
possible. The method may be appropriate to determine dynamic amplification effects due to extreme
wave loads on fixed jacket structures and also to perform fatigue damage accumulation calculations.
D.5.5.3
Time history analysis, e.g. by direct integration, will have to be used for dynamic problems with
non-linear nature.
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D.6
Earthquake analysis
D.6.1
Strength and stiffness of structure
For seismically active areas the strength and stiffness of offshore structures shall be adequate to ensure
that no significant damage will occur due to the expected design earthquake. 1
D.6.2
Resistance against earthquake loading
An earthquake analysis is not required for areas where the design horizontal ground acceleration
(strength level) is less than 0.05 g, provided other significant environmental loads are to be accounted
for, so that sufficient resistance against earthquake loading is ensured.
D.6.3
Dynamic response
The analysis of the dynamic response should be performed using recognized procedures such as
response spectrum analysis
time history analysis, see D.5.5
Generally a three-dimensional structure model shall be used for the analysis.
D.6.4
Modal maxima
When the response spectrum analysis is applied for the combination of the modal maxima, the use of the
"Complete Quadratic combination" (CQC) method is recommended.
D.6.5
Earthquake induced response
The earthquake induced structural response has to be combined with other load components acting permanently on the structure, see C.
Effective Width of Plating
E.1
Frames and stiffeners
Generally, the spacing of frames and stiffeners may be taken as effective width of plating.
E.2
Girders
E.2.1
The effective width of plating em of frames and girders may be determined according to Table
3.3 considering the type of loading.
Special calculations may be required for determining the effective width of one-sided or non-symmetrical
flanges.
E.2.2
The effective cross sectional area of plates is not to be less than the cross sectional area of
the face plate.
Cantilevers
Where cantilevers are fitted at a greater spacing the effective width of plating at the respective cross section may approximately be taken as the distance of the cross section from the point on which the load is
acting, however, not greater than the spacing of the cantilevers.
As a guideline for the design of a platform for earthquake ground motion the use of American Petroleum Institute API RP2A
Recommended Practice for Planning, Designing and Constructing Fixed Offshore Platforms" is recommended.
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Table 3.3
Effective width of plating em for frames and girders
l/e
em1 / e
0.36
0.64
0.82
0.91
0.96
0.98
1.00
1.0
em2 / e
0.20
0.37
0.52
0.65
0.75
0.84
0.89
0.9
em1 is to be applied where girders are loaded by uniformly distributed loads or else by not less than 6 equally spaced single
loads.
em2 is to be applied where girders are loaded by 3 or less single loads.
Intermediate values may be obtained by direct interpolation.
l
= length between zero-points of bending moment curve, i.e. unsupported span in case of simply supported girders and 0.6
x unsupported span in case of constrained of both ends of girder
e
= width of plating supported, measured from centre to centre of the adjacent unsupported fields
Beam Member Design
All structural beam members shall fulfil the requirements of this Section. It covers strength against tension, compression, shear, bending, torsion and buckling.
Buckling of plates is covered in H.
F.1
Tubular wet members
This section covers all unstiffened and ring stiffened cylindrical tubulars that may be subjected to hydrostatic pressure. These are typically part of jackets, towers or jack-ups.
The tubes have a thickness of more than 6 mm and a diameter to thickness ratio of D/t 120. In addition,
yield strengths shall be less than 500 MPa.
Nontubular members shall be designed according to F.2.
F.2
Hydrostatic pressure
For each element the hydrostatic pressure has to be evaluated:
p = f w g H z
Hz = z +
H w cos h [ k(d + z)]

2
cos h (k d)
with
: 1.0 for allowable stress design (ASD)

: G1 for load resistance factor design (LRFD), load factor for permanent loads G1
: density of the sea water [kg/m3]
: acceleration due to gravity [m/s2]
: depth of the member relative to still water level, measured positive upwards [m]
: still water depth to the sea floor [m]
Hw
wave height [m]
wave number, k = 2 / [1/m]
: wave length [m]
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F.2.1
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Member checks using ASD
For each load combination as defined in Table 3.1 the design has to be checked according to API RP 2A
WSD Section 3. For extreme environmental conditions (C, loading condition 3) the allowable stresses
may be increased by 33 %.
F.2.2
Member checks using LRFD
For each load combination as defined in Table 3.2 the design has to be checked according to ISO 19902
Section 13
F.3
Dry members
Dry members are those that are not subjected to hydrodynamic loading, generally topside beams.
The design has to be checked according to ANSI/AISC Specifications for Structural Steel Buildings that
provide rules for ASD as well as LRFD. The relevant load combinations have to be chosen accordingly as
defined in Table 3.1 (ASD) or Table 3.2 (LRFD)
Tubular Joint Design
G.1
General
Tubular joints are of primary importance for offshore steel structures.

The requirements given in this section apply to tubular connections within the following validity ranges:
yield strength less than 500 MPa
brace angle between 30 and 90
: d/D between 0.2 and 1.0
: D/2T between 10 and 50
: t/T smaller than 1.0
t
T
g
Q
g
t
T
d
D
=
=
=
=
=
=
Fig. 3.2
G.2
brace angle (measured from chord)

gap
brace thickness
chord thickness
brace diameter
chord diameter
Brace connection; definitions
Classification of Joints
A plane is defined by a chord and a brace. A joint is made up of this and possibly other braces that are on
the same plane or tilted less than 15 to it. Are there more braces lying on different sides (planes) connected to the chord they comprise other joints that are treated differently.
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There are three basic joint types: Y, K and X. Although their names are derived from their respective
geometric shapes, the classification almost entirely depends on the distribution of the axial loads.
The classification is done like this:
1. a brace is a K-joint if the component of axial force in the brace perpendicular to the chord is balanced to within 10 % by force components (perpendicular to the chord) in other braces in the same
plane and on the same side of the joint;
2. a brace is a Y-joint if it does not meet the criteria a) and if the component of axial force in the brace
perpendicular to the chord is reacted as beam shear in the chord. This is always true for single
braces.
3. a brace should be considered as an X-joint if it does not meet the criteria a) and b); in this classification the axial force in the brace is transferred through the chord to the opposite side (e.g. to other
braces, to padeyes, launch rails or similar structural components).
The classification of each individual brace-chord combination for a given load case shall be as a Y-, K- or
X-joint. If the brace-chord combination carries part of the axial brace force as a K-joint, and part as a Yjoint or X-joint, it shall be classified as a proportion of each relevant type, e.g. 70 % as a K-joint and 30 %
as an X-joint.
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Section 3

50 % K, 50 % Y
1400
1400
1000
1
2
500
b)
a)
1000
c)
1400
g1
500
1400
K
1
2
1
2
g2
500
g1
1400
1
2
1
2
g1
1
2
1400
1400
2000
d)
e)
1400
f)
50 % K, 50 % X
1400
1000
1
2
1400
K
K
K
Fig. 3.3
G.3
1000
500
4
K
Key
g1 gap 1
g2 gap 2
1
2
K
K
500
1400
g)
h)
Shows some simple examples of the brace joint classification scheme
Tubular joint design using ASD
For each load combination as defined in Table 3.1 the design has to be checked according to API RP 2A
WSD Section 4.
G.4
Tubular joint design using LRFD
For each load combination as defined in Table 3.2 the design has to be checked according to ISO 19902
Section 14.
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Complex joints
Complex joints not covered here shall be designed on the basis of appropriate theoretical or experimental
investigations. These include overlapping joints, conical transitions, grouted joints, etc. See API RP 2A
WSD or ISO 19902 for further details.
Buckling of Plates
H.1
General indications
H.1.1
Structural elements subjected to predominantly compressive or shear stresses, which may
also result from bending or torsion, are to be investigated for overall and/or local buckling failure.
H.1.2
Deformations due to loads (e.g. lateral load producing bending) or manufacture (fabrication
tolerances, welding distortion) shall be taken into account where they may be important, using e.g. second order theory. On the other hand, buckling calculations may result in special manufacturing instructions regarding tolerable imperfections.
H.1.3
Local buckling may be admitted where the structure is designed with sufficient redundancy,
i.e. where adjoining elements are designed to take over the load originally carried by the buckled part with
sufficient safety. Serviceability considerations have to be kept in mind.
H.1.4
Detailed buckling analysis may be carried through according to recognized codes and standards such as
GL Rules for Hull Structures (I-1-1), Section 3
Eurocode 3
AISC (Specification for the Design, Fabrication and Erection of Structural Steel for Buildings, and
Manual of Steel Construction).
Fatigue Strength
I.1
General
A full fatigue analysis of the foundation of a fixed offshore structure is to be carried out according to API
RP 2A WSD or ISO 19902. For a jacket type structure the tubular joints and for a monopole structure the
girth welds as well as the welds of attachments are to be checked for fatigue damage.
A full fatigue analysis of all joints can be dispensed with in case that for these joints it can be shown that
the acceptance criteria of the simplified method are fulfilled. The simplified method is described in paragraph I.2.
Fatigue critical details other than tubular joints and girth welds (e.g. brackets, welds of plates with different thicknesses, etc.) are to be assessed as described in GL Rules for Hull Structures (I-1-1), Section 20
I.2
Simplified method
I.2.1
This method can be used to check if a full fatigue analysis is required
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Definitions
(+)
smin
sm
Ds
smax
time
(-)
Fig. 3.4
Stress cycle
: applied stress range (max - min) [N/mm2]
max
: maximum upper stress of a stress cycle [N/mm2]
min
: maximum lower stress of a stress cycle [N/mm2]
max
: applied peak stress range within a stress range spectrum [N/mm2]
: mean stress (max / 2 + min / 2) [N/mm2]
: permissible stress range [N/mm2]
: corresponding range for shear stress [N/mm2]
: number of applied stress cycles
: number of endured stress cycles according to S-N curve ( = endured stress cycles under
constant amplitude loading)
: fatigue strength reference value of S-N curve at 2 cycles of stress range [N/mm2]
ft
: correction factor for thickness effect
fc
: correction factor for corrosion effects
fm
: correction factor for material effects
fR
: correction factor for mean stress effect
fW
: correction factor for weld shape effect
fi
: correction factor for importance of structural element
fS
: additional correction factor for hot spot stress analysis
fn
: factor considering stress spectrum and number of cycles for calculation of permissible stress
range
Rc
: corrected fatigue strength reference value of S-N curve at 2 106 stress cycles [N/mm2]
fat
: safety factor for fatigue
: cumulative damage ratio
I.2.3
Scope
A fatigue strength analysis is to be performed for all structures which are predominantly subjected to cyclic loading, in order to ensure structural integrity and to assess the relative importance of possible fatigue
damages for the establishment of an efficient inspection programme. The extent of the analysis is influenced by the local stress range and/or the number of cycles due to alternating loads on the structure.
Wave loading is the main source of potential fatigue cracking in jacket structures. However, any other
cyclic loading may contribute to fatigue failure and should therefore be considered.
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The notched details, i.e. the welded connections at tubular joints and girth welds, plates and beams as
well as notches at free plate edges are to be considered individually. The fatigue strength assessment is
to be carried out on the basis of a cumulative damage ratio, according to the Minor Rule. Preliminary assessments can be done on the basis of a permissible peak stress range for standard stress spectra.
I.2.4
Application
The rules are applicable to structural steels up to a specified minimum yield strength of 690 N/mm2. Bolts
are acceptable up to a tensile yield strength of 1000 N/mm2. Other materials such as cast steel, and hybrid joints, can be treated in an analogous manner by adopting appropriate stress concentration factors
and design S-N curves. These must be agreed upon with GL prior to application.
I.2.5
Low cycle fatigue
Low cycle fatigue problems in connection with extensive cyclic yielding have to be specially considered.
When applying the following rules, the calculated nominal stress range should not exceed 1.5 times the
minimum nominal upper yield point. In special cases the fatigue strength analysis may be performed by
considering the local elasto-plastic stresses.
I.2.6
Limitation of fatigue assessment
No fatigue assessment is required if one of the following conditions is satisfied:

I.2.6.1
The maximum stress range max due to wave loads satisfies the following criterion and adequate protection exists in the case of corrosive environment:
fat max R ft fW fm fR fi fS
The above criterion is based on the conservative assumption that the long term distribution of stress
range resembles a Weibull distribution with a shape parameter h 2 and that the total number of cycles is
below 109.
I.2.6.2
The expected number of cycles during the life-time of the structure is less than
2 106 [R ft fC fW fm fR fi fS / (fat max) ]3
max
: the maximum nominal stress range or, for tubular joints, the maximum hot spot stress range,
[N/mm2] see I.2.8
fat
: safety factor according to Table 3.4
: the fatigue strength reference value (for tubular joints, R = 100 N/mm2
ft fC fW fm fR fi fS see I.2.9
I.2.7
Fatigue assessment procedure
The fatigue assessment shall verify that within an acceptable probability level the performance of the
structure during its design life is satisfactory so that fatigue failure is unlikely to occur. An assessment
should be made for every potential crack location.
I.2.7.1
Influence of stress range
The number of stress cycles which may be endured by the structural element depends mainly on the
magnitude of the stress ranges . The influence of the mean stress m is generally small and may be
taken care of by the correction factor fR defined in I.2.9.5
I.2.7.2
Safety factor
For the fatigue assessment procedure the stress ranges shall be multiplied by a safety factor fat which
covers the accessibility of the detail considered and the consequences of failure. Concerning the consequences of failure, the following two types of structures are to be considered:
"fail-safe" structures, with reduced consequences of failure, i.e. local failure of a component does not
result in a catastrophic failure of the structure
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"non fail-safe" structures, where local failure of a component leads rapidly to a catastrophic failure of
the structure
The safety factors to be applied are given in Table 3.4.
Table 3.4
Safety factors on stress range for the fatigue assessment
Structural detail is
part of a fail-safe structure
part of a non fail-safe structure
easily accessible
fat = 1.00
fat = 1.25
not easily accessible (e.g. under water)
fat = 1.15
fat = 1.35
I.2.8
I.2.8.1
Hot spot stress definition

General
As mentioned above, tubular joints shall be assessed on the basis of the hot spot stress range at the
weldtoe. This is the largest stress value at the intersection of the brace and chord and is defined as the
extrapolation of the structural or geometric stress distribution to the weld toe, see Fig. 3.5. With this definition the hot spot stress incorporates the effects of the overall geometry (structural or geometric stress
concentration) but omits the influence of the notch at the weld toe (local stress concentration). The hot
spot stress has to be considered in connection with a particular design S-N curve which reflects the microscale effect occuring at the weld toe.
Nodal joint
nomenclature
Crown point
Brace
Saddle point
Weld
Chord
Stress distribution
in brace
Increase in stress due

to overall joint geometry
Nominal stress
Stress in brace
Brace wall
Extrapolation of geometric
stress distribution to
weld toe
Weld toe
Weld
Chord wall
Stress increase due
to weld geometry
Brace hot spot stress = nominal
stress in brace SCFBrace
Stress distribution
in chord
Increase in stress
due to overall joint
geometry
Extrapolation of geometric
stress distribution to weld
Stress increase due

to weld geometry
Stress in chord
Brace wall
Weld
Chord hot spot

stress = nominal
stress in brace SCFChord
Chord wall
Weld toe
Fig. 3.5
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I.2.8.2
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Stress concentration factors
The hot spot stress can be calculated as the sum of nominal stresses due to the individual load components (i.e. axial load, in-plane and out-of-plane bending moment), each multiplied by a corresponding
stress concentration factor (SCF). Stress concentration factors for the individual load components may be
derived from finite element analyses, model tests or semi-empirical parametric equations based on such
methods. Parametric equations should be used with caution in view of their accuracy and inherent limitations.
At least four different locations around the chord/brace intersection shall be considered because the individual load components produce different stress peaks at the crown and saddle points, see Fig. 3.5. Both
the chord and the brace side of the weld shall be checked in the fatigue analysis.
I.2.8.3
Alternative stress concentration factors
For tubular joints other stress concentration factors are also applicable:
M. Efthymiou (Development of SCF formulae and generalised influence functions for use in fatigue
analysis Recent Developments in Tubular Joint Technology, OTJ 88, London, plus updates)
A. Almar-Nss (Fatigue Handbook Offshore Steel Structures, Tapir Akademisk Forlag, Trondheim)
I.2.8.4
Complex geometry
Tubular joints with complex geometry (braces overlapping or stiffened by gusset plates or ring stiffeners)
have to be investigated by a special analysis.
I.2.8.5
Root failure
In addition to the assessment of the hot spot stress at the weld toe, the fatigue strength with regard to
root failure has to be considered for partial penetration welds by application of the respective detail classification, see GL Rules for Hull Structures (I-1-1), Section 20.
I.2.9
Correction of the reference value of the design S-N curve
I.2.9.1
A correction of the reference value of the S-N curve (or detail category) is required to account
for additional influence factors on fatigue strength as follows:
Rc = ft fC fW fm fR fi fS R
ft, fC, fW, fm, fR, fi, fS as defined in I.2.9.2 I.2.9.8
For the description of the corrected design S-N curve, the formulae may be used, replacing R by Rc.
I.2.9.2
Thickness effect (ft)
For welded connections oriented transversely to the direction of the applied stress with plate thickness t
[mm], exceeding 25 mm at the potential crack locations:
ft = (25 / t) 0.25
For all other cases:
ft = 1.0
I.2.9.3
Corrosion effect (fC)
For parts of a structure in corrosive environment without adequate corrosion protection:

fC = 0.7
For all other cases:
fC = 1.0
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I.2.9.4
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Material effect (fm)
For welded joints it is generally assumed that the fatigue strength is independent of steel strength i.e.:
fm = 1.0
I.2.9.5
Effect of mean stress (fR)
The correction factor is calculated as follows:

in the range of tensile pulsating stresses:
fR = 1.0
m max / 2
in the range of alternating stresses:
fR = 1 + c (1 2 m / max)
max / 2 m max / 2
in the range of compressive pulsating stresses:
fR = 1 + 2 c
m max / 2
c
: 0 for welded joints subjected to constant stress cycles

: 0.15 for welded joints subjected to variable stress cycles
I.2.9.6
Effect of weld shape (fW)
In normal cases:
fW = 1.0
A factor fW > 1.0 applies for welds treated e.g. by grinding. By this surface defects such as slag inclusions,
porosity and crack-like undercuts shall be removed and a smooth transition from the weld to the base
material shall be achieved. Final grinding shall be performed transversely to the weld direction. The depth
should be approx. 0.5 mm larger than that of visible undercuts. For ground weld toes of fillet and K-butt
welds:
fW = 1.15
For butt welds ground flush a weld shape factor
fW = 1.25
may be applied in case of effective protection from sea water corrosion.
The assessment of a local post-weld treatment of the weld surface and the weld toe by other methods
has to be agreed on in each case.
I.2.9.7
Influence of importance of structural element (fi)
The influence of importance is usually covered by the safety factor fat, see Table 3.4, i.e.:
fi = 1.0
I.2.9.8
Hot spot stress analysis (fS)
For tubular joints the factor fS is always 1.
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Application of BSH Requirements
J.1
Scope
The Bundesamt fur Seeschifffahrt und Hydrographie (BSH) requires design checks according to Eurocode 3 that uses an LRFD algorithm. The rules are found in:
DIN EN 1990:2010-12 + DIN EN 1990/NA:2010-12 (National Annex for Germany)
DIN EN 1993-1-1:2010-12 + DIN EN 1993-1-1/NA:2010-12 (National Annex for Germany)
DIN EN 1993-1-8:2010-12 + DIN EN 1993-1-8/NA:2010-12 (National Annex for Germany)
The following describes GLs interpretation of how to apply these rules for offshore installations. However,
the final decision of using them correctly lies with the BSH.
Note
GL advices to perform the structural design according to the API or ISO standards as cited in this Section
and to do the required EURO CODE checks in addition. Scope of these additional checks has to be defined case by case.
J.2
Basic Loads
J.2.1
Permanent Loads G
These are loads that vary never or only little over time. Examples are self weight, weight of embedded
equipment, etc. but also buoyancy.
J.2.2
Variable Loads Q
Q summarizes all other loads that occur during operation. This includes live loads on decks, movable
equipment and environmental loading like effects of ice drift, aero- and hydrodynamic forces. These loads
are to be calculated as outlined in Section 1 and 2.
J.2.3
Pretension P
Generally pretension is negligible for offshore structures and need not to be accounted for.
J.2.4
Accidental Loads A
These are extraordinary loads such as explosions, collisions, earthquakes.

J.3
Combination of Basic Loads
J.3.1
Applicable Formula
All design checks have to be done for the following kinds of possible failure modes:
STR: failure of any structural element
EQU: loss of onbottom stability
GEO: insufficient soil stiffness
DIN EN 1990/NA (German national annex to DIN EN 1990:2010-12) states that only the sum of the following equation yields the loading. The use of equationss. 6.10 a, b of DIN EN 1990:2010-12 is not allowed.
Ed =
G, j EGk, j + P E Pk + Q,1 EQk,1 + Q,i 0,i EQk,i

j 1
i >1
EQk,1 is the leading action. To limit the number of calculations the leading action will be defined in J.3.2
and J.3.3
are the partial load factors, see Table 3.5
are the combination factors applicable when adding different loads, see Table 3.6
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Table 3.5
Partial Load Factors
Action
permanent loads G
STR / GEO
max 1.35
min 1.00
EQU
max 1.1
min 0.9
pretension P
Refer to DIN EN 1992 until 1999
environmental / variable loads Q
STR / GEO
max 1.5
min 0.0
EQU
max 1.5
min 0.0
Table 3.6 Combination Factors 0

Action
0,i
walkways
0.7
laydown areas, helicopter deck
1.0
ice loads on deck
0.5
aerodynamic loads
0.6
hydrodynamic loads
0.6
J.3.2
Leading action for Jacket Structures
As leading action for jackets hydrodynamic loads are recommend (wave and current with a return period
of 100 years). Sustained wind (1 min) is an accompanying action.
Forces due to environmental loading should be calculated as outlined in Section 2. Characteristic parameters such as wave heights, periods, currents and wind speeds are site specific and should be discussed with GL.
J.3.3
Leading action for Topsides
For topsides the leading action is the variable gravitational loads (equipment, live loads, etc.). There may
be special cases where other loads might be dominant, so project specific exceptions may be discussed
with GL.
J.4
Member Checks (DIN EN 1993-1-1:2010-12 + DIN EN 1993-1-1/NA:2010-12)
Member checks must be done as described in F as the methods in F includes hydrodynamic pressure. In
addition Eurocode 3 can be used.
The design resistance Rd is defined by the representative resistance Rk divided by the safety factor Mi :
Rd = Rk / Mi
Table 3.7
with
Safety Factors Mi
Mi
Applicable for
1.00
Strength check of member and joints
1.10
Stability checks
1.25
Rupture (tension)
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Tubular Joint Design (DIN EN 1993-1-8:2010-12 + DIN EN 1993-1-8/NA:2010-12)
Partial safety factor M = M5 = 1.0

Joints are classified solely by their geometric shapes
Y or T joint (single brace)
X joint
K or N joint
Depending on the axial force in the brace(s) different formulae have to be used to check against punching
shear.
DIN 1993 further requires the consideration of three dimensional effects if a node consists of several
joints (only for KK and XX joints). It is done by reducing the resistance.
J.6
Fatigue
The proof of fatigue resistance has to be done as outlined in I.
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Section 4
Steel Structures
Section 4
A
B
C
D
E
F
G
H
I
J
K
Steel Structures
Materials ..................................................................................................................... 4-1

Fabrication ................................................................................................................ 4-20
Welding ..................................................................................................................... 4-39
Survey, Inspection and Testing ................................................................................ 4-66
Survey and Inspection Scheme ................................................................................ 4-68
Non-Destructive Testing ........................................................................................... 4-69
Visual Inspection....................................................................................................... 4-74
Magnetic Particle Inspection..................................................................................... 4-75
Penetrant Testing...................................................................................................... 4-77
Radiographic Testing ................................................................................................ 4-78
Ultrasonic Testing ..................................................................................................... 4-80
Materials
A.1
General
A.1.1
The material requirements for fixed offshore installations and mobile offshore units shall reflect
the overall philosophy regarding design life time, cost profile, inspection and maintenance philosophy,
safety and environmental profile, failure risk evaluation and other project requirements.
A.1.2
Structures shall be categorized by various levels to determine criteria that are appropriate for
the intended service of the structure.
The levels are determined by consideration of life-safety and of environmental and economic consequences.
The life-safety category, see Table 4.1, addresses personnel on the platform and the likelihood of successful evacuation before a design environmental event occurs:
Table 4.1
Life safety category
Category Explanation
Further details
S1
Manned nonevacuated
ISO 19902 Chapter 6.6.2,

GL Rules for Certification and Surveys (IV-7-1),
Section 1, B.4.3.1
S2
Manned evacuated
ISO 19902 Chapter 6.6.2

GL Rules for Procedure (VI-7-1), Section 1,
B.4.3.2
S3
Unmanned
ISO 19902 Chapter 6.6.2

GL Rules for Certification and Surveys (IV-7-1),
Section 1, B.4.3.3
The consequence category, see Table 4.2, considers the potential risk to life of personnel brought in, to
react to any incident the potential risk of environmental damage and the potential risk of economic loss:
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Structural Design
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Table 4.2
Consequence category
Category
Explanation
Further details
C1
High consequence
ISO 19902, Chapter 6.6.3
C2
Medium consequence
C3
Low consequence
The three categories for both life-safety and consequence shall be combined into nine Exposure Levels.
However, the level to be used for structure categorization is the more restrictive level for either life-safety
or consequence. The results are illustrated in Table 4.3:
Table 4.3
Exposure levels
Consequence category
Life-safety category
C1 High
C2 Medium
C3 Low
S1 Manned non-evacuated
L1
L1
L1
S2 Manned evacuated
L1
L2
L2
S3 Unmanned
L1
L2
L3
The Exposure Levels applicable to a structure, see Table 4.4, shall be determined by the Owner prior to
the design of a new structure and be agreed upon by the Certifying Body where applicable in addition to
the selection in the oil and gas industries the following selection shall apply:
Table 4.4
Classification of typical constructions

Type of construction
Exposure Level
Transformer stations
L1
Converter station
L1
Accommodation platform
L1
Mobile offshore units
L2
Offshore meteo station
L2
Handling tools for MWS

(Marine Warranty Survey)
L3
Based on this selection the requirements for the structural material (e.g. minimum Charpy V-notch impact
energy) and welding procedure qualification (WPQ) is specified in both Tables 4.10 and 4.11
A.1.3
The materials for fixed offshore installations shall fulfil the minimum requirements detailed in
this Section. This Section defines typical structural elements used in offshore steel structures, where ordinary building codes or Shipbuilding Rules lack relevant recommendations. Such elements are tubular
members, tubular joints, conical transitions and some load situations for plates and stiffened plates.
The material requirements of this Section shall apply to following parts:
all sub-sea structures
all parts below the atmospheric zone
all parts of the foundation structure including deck-to leg connections
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The battery limits related to the application of this Section and Shipbuilding Rules or ordinary building
codes have to be defined in the specific project considering A.1.1.
The minimum requirements for parts outside of this Section shall be as for exposure level L2.
In the event that Shipbuilding Rules shall be used the material class III applies for special members and
class II applies for primary members for Design Temperature > - 20 C and GL Rules for Hull Structures
(I-1-1), Section 2, Table 2.10 for Design Temperature -20 C, see GL Rules for Hull Structures (I-1-1),
Section 2, Table 2.7.
A.1.4
Materials for the steel structure shall be supplied by manufacturers approved by GL.
Approvals by other recognized Certifying Bodies may be accepted.

A.1.5
As far as possible, steels suitable for welding are to be employed in accordance with recognized standards. If other steels are intended to be used, the relevant specifications with all details required for appraisal are to be submitted to GL for approval.
A.2
Categories of structural members
A.2.1
General
For the selection of materials for the different members of the steel structure the criteria explained below
are to be observed, see also Section 3, A.2.6:
importance of the member within the structure (consequence of failure, redundancy)
character of load and stress level (static or dynamic loads, residual stresses, stress concentrations,
direction of stresses in relation to the rolling direction of the material, etc.)
design temperatures
chemical composition (suitability for welding)
yield and tensile strength of the material (dimensioning criteria)
ductility of the material (resistance to brittle fracture at given design temperature)
through-thickness properties (resistance to lamellar tearing)
Additional properties, such as corrosion resistance, may have to be considered.
A.2.2
Structural members
Depending on the importance of the structural members and on the type of load and the stress level, a
structure can be subdivided into the following component categories:
A.2.2.1
Special structural members
These are members essential to the overall integrity of the structure and which, apart from a high calculated stress level, are exposed to particularly arduous conditions (e.g. stress concentrations or multi-axial
stresses due to the geometric shape of the structural member and/or weld connections, or stresses acting
in the through-thickness direction due to large-volume weld connections on the plate surface).
Note
This applies especially to: cans of tubular nodes, thick-walled deck-to leg and column connections thickwalled points of introduction or reversal of forces, etc.
A.2.2.2
Primary structural members
These are members participating in the overall integrity of the structure or which are important for operational safety and exposed to calculated load stresses comparable to the special structural members, but
not to additional straining as mentioned above.
Note:
These are, e.g. all other tubes of tubular truss work structures (jacket legs, bracings other than cans,
piles), riser support structures, boat landing structures, girders and beams in the deck, self-supporting
plating, helicopter decks, module support structures, crane columns and cranes, etc.
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A.2.2.3
Industrial Services
Structural Design
Steel Structures
Secondary structural members
These are all structural members of minor significance, exposed to minor stresses only, and not coming
under the above categories of both special and primary.
Note:
These are e.g. non-structural walls, stairs, pedestals, rails, mountings for piping and cables, etc.
A.2.2.4
Identification of structural members
The categories of structural members as per A.2.2 are to be fixed in the design stage and indicated in the
construction documentation.
A.3
Selection criteria of steels
A.3.1
Structural steels are defined depending on their specified minimum yield strength (SMYS) in
the following strength classes:
normal strength (mild) steels with SMYS up to 275 MPa
higher strength steels with SMYS over 275 MPa up to 360 MPa
high strength steels with SMYS over 360 MPa
Note
Fine grained structural steels, applied for special and primary structure in case of resistance to fatigue,
are recommended with a nominal yield strength not exceeding 360 MPa.
High strength steels having SMYS exceeding 500 MPa may be employed in technically motivated exceptional cases only with GLs consent. Application of steels with SMYS higher than 690MPa however is not
covered by this Rule.
A.3.2
The strength class chosen for the respective structural member and/or the kind of material
corresponding to it are to be indicated in the construction documentation. The same applies to the special
requirements possibly to be met by the material.
A.3.3
Steels with improved through-thickness properties are to be employed where structural members are rigid and/or particularly thick and where high residual welding stresses are to be expected, e.g.
due to large-volume single-bevel butt joints or double-bevel butt joints with full root penetration, simultaneously implying high stresses acting in the through-thickness direction of the materials.
This will normally be the case where special structural members are concerned.
The same applies for members subject to high external loads acting in thickness direction.
A.3.4
Depending on the structural member category, the design temperature and the material thickness of all steels to be employed for the structure, have to meet the requirements listed in A.4, in particular those for impact energy.
A.3.5
Owing to the risk of hydrogen induced stress cracking (HISC), steels with a SMYS of > 500
MPa shall not be used for critical cathodically protected components without special considerations, i.e. in
the submerged zone of fixed offshore structures or mobile offshore units, see Section 5. This imposes
some restrictions:
any welding or other construction method affecting ductility or tensile properties shall be carried out
according to a qualified procedure which limits hardness to 325 HV10 (300 HB for base material)
this restricts the use of welded structural steels with SMYS of 690 MPa.
A.4
Requirements for steels
A.4.1
Manufacturing procedures
All steels shall be made by generally both the basic oxygen process and basic electric arc process, or by
other methods approved by GL. The open hearth furnace process shall not be used.
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Steel Structures
Steel shall be as follows:

steels with an Charpy V-notch impact test temperature of > 0 C, see Table 4.11, shall be semi-killed
as a minimum, i.e. equivalent to the deoxidation method FN of EN 10025
steels with an Charpy V-notch impact test temperature of < 0 C, see Table 4.11, shall be fully killed,
i.e. equivalent to the deoxidation method FF of EN 10025
all Z35 steels according to EN 10164 and Z30 steels according to API Specification 2H, S4 shall be
fully killed and fine grained
A.4.2
Supply condition and heat treatment
Steels intended for special and primary structural members shall be supplied as follows:
steels with minimum yield strength up to 275 MPa: normalized/normalized rolled (N)
steels with minimum yield strength over 275 and up to 360 MPa: normalized/normalized rolled (N),
thermomechanical rolled (M) or quenched and tempered (QT)
steels with minimum yield strength over 360 MPa: thermomechanical rolled (M) or quenched and
tempered (QT) as defined in EN 10225.
The following thickness limits shall apply:
normalized/normalized rolled (N):
up to 250 mm
thermomechanical rolled (M):
up to 150 mm for normal and higher strength steels
up to 100 mm for high strength steels
quenched and tempered (QT):
up to 150 mm for higher strength steels
up to 100 mm for high strength steels
The minimum rolling reduction ratio of concast material for plates shall be 4 : 1, except for piling, where it
shall be 3 : 1.
A.4.3
Chemical composition and suitability for welding
The steels shall conform to the requirements for chemical composition, as determined by heat analysis,
prescribed in the both Tables 4.5, 4.7, 4.8 and 4.9 or equal.
The Carbon Equivalent CEV and Pcm of the heat analysis shall be calculated by both of the following
equations:
CEV = C + Mn/6+ (Cr + Mo + V) / 5 + (Ni + Cu) / 15
Pcm = C + Si/30 + (Mn + Cu + Cr) / 20 + Ni/60 + Mo/15 + V/10 + 5B
The maximum Carbon Equivalent CEV and Pcm shall not exceed the values prescribed in the relevant
standards or the values of Table 4.5, the smaller value shall apply. CEV and Pcm computed on product
shall not exceed the CEV and Pcm computed on heat by more than 0.02 % and 0.01 % respectively.
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Structural Design
Steel Structures
Table 4.5
Maximum carbon equivalent

Pcm1
CEV 1
Steel strength class

N
QT
QT
Normal strength class
0.43
0.38
Higher strength class
0.45
0.43
0.43
0.24
0.24
0.24
High strength class
0.45
0.43
0.43
0.25
0.25
0.25
1 Valid for steel classes with maximum yield strengths up to 500 MPa
A.4.4
Mechanical properties
A.4.4.1
Tensile test properties
The requirements for tensile strength Rm, specified minimum yield strength (SMYS or ReH) and for elongation at break, as stated in the GL Rules II Materials and Welding, relevant standards and/or approved
material specifications, are to be observed; see also A.3.1.
Beyond this, for steels with required notch bar impact tests at test temperature < -20 C, see Table 4.11,
the yield strength ratio ReH / Rm respectively Rp0.2 / Rm as defined in Table 4.6 shall not be exceeded.
Table 4.6
Yield strength ratios ReH / Rm (Rp0.2 / Rm respectively)
Steel strength class
Material quality N
Material quality M, QT
t 16 mm
t > 16 mm
t 16 mm
t > 16 mm
High strength 1
0.87
0.85
0.93
0.90
Higher strength
0.87
0.85
0.93
0.90
Normal strength
0.80
0.80
0.80
0.80
1 Valid for steel classes with maximum yield strengths up to 500 MPa
A.4.4.2
Impact energy
The minimum values listed in Table 4.10 apply, proof of which to be furnished at the test temperature TT
indicated in Table 4.11.
A.4.4.3
Through-thickness properties
Through thickness testing is required for special structural members, if stresses acting in throughthickness direction. The through-thickness test shall be carried out in the final heat treatment condition in
accordance to EN 10164 or API Specification 2H, Supplementary Requirement S4 and the test results as
follows: Z35 for EN 10164 and Z30 for API Spec. 2H, S4. Through-thickness testing is not required for a
product thickness below 25 mm or if the sulphur content is below 0.007 %. For 6 mm t < 25 mm UT in
accordance to EN 10160 Class S1/E2 is required. Plates and rolled section of special and primary structural members without through thickness stresses shall be inspected by UT per Class S0/E1 of EN
10160.
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42 (T) 1
42 (T) 1
41 (T)
42 (T) 1
60 (T) 1
60 (T) 1
48 (T)
48 (T)
60 (T) 1
420/16
420/16
414/all
414/all
460/16
S420G2 + QT
S420G2 + M
EN 10225
EN 10225
API Spec 2Y Grade 60(+QT)
API Spec 2W Grade 60(+M)

High
strength
steel
S460G1 + QT
EN 10225
60 (T)
48 (T)
48 (T)
420/16
414/all
414/all
S420G1 + M
EN 10225
API Spec 2Y Grade 60(+QT)

(T) transversal
42 (T) 1
60 (T) 1
420/16
S420G1 + QT
EN 10225
41 (T)
41 (T)
42 (T)
42 (T) 1
60 (T) 1
460/16
S460G1 + M
41 (T)
EN 10225
Remarks:
1 options or supplementary requirements of the standard
Special
members
without
Through
Thickness
Properties
acc. to
A.4.4.3
42 (T) 1
60 (T) 1
460/16
S460G2 + M
EN 10225
Z 35 1
Z 30 1
Z 30 1
-60 C 1
-60 C 1
0.010
-60 C 1
-40 C
0.010
-60 C 1
-40 C
0.010
0.010
0.010
-40 C
0.010
0.006 1
0.006 1
0.007
0.007
0.007
0.03
0.03
0.02
0.02
0.02
0.02
0.03
0.03
0.02
0.02
0.02
0.02
[%]
[%]
0.007
Max.
P content
Max.
S content
Z 35 1
Z 35 1
Z 35 1
Through
thickness
value
[%]
Lowest
Charpy test
temp.
[C]
-40 C
-40 C
-40 C
-40 C
-40 C
-40 C
-40 C
-40 C
-40 C
Standard
Charpy test
temp.
[C]
100
100
100
100
100
100
100
100
100
100
100
100
[mm]
Max.
thickness
Section 4
42 (T)
60 (T)
460/16
S460G2 + QT
EN 10225
Standard
Designation
of material
Min.
single
Charpy
value
[J]
Min.
average
Charpy
value
[J]
Min. yield
strength
[MPa]/
at thickness
[mm]
Steel
strength
class
IV
7
2
Special
members
with
Through
Thickness
Properties
acc. to
A.4.4.3
Structural
member
category
Rules
Part
Chapter
Industrial Services
Structural Design
Steel Structures
Table 4.7a Appropriate steels for plates (special structural members/high strength steel)
Page 47
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50 (T) 1
41 (T)
41 (T)
355/25
345/all
345/all
345/63
S355G10 + M
API Spec 2Y Grade 50(+M)
API Spec 2W Grade 50(+QT)
Grade 50(+N)
P355NL2
P355QL2
Grade 42(+N)
S355G7 + M
S355G7 + N
EN 10225
API Spec 2H
EN 10028-3
EN 10028-6
API Spec 2H
EN 10225
EN 10225
41 (T)
41 (T)
41 (T)
34 (T)
345/all
345/all
345/63
289/all
API Spec 2Y Grade 50(+N)
API Spec 2H Grade 50(+N)
Grade 42(+N)
(T) transversal
40 (T)
355/50
P355QL1
EN 10028-6
API Spec 2H
35 (T) 1
50 (T) 1
355/25
S355G9 + M
EN 10225
27 (T)
34 (T)
34 (T)
34 (T)
28 (T)
35 (T) 1
50 (T) 1
35 (T) 1
50 (T) 1
355/25
355/25
35 (T) 1
50 (T) 1
355/25
S355G9 + N
27 (T)
28 (T)
34 (T)
40 (T)
28 (T)
289/all
355/50
40 (T)
34 (T)
34 (T)
34 (T)
EN 10225
Remarks:
Special
members
without
Through
Thickness
Properties
acc. to
A.4.4.3
35 (T) 1
50 (T) 1
355/25
S355G10 + N
EN 10225
355/16
35 (T) 1
50 (T)
355/25
S355G8 + N
EN 10225
41 (T)
S355G8 + M
EN 10225
Z 30 1
Z 35 1
Z 35 1
Z 30 1
-60 C 1
-60 C 1
0.01
-40 C
-40 C
0.01
-60 C 1
-60 C
0.01
-60 C 1
-40 C
0.01
0.008
0.01
0.01
0.01
0.01
0.006 1
0.006 1
0.006 1
0.005
-60 C
0.005
Z 30 1
-60 C 1
0.005
Z 30 1
-60 C 1
0.006 1
Z 35 1
0.005
Z 35 1
0.007
0.03
0.03
0.03
0.03
0.02
0.02
0.02
0.02
0.02
0.03
0.02
0.02
0.03
0.03
0.03
0.015
0.015
0.02
0.02
[%]
[%]
0.007
Max.
P content
Max.
S content
Z 35
Z 35 1
Through
thickness
value
[%]
Lowest
Charpy test
temp.
[C]
-40 C
-20 C
-40 C
-40 C
-40 C
-40 C
-40 C
-40 C
-20 C
-40 C
-40 C
-40 C
-40 C
-40 C
-40 C
-40 C
Standard
Charpy test
temp.
[C]
100
100
150
150
150
100
150
150
100
100
150
250
100
150
150
100
150
150
100
[mm]
Max.
thickness
Table 4.7b
35 (T)
35 (T) 1
50 (T) 1
355/25
Designation
of material
Standard
Min.
single
Charpy
value
[J]
Min.
average
Charpy
value
[J]
Min. yield
strength
[MPa]/
at thickness
[mm]
Section 4
High
strength
steel
Steel
strength
class
IV
7
2
Special
members
with
Through
Thickness
Properties
acc. to
A.4.4.3
Structural
member
category
Rules
Part
Chapter
Industrial Services
Structural Design
Steel Structures
Appropriate steels for plates (special structural members/ higher strength steel)
Page 48
Standard
Designation
of material
Min.
single
Charpy
value
[J]
Standard
Charpy test
temp.
[C]
Lowest
Charpy test
temp.
[C]
Through
thickness
value
[%]
Max.
P content
[%]
Max.
S content
[%]
[mm]
Max.
thickness
Edition 2013
Germanischer Lloyd
P355 Q
S355 N
S355 NL
S355 M
S355 ML
S355 K2
S355 JO
S355 J2
EN 10025-3
EN 10025-4
EN 10025-4
EN 10025-2
EN 10025-2
EN 10025-2
P355 NL1
EN 10028-3
EN 10025-3
P355 N
EN 10028-3
EN 10028-6
S355 G6+M
EN 10025
P355 M
S355 G5+M
EN 10025
P355 ML1
S355 G3+N
EN 10025
EN 10028-5
S355 G2+N
EN 10025
EN 10028-5
S420 M
S420 ML
EN 10025-4
EN 10025-4
EN 10025-4
S460 M
S460 ML
EN 10025-4
355/16
355/16
355/16
355/16
355/16
355/16
355/16
355/50
355/40
355/40
355/16
355/16
355/16
355/16
355/16
355/16
420/16
420/16
460/16
460/16
27 (L) 2
19 (L) 2
19 (L)
27 (L)
28 (L)
28 (L)
28 (L)
28 (L)
28 (L)
40 (L)
40 (L)
40 (L)
40 (L)
40 (L)
19 (L)
27 (L)
19 (L) 3
27 (L) 3
19 (L)
27 (L)
28 (L)
31 (L)
35 (L)
35 (L)
35 (L)
35 (L)
33 (L)
33 (L)
35 (L)
38 (L)
40 (L)
45 (L)
50 (L)
50 (L)
50 (L)
50 (L)
47 (L)
47 (L)
51 (L)
55 (L)
0 C
-20 C 2
-20 C
-30 C
-20 C
-30 C
-20 C
-20 C
-40 C 3
-20 C
-40 C
-20 C
-40 C
-20 C
-40 C
-20 C
-20 C
-10 C
+20 C
2 steels with Charpy values of 27 J may be used as 40 J at 20 C higher test temperature or 30 J at 10 C higher test temperature
3 e.g. 27 J (T) 40 J (L) (see table 6 in EN 10028-3)
Remarks:
High
strength
steel
High
strength
steel
(L) longitudinal
(T) transversal
0.025
0.020
0.025
0.030
0.025
0.020
0.025
0.030
0.025
0.025
0.030
0.030
0.025
0.025
0.025
0.020
0.025
0.010
0.008
0.010
0.025
0.030
0.025
0.008
0.035
0.030
0.025
0.030
0.025
0.010
0.035
0.025
0.030
0.020
0.030
0.025
0.020
0.025
0.030
0.025
30
30
30
63
63
250
250
150
63
63
250
250
40
20
40
20
40
40
16
16
Section 4
Steels for "special" members may be used. The required options on supplementary requirements according to remark 1 (like Z35, Z30, (T)) are not necessary.
The Charpy values-transversal of special members may be used for Charpy values-longitudinal of "primary" members at 20 C deeper.
Steel
strength
class
Min.
average
Charpy
value
[J]
IV
7
2
Primary
members
Structural
member
category
Min. yield
strength
[MPa]/
at thickness
[mm]
Rules
Part
Chapter
Industrial Services
Structural Design
Steel Structures
Table 4.7c Appropriate steels for plates (primary and secondary structural members)
Page 49
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275/16
275/16
S275 M
S275 ML
S275 JO
EN 10025-4
EN 10025-4
EN 10025-2
19 (L)
27 (L)
235/16
S235 JO
S235 J2
EN 10025-2
EN 10025-2
EN 10025-2
Steels for "special" and "primary" members may be used
235/16
19 (L)
27 (L)
235/16
19 (L)
27 (L)
275/16
S275 J2
S235 JR
EN 10025-2
19 (L)
27 (L)
21 (L)
19 (L) 2
31 (L)
28 (L)
21 (L)
28 (L)
21 (L)
Min.
single
Charpy
value
[J]
27 (L) 2
40 (L)
31 (L)
40 (L)
30 (L)
Min.
average
Charpy
value
[J]
+20 C
0 C
+20 C
-20 C
0 C
-40 C
-20 C
-40 C
-20 C
-50 C
Through
thickness
value
[%]
Lowest
Charpy test
temp.
[C]
(L) longitudinal
(T) transversal
Standard
Charpy test
temp.
[C]
2 steels with Charpy values of 27 J may be used as 40 J at 20 C higher test temperature or 30 J at 10 C higher test temperature
Remarks:
Secondary
members
275/16
S275 NL
EN 10025-3
275/16
275/16
S275 N
EN 10025-3
275/16
P275 NL1
EN 10028-3
Standard
Designation
of material
Min. yield
strength
[MPa]/
at thickness
[mm]
0.025
0.030
0.035
0.025
0.025
0.030
0.035
0.025
0.030
0.025
0.020
0.030
0.030
0.025
0.025
0.030
0.020
0.025
0.025
[%]
[%]
0.008
Max.
P content
Max.
S content
400
250
250
150
150
150
150
250
250
250
[mm]
Max.
thickness
Section 4
Normal
strength
steel
Steel
strength
class
IV
7
2
Primary
members
Structural
member
category
Rules
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Table 4.7c Appropriate steels for plates (primary and secondary structural members) continued
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355/20
EN 10225 S355G14+QT
355/20
355/20
S355G15QT
355/20
460/20
S355G14+N
EN 10225
EN 10225
S355G15+N
S460G6+QT
420/20
35 (T) 1
35 (T) 1
50 (T) 1
35 (T) 1
35 (T) 1
42 (T) 1
42 (T) 1
50 (T) 1
50 (T) 1
50 (T) 1
60 (T) 1
60 (T) 1
-40 C
-40 C
-40 C
-40 C
-40 C
-40 C
Z35 1
Z35 1
Z35 1
Through
thickness
value
[%]
0.010
0.010
0.007
0.007
0.010
0.025
0.025
0.025
0.025
0.025
0.025
40
40
40
40
40
40
[mm]
[%]
[%]
0.007
Max.
thickness
Max.
P content
Max.
S content
Normal
strength
steel
Higher
strength
steel
High
strength
steel
355/20
355/20
EN 10225 S355G13+QT
EN 10225
50 (L)
50 (L)
50 (L)
60 (L)
60 (L)
(L) longitudinal
(T) transversal
Steels for "special" and "primary" members be used.
S355G1+N
355/20
S355G13+N
EN 10225
420/20
S420G5+QT
EN 10225
460/20
S460G5+QT
EN 10225
35 (L)
35 (L)
35 (L)
42 (L)
42 (L)
-20 C
-40 C
-40 C
-40 C
-40 C
0.030
0.015
0.015
0.015
0.015
0.035
0.025
0.025
0.025
0.025
20
20
20
20
20
Higher
strength
steel
EN 10225
EN 10225
Remarks:
Secondary
members
Primary
members
Special members
without Through
Thickness
Properties acc. A.4.4.3
Special members
with Through
Thickness
Special members
without Through
Thickness
S420G6+QT
Lowest
Charpy test
temp.
[C]
Table 4.8
EN 10225
Standard
Charpy test
temp.
[C]
Section 4
High
strength
steel
Steel
strength Standard
class
Min.
single
Charpy
value
[J]
IV
7
2
Special members
with Through
Thickness
Structural
member
category
Min.
Min. yield
average
strength
Designation
Charpy
[MPa]/
of material
at thickness value
[mm]
[J]
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355/16
S355G12+M
EN 10225
35 (T)
50 (T)
35 (T)
50 (T) 1
42 (T) 1
60 (T) 1
-40 C
-40 C
-40 C
-40 C
Z35
Z35
Z35
Z35
Through
thickness
value
[%]
Lowest
Charpy test
temp.
[C]
420/16
S420M
S420ML
EN 10225-4
355/16
355/16
S355G4+M
S355G1+N
EN 10225
EN 10225
355/16
355/16
355/16
S355K2
S355JO
S355J2
40 (L)
27 (L) 2
27 (L) 2
40 (L)
40 (L)
50 (L)
50 (L)
50 (L)
50 (L)
47 (L)
47 (L)
-40 C
-20 C
0 C 2
-20 C 2
-30 C
-20 C
-20 C
-20 C
-40 C
-40 C
-20 C
0 C
+20 C
-40 C
(L) longitudinal
28 (L)
19 (L) 2
19 (L) 2
28 (L)
28 (L)
35 (L)
35 (L)
35 (L)
35 (L)
33 (L)
33 (L)
42 (L)
38 (L)
42 (L)
(T) transversal
Steels for "special" and "primary" members be used.
355/16
S355NL
60 (L)
60 (L)
55 (L)
2 steels with Charpy values of 27 J may be used as 40 J at 20 C higher test temperature or 30 J at 10 C higher test termperature
Normal
strength
steel
355/16
S355N
355/16
EN 10225
355/16
S355G11+N
S355G11+M
EN 10225
EN 10225-3
Higher
strength EN 10225-3
steel EN 10225-2
EN 10225-2
EN 10225-2
High
strength
steel
460/16
S460M
High
strength EN 10225-4
steel EN 10225-4
420/16
420/16
S420G3+M
460/16
S460G3+M
EN 10225
EN 10225
Remarks:
Secondary
members
Primary
members
355/16
S355G12+N
EN 10225
420/20
S420G6+QT
EN 10225
42 (T) 1
60 (T) 1
Standard
Charpy test
temp.
[C]
0.007
0.007
0.007
0.020
0.020
0.020
0.020
[%]
[%]
0.007
Max.
P content
Max.
S content
63
63
63
63
[mm]
Max.
thickness
0.025
0.030
0.025
0.020
0.025
0.030
0.030
0.015
0.015
0.020
0.025
0.025
0.015
0.015
0.025
0.030
0.025
0.025
0.030
0.035
0.035
0.025
0.025
0.025
0.030
0.030
0.025
0.025
30
30
30
250
250
40
40
63
63
16
16
16
63
63
Higher
strength
steel
460/20
S460G6+QT
Min.
single
Charpy
value
[J]
Table 4.9
EN 10225
Min.
Min. yield
strength
average
Designation
[MPa]/
Charpy
of material
at thickness value
[J]
[mm]
Section 4
High
strength
steel
Steel
strength Standard
class
IV
7
2
Special members
with Through
Thickness
Properties acc.
A.4.4.3
Structural
member
category
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1, 2, 3
Table 4.10 Minimum Charpy V-notch impact energy requirements

Minimum nominal yield strength 4 [MPa]
Transversal:
Special category
Charpy VEnergy
[Joule]
Longitudinal:
primary + secondary
category
235
275
290
355
420
Minimum average
27
30
34
40
48
Minimum single
19
21
24
28
34
Minimum average
27
30
34
40
47
Minimum single
19
21
24
28
33
460
500
550
620
690
Minimum average
50
50
55
62
69
Minimum single
35
35
39
44
49
Minimum average
50
50
55
62
69
Minimum single
35
35
39
44
49
Minimum nominal yield strength 4 [MPa]

Transversal:
Special category
Charpy VEnergy
[Joule]
1
2
3
4
Longitudinal:
primary + secondary
category
average value from 3 specimens, one single value may be below minimum average
steels with Charpy values of 27 J may be used as 40 J at 20 C higher test temperature or 30 J at 10 C higher test temperature
e.g. 27 J(T) 40 J(L) (see Table 6, EN 10028-3)
intermediate values may be interpolated
Table 4.11 Charpy V-notch impact test temperatures TT [C] for exposure levels L1, L2 and L3
1, 2,
Category of sea
(Temp. range)
Thickness t of product [mm]
Steel
category
TD
Polar sea
e.g. Alaska Sea,
Bering Sea
1
(TD 20 C)
Exp.
level
L1
25 < t 50
20 C
20 C
Special
30
Primary
Secondary
L2
L3
L1
20
20
50
20
20
20
10
10
10
Edition 2013
12,5 < t 25
20 C
TD
Cold sea
e.g. North sea,
Baltic Sea, Irish Sea
1
(15 C TD 0
C)
12,5
L2
L3
L1
35
20
50
30
20
20
10
10
10
10 C
L2
>
50
20 C
L2
L3
L1
35
20
50
35
20
50
35
20
50
35
20
30
20
20
10 C
10 C
L3
10 C
Exp.
level
Special
L1
L2
L3
L1
L2
L3
L1
L2
L3
L1
L2
L3
20
10
10
40
25
10
40
25
10
40
25
10
Primary
10
10
10
20
10
10
40
25
10
40
25
10
Secondary
20
10
10
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TD
Temperate sea
e.g. English Channel,
Bay of Biscay,
West Mediterranean
1
(0 C TD +15
C)
0 C
0 C
0 C
Exp.
level
L1
L2
L3
L1
L2
L3
L1
L2
L3
L1
L2
L3
Special
10
30
15
30
15
30
15
Primary
10
30
15
30
15
Secondary
+10
+10
+10
+10
+10
+10
10
TD
Warm sea
e.g. Gulf of Guinea,
Arabian and Persian
Gulf, Indian Sea,
East Mediterranean
1
(TD > +15 C)
0 C
+20 C
L2
Exp.
level
L1
Special
+10
Primary
+20
Secondary
+30
+20 C
L3
L1
+20
+20
10
+20
+20
+30
+30
+20 C
L2
L3
L1
+5
+20
10
+10
+20
+20
10
+30
+30
+30
+10
L2
+20 C
L2
L3
L1
+5
+20
10
+5
+20
+5
+20
10
+5
+20
+20
+20
L3
TD = design temperature to be determined in accordance with Section 1, F.1A
For intermediate temperatures TD the Charpy V-notch impact test temperatures TT may be interpolated.
The Charpy V-notch test temperature TT stated in Table 4.11 may differ from the values stated in the various material standards
because they are depending on the design temperature TD and the exposure level. For ordering of materials it is possible to
either specify the Charpy V-notch values according to Table 4.10 and the test temperatures according to Table 4.11 or to use
comparable materials (see examples in the following describing the way to find comparable complying materials).
A.4.4.4
Ordering of material
For ordering materials it is not necessary to specify the Charpy V-notch values (Table 4.10) and TT (Table
4.11) in accordance to these Tables; comparable materials can be used. The following examples shall
explain one possible way to find comparable materials in accordance to this Section.
1.
Use the Tables 4.7 to 4.9 for pre-selection
These Tables provide materials listed with the most important properties for material selection.
a) Selection of different structural members, e.g. sulphur values ( 0.007 % or Z35/Z30, see A.4.4.3)
and Charpy V-notch values in transversal direction for special members.
b) Selection of material suitable for welding, e.g. all listed material have CEV- and PCM -values in
accordance to Table 4.5. The thickness limitations of some steel grades are based on these requirements.
2.
Use tables of standards showing the requirements of Charpy V-notch values depending on TT like
EN 10025 Part 3,4 and 6, both Tables 6 and 7 , EN 10028 Part 3, 5 and 6, Tables 4, 5 and 6 or
standards with Charpy V-notch values at two different test temperatures as additional options , like
API Specification 2 H, 2 W and 2Y.
A.4.4.5
Examples for steel selection
Table 4.12 Example no. 1
Material type
SMYS
TD
[MPa]
[C]
[mm]
355
-15
60
Exposure Level
L1
Application
Plate for can with diameter of 950 mm
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Explanation:
1.
We preselect the Grade S355G8 + M (EN 10225), because cans of tubular nodes are exposed to
stress acting in the through-thickness direction, i.e. special members with through-thickness properties
are required, see both A.4.4.3and Table 4.7b. This is fulfilled with a maximum sulphur value of 0.007 %,
i.e. no supplementary requirements no. 13 with through-thickness testing are required. Grade S355G8 +
M has a CEVmax. = 0.43 % and Pcmmax. = 0.24 %, i.e. the requirements for suitability for welding are fulfilled, see Table 4.5. The required safety factor Yield Strength Ratio of maximum 0.90, see Table 4.6, will
also be reached, see EN 10225, Table 10.
In accordance to both Table 4.10 and 4.11 the material shall provide minimum average Charpy V-notch
values of 40 J at -45 C in transversal direction (T). In EN 10225 and Table 4.7b S355G8 + M the minimum average Charpy V-notch value is 50 J (transversal)) at -40 C.
2.
The comparability of 40 J (T) at -45 C and 50 J (T) at -40 C can be verified by comparison of
Grade 50 (+M) of API Specification 2 W with S355G8 + M.
Table 4.13 Material properties example no. 1
CEV
max.
[%]
Pcm
max.
[%]
S max.
[%]
Charpy V-notch
value min. average
Grade 50 (+M)
0.43
0.24
0.010
41 J at -60 C
S355G8 + M
0.43
0.24
0.007
50 J at -40 C
3.
Therefore is 50 J (T) at -40 C comparable with 41 J (T) at -60 C and this includes 40 J (T) at 45 C. This comparison shows, that S355G8 + M is acceptable down to a Design Temperature TD of -30
C for the Exposure Level 1.
4.
In the same manner the comparability of all Grades of EN 10225 listed in the Table 4.7 to 4.9
can be verified by comparison with API Specification 2H, 2W and 2Y.
Table 4.14 Example no. 2
Material type
Application
SMYS
[MPa]
TD
[C]
t
[mm]
Exposure Level
355
-10
60
L1
Plate for legs with diameter of 950 mm
Explanation:
1.
We pre-select Grade P355ML1 (EN 10028-5). Grade P355ML1 specify only the CEV max. value
with 0.40 %. This is acceptable in accordance to both A.4.3 and Table 4.5. The required safety factor
Yield Strength Ratio can be calculated by:
ReH (min.)/Rm(min.) = 345/450MPa = 0.766
This value is below 0.90, i.e. is acceptable, see both A.4.4.1 and Table 4.6. In accordance to both Tables
4.10 and 4.11 the material shall provide minimum average Charpy V-notch values of 40 J at - 40 C in
longitudinal (L) direction. In EN 10028-5 Table 5 P355ML1 provides 27 J at -40 C in transversal (T) direction.
2.
The comparability of 40 J (L) at -40 C and 27 J (T) at -40 C can be verified by comparison with
Grade S355 ML (EN 10025-4).
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Table 4.15 Material properties example no. 2

CEV max.
[%]
S355ML
0.4
P355ML1
0.4
Charpy V-notch value

min. average (L)
Charpy V-notch value

min. average (T)
31 J at - 40 C
20 J at - 40 C
155 %
100 %
41.8 at - 40 C
27 J at - 40 C
155 %
100 %
3.
Therefore 27 J (transversal) at - 40 C is comparable with 41.8 J (longitudinal) at - 40 C for
P355ML1; i.e. the charpy properties are acceptable.
A.4.5
Stress relieving treatment
A.4.5.1
General
Where the thickness, complexity or high level of stresses of the welded assemblies will require, or at least
indicate, the probable requirement of stress relieving treatment after welding, the corresponding steels
shall be ordered with tests on their physical properties (at least for tensile and impact properties) after
such a treatment or after welding without such a treatment, see also CTOD, A.4.5.5.
A.4.5.2
Reference thickness and thickness limits for stress relieving treatment
Stress relieving treatment is required for materials of a Reference Thickness exceeding 50 mm for Special Category and high strength steels of Primary Category members joined by full penetration welds.
For mobile offshore units and structure of exposure level L3, see Table 4.4, the stress relieving treatment
may be waved, if inspection intervals are shortened and inspections are performed based on specific test
plans. These test plans shall be based on the stress history since the last inspection.
In a full penetration weld (e.g. butt welds, T-, K-, Y- welds, etc.) the Reference Thickness is that thickness
which governs the thickness of the weld. For example:
thickness of thinner member in a butt weld
thickness of stub in stub/can junction in a tubular node
i.e. stress relieving treatment is not generally required for Special Structural Members with a thickness of t > 50 mm. It is only required, if the stress acting on Special Structural Members are as
specified in A.2.2.1. In the case of stub/can conjunction stress relieving treatment is only required, if
the thickness of the stub is thicker than 50 mm, but not if only the can is thicker than 50 mm, see
Fig. 4.33.
stress relieving treatment can be waived by CTOD tests, see A.4.5.5.
A.4.5.3
Post-weld heat treatment (PWHT)
This heat treatment shall be defined by the steel producing mill and shall be submitted to GL for information, see EN 10225, Chapter 8.3.2. The holding time shall be 2 minutes per mm of thickness. Acceptance
tests shall then be performed on samples having undergone the heat treatment under simulated conditions. The results shall comply with requirements stated in this specification or other contractual documents with upgrading values concerning steel qualities and grades.
A.4.5.4
Weld improvement techniques
A.4.5.4.1 General
Weld improvement techniques may be considered as a last resort measure that only can be justified
when the project is too far advanced to still enable design changes to be introduced in a timely and practical manner.
A.4.5.4.2 Peening
Peening of local areas of weld toes or weld transitions to improve fatigue life of structures is to be specified in a detailed procedure about performance, tools, measurements and documentation.
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Application has to be specifically agreed with GL case by case.

A.4.5.4.3 TIG dressing
Due to uncertainties regarding quality assurance of the welding process, this method may not be recommendable for general use in the design stage.
In case of performance on a later stage a detailed procedure to be submitted and approved. Specific areas are to be mentioned.
A.4.5.4.4 Weld toe grinding
This method shall apply only for high fatigue utilization, see also B.10.15. A detailed procedure is to be
prepared by the manufacturer and to be approved by GL.
In case of removal of undercuts in the toe area a smooth transition to be ground and toe defects to be
removed. The minimum radii of the weld profiles shall not less than 10 mm. Grinding marks shall run perpendicular to the weld axis and under no circumstances parallel. After grinding both 100 % visual examination and 100 % MT shall be performed. The ground surface shall be free of any cracks and crack-like
indications.
A.4.5.5
Crack tip opening displacement (CTOD)
A.4.5.5.1 General
The CTOD test may wave the stress relieving treatment in accordance to A.4.5 and shall meet a requirement of minimum 0.25 mm (as-welded) at -10 C for Design Temperature down to -15 C, see Table 4.11:
Cold sea, and above submerged zone (0 C for submerged zone). CTOD-testing of welds shall be carried
out with the fatigue notch tip positioned in the coarse grained region of the heat affected zone (HAZ) and
in the weld.
Other test temperatures, especially for a design temperature < -15 C, see Table 4.11: Polar sea, shall be
prescribed by the Designer and approved by GL. (For CTOD-testing, see both EN 10225 Attachment E
and BS 7448 3).
A.4.5.5.2 Pre-production qualification
The CTOD testing of the heat affected zone (HAZ) may be omitted if the following requirements of the
pre-qualification by the manufacturer are qualified:
CTOD tests shall be performed for each condition of material supply from each manufacturer.
CTOD data for the HAZ is generally provided by the steel supplier's weldability data.
CTOD testing of the HAZ of the test weld may be specified in the welding procedure qualification requirements.
Charpy V-notch tests results on the PQR should not be substantially lower than those obtained by
the steel supplier.
Qualification welding shall be conducted at both the highest heat input/interpass temperature and
lowest heat input/interpass temperature to be allowed for production welding, as governed by the
welding procedure specification (WPS).
The test welding positions shall be selected as those representing the highest and lowest heat input
of the procedure(s) to be qualified by such tests.
A.4.5.5.3 Additional essential variables
For welding procedures that are CTOD-tested, the following changes shall be considered essential variables, in addition to the essential variables listed in the selected welding standard, see also C.3.7.2, etc.:
any increase in the maximum interpass temperature over that qualified in the high heat input CTOD
procedure qualification test
an increase in joint thickness greater than that used for the CTOD procedure qualification tests
a decrease in heat input from the heat input qualified during low heat input CTOD procedure prequalification test for the HAZ
any increase in the heat input from the average heat input qualified of the fill passes during the high
heat input CTOD procedure qualification tests
any change in electrode or electrode/flux brand name or the place of manufacturer
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a reduction in the depth of back-gouging as measured during the CTOD qualification testing
a reduction in the width of back-gouging as measured during the CTOD qualification testing
an increase in the layer thickness (as measured in the fusion line) greater than 10 %, versus that
measured during CTOD pre-qualification testing
A.4.6
Impact energy after strain ageing
Steels which are to be subjected to a cold (below 250 C) or a warm forming process of more than 5 %
strain, either heat treatment shall be performed, or strain ageing tests shall be carried out according to the
following procedure:
material shall be strained locally to the design deformation
material shall be heated at 250 C for 1 hour
set of 3 impact test specimens shall be tested from the base material in the strained plus heated
condition; the notch shall be located within the strained portion, where the part has received the
highest strain
the impact test temperature shall be in accordance to Table 4.11
the impact energy shall comply with Table 4.10 and not be more than 25 % lower than the impact
value for the material before deformation and strain ageing
If straining is performed at a temperature above 250 C, it shall be documented that the material properties, weldability, weld and HAZ properties satisfy the material Certificate and this Section.
A.4.7
Non-destructive testing
A.4.7.1
Plates and rolled sections
Plates and rolled sections of H and I shaped type (or equivalent) shall be ultrasonic inspected in accordance with EN 10160 for plates and EN 10306 for H and I shaped type. UT scanning shall be carried out
over 100 % of webs and flanges of rolled sections and edges and body of plates.
Each plate and rolled section of Special members with Through Thickness Properties shall be inspected
as per Class S1/E2 of EN 10160 or equivalent.
Plates and rolled sections of Special and primary members without Through Thickness Properties shall
be inspected as per Class S0/E1 of EN 10160 or equivalent.
A.4.7.2
Welded and seamless tubes
This Section applies to structural tubulars manufactured by pipe mills or tubular workshops which are
qualified to produce tubulars according to API Specification 2B or EN 10225.
A.4.7.2.1 Welded tubes
Steel plates shall be ultrasonically tested in accordance with the requirements of A.4.7.1. No weld repairs
shall be permitted on plates.
A.4.7.2.2 Seamless tubes
All tubulars shall be NDT tested over their full length. Ultrasonic testing shall apply for wall thickness of
10 mm and above, details see EN 10225, Chapter 8.5.3.2.
A.4.8
Inspections
Inspections of materials shall be documented by the following Inspection documents according to EN

10204:
Secondary structural members:
2.2 Test report
Primary structural members
3.1 Inspection Certificate
Special structural members
A.4.9
Identification and marking
A.4.9.1
All products are to be marked according to the standard such as to enable their clear identification and correlation to the inspection documentation.
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A.4.9.2
Products which cannot be clearly identified shall be rejected, unless the properties stipulated
can be determined by both re-inspection and re-testing, see also B.5.2.
A.5
Steel forgings and castings
A.5.1
General
Where steel forgings or castings are intended to be employed for special and primary structural members,
relevant material specifications containing all details required for assessment are to be submitted to GL.
For secondary structural members appropriate materials in accordance with the standards may be employed.
A.5.2
Approval test
Steel forgings and castings for special and primary structural members are to be subjected to an approval
test by GL.
The scope of testing will be fixed from case to case. An approval test may be dispensed with, where standardized forgings and castings with nominal yield points up to 360 MPa are concerned, which do not have
to meet any special requirements.
A.5.3
Supply conditions
All products are to be supplied in heat-treated condition. Heat treatment may comprise:
normalizing
normalizing and tempering
quenching and tempering
A.5.4
Chemical composition and suitability for welding
The composition of forged and cast carbon and carbon manganese steel grades suitable for welding has
to meet the minimum requirements defined in both Table 4.16 and 4.17. The values apply to both ladle
and product analysis.
Table 4.16 Forged structural steel
Min. Yield strength
SMYS
Max.
S content
Max.
P content
Max.
CEV
Max.
Pcm
[MPa]
[%]
[%]
[%]
[%]
355
0.005
0.015
0.45
0.22
420
0.007
0.015
0.47
0.22
460
0.007
0.015
0.55
0.27
Table 4.17 Cast structural steel

Min. Yield strength
SMYS
Max.
S content
Max.
P content
Max.
CEV
Max.
Pcm
[MPa]
[%]
[%]
[%]
[%]
310
0.008
0.012
0.41
0.24
420
0.008
0.012
0.48
0.26
460
0.005
0.012
0.55
0.28
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Weldability data are required for a weld bevel thickness above 25 mm. The documentation of weldability
shall be in accordance with EN 10225, Annex E. The heat input shall be 3.5 0.2 KJ/mm, see EN 10225,
Table E.3.
A.5.5
Material properties
Product testing shall be carried out for each cast and forged item above 1 t weight. For smaller forgings or
large series another test frequency may be agreed upon. The results obtained shall comply with Tables
4.6, 4.10 and 4.11.
A.5.6
Inspections
Unless otherwise fixed or agreed, plates for special structural members are to be tested individually per
rolled length. For all other products the inspection lots as indicated in the standards and/or GL Rules II
Materials and Welding apply.
Inspections of materials shall be documented by the following Inspection documents according to EN
10204:
Secondary structural members:
2.2 Test report
Primary structural members:
Special structural members:
A.5.7
Identification and marking
A.5.7.1
All products are to be marked according to the standard such as to enable their clear identification and correlation to the inspection documentation.
A.5.7.2
Products which cannot be clearly identified shall be rejected, unless the properties stipulated
can be determined by both re-inspection and re-testing, see also B.5.2.
A.6
Non-welded steels and bolts
The properties of non-welded steels are determined by the categories of structural members. Depending
on the structural member category and the design temperature to be employed for the structure, have to
meet the following requirements listed in A.4 and A.5:
Owing to the risk of hydrogen induced stress cracking (HISC), steels with SMYS of > 500 MPa shall
not be used for critical cathodically protected components without special considerations, i.e. in the
submerged zone of fixed offshore structures or mobile offshore units, see Section 5. This imposes
some restrictions:
a) any construction method affecting ductility or tensile properties shall be carried out according to
a qualified procedure which limits hardness to 300 HB (or 32 HRC),
b) this restricts the use of structural steels with SMYS of 690 MPa and bolts with class 8.8 according to ISO 898.
The minimum Charpy V-notch impact properties in accordance to both Tables 4.10 and 4.11, but independent of the material thickness at Charpy V-notch test temperature for 12.5 mm.
Bolts with a diameter above 25 mm shall be impact tested to the same requirements as for nonwelded steels be bolted, see also B.10.11.
Fabrication
B.1
General
B.1.1
Fabrication, other than welding, shall be in accordance with a national or regional fabrication
specification that complements the design code used. Fabrication tolerances shall be compatible with
design assumptions, except where specific service requirements dictate the use of more severe control
over the deviations assumed in the design.
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B.1.2
The minimum requirements for the fabrication and construction of steel structures are defined
herein. These requirements analogously apply to work carried out on the steel structure prior to or during
transport, installation and operation and for repairs. For welding, see C and for inspection and testing, see
D.
B.2
Standards and specifications
The application of relevant codes, standards, guidelines, specifications, etc. (e.g. AWS D 1.1, NORSOK
M-101 or EEMUA No. 158) may be agreed by GL. Should such codes, standards, guidelines, specifications, etc. contradict the present rules then the latter shall take precedence over all others.
B.3
Fabrication specifications, schedule
Prior to commencement of the work the contractor shall submit specifications containing the main aspects
of fabrication and construction to GL for approval.
Additionally following items are required:
welding procedure specifications (WPSs)
NDT specifications
related drawings and/or descriptive lists/tables with weld details and NDT requirements
inspection and testing plans (ITPs)
B.4
Quality assurance and control
B.4.1
Manufacturers will be responsible for compliance with these Rules, with the approved drawings and specifications as well as with any other conditions which may be agreed or stated in the approvals. The inspections performed by GL do not relieve manufacturers of their responsibility.
B.4.2
Manufacturers are to introduce a quality assurance system which ensures that the materials,
fabrication and construction are in accordance with these Rules.
The manufacturer shall have an implemented and documented quality system with minimum requirements of ISO 3834-2 for special and primary members and of ISO 3834-3 for secondary members.
B.4.3
The quality control shall be performed by the competent personnel with defined responsibilities
covering all aspects of quality control including welding and NDT. The quality assurance department shall
be independent from the manufacturing department.
An organization chart, including proof of qualification of the personnel in charge of control, is to be submitted to GL.
B.4.4
During fabrication and construction adequate controls shall be carried out by the contractor,
inter alia, as to:
the storage and marking of materials
the preparation and assembly of components
the accuracy to size of the components and the overall structure
faults and deficiencies shall be corrected before painting or other means of permanent covers have
been applied
B.4.5
The quality assurance is also to cover all work which may affect the integrity and strength of
the structure, including the fitting of auxiliary structures and equipment to the structure, fairing and repair
work, as well as corrosion protection measures.
B.4.6
All quality assurance measures are to be recorded, thus proving the kind, scope and results of
the checks. A summary analysis of results is to offer a clear picture of the progress of work, including
possible rework and controls. The records and analysis are to be presented to the GL Surveyor for approval at reasonable intervals.
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B.5
Industrial Services
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Steel Structures
Identification and storage of materials
B.5.1
All materials (plates, girders, shapes, tubes, etc.) or other types of shape for main structural
parts (special and primary) are to be clearly marked as to enable them to be definitely identified on the
basis of the pertinent Certificates.
B.5.2
Non-identified materials are to be rejected, unless compliance with these Rules and/or the
approved specifications has been verified by renewed testing. The number and type of tests shall be in
accordance with A.4.9.2 or A.5.7.2, respectively.
B.5.3
Manufactures shall have a system, to trace the material within the structure. During each
stage of manufacture correlation of the pertinent material Certificates to each individual component shall
be possible.
B.5.4
All materials and structural members are to be stored and handled such as to exclude their
surface finish and properties being unduly affected. For the storage of welding consumables and auxiliary
materials, see C.2.3.
B.6
Deviations, defects and repair work
B.6.1
Any deviation from the Rules, approved drawings and specifications or conditions agreed or
stated in the approvals require prior approval by GL. The same applies analogously to major repairs. A
proposal for intended repair work is to be prepared by the manufacturer and to be presented to GL for
approval together with a report on defects. Repair work shall be started only following approval of the
repair procedure by GL. For admissible tolerances, see B.15.
B.6.2
For any such substitutions and revisions made during fabrication, suitable records shall be
documented by the fabricator and listed as corrections to the fabrication drawings.
B.6.3
Following types of documents are required:
Non-conformity Report (NCR)

Technical Query (TQ)
Site Query (SQ)
Whenever such a document was raised by the contractor the approval of the Owner/Purchaser and GL
Surveyor shall be mandatory. In certain major cases, i.e. involvement in special and/or primary structural
elements, the approval of GL HO is required.
B.6.4
The responsibility for the compilation of these records with other documentation related to the
construction and inspection of the structure and the retention of these permanent records shall be specified by the Owner/Purchaser.
B.7
Surface and edge preparation of both materials and structural members
B.7.1
When applying thermal (cutting) procedures, the possibility of hardening of the basic material
and depending on the materials employed variation of the strength and/or toughness values and are
to be taken into account.
B.7.2
Excessive flame cutting drag lines, (e.g. due to burner failure) are to be ground notch-free with
smooth transitions. Where possible, weld repairs are to be avoided and require approval by the GL Surveyor.
B.7.3
Plates or tubes shall be prepared by machining or by thermal cutting (flame cutting, plasma
cutting, etc.) followed by mechanical cleaning where appropriate in accordance with an internationally
accepted standard. The same applies analogously to shear cuts, the fins of which are to be rough-planed
in all cases.
Surfaces to be welded shall be visually examined and to be free of any kind of defects, details see
C.6.3.10.
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B.7.4
Flame cut edges that are not subsequently welded shall be ground to remove nicks and burrs.
The use of flame gouging or washing is not permitted.
B.7.5
Where practicable, penetrations through main members (e.g. for piping or cables) are to be
drilled. Flame-cut penetrations shall, under all circumstances, be completely ground notch-free. The
edges are to be chamfered or rounded off.
B.7.6
The surface of piles and followers shall be untreated bare metal, free from mill varnish, oil and
paint, except for specific markings. The area of the surface used for markings shall be minimum required
consistent with adequate identifications.
B.8
Cold and hot forming
B.8.1
Cold forming (i.e. forming below 250 C) resulting in permanent deformation (elongation) by
more than 5 % requires strain ageing test of the base material with retesting of mechanical properties,
see A.4.6.
B.8.2
The forming of T-sections into flanged ring stiffeners of any diameter may require mechanical
tests to demonstrate that the properties required by the application are maintained after forming and
welding.
Acceptance of wedges or other techniques to assist rolling will be subject to the visual acceptability of the
product and to acceptable mechanical test results from regions of maximum strain.
B.8.3
In opposite to TMCP steels it is possible to recover the original properties by normalizing or
quenching and tempering in case of N or QT steels. The mechanical tests in the final condition shall be
carried out. Hot forming is not allowed for TMPC steels.
B.9
Splices
B.9.1
General
Splices shall be fabricated using full penetration welds and subject to the following restrictions. The location of all splices shall be shown in both design and as-built drawings.
B.9.2
Pipes
Pipe splices should be in accordance with the requirements of API Specification 2B, Section 5.4 to 5.6.
Pipes used as beams shall comply with the requirements of B.9.5.
B.9.3
Ring stiffeners
Ring stiffeners shall be spaced at least 100 mm from circumferential seams. Where this is not possible,
the welds shall overlap by at least 10 mm. Exceptions are rings used to stiffen cone-cylinder junctions
which shall not be offset and the welds shall be overlapped by at least 10 mm to avoid coincident location
of weld toes.
B.9.4
Tubular joints
In tubular joints, circumferential and longitudinal weld joints should not be placed in the shaded areas,
see in both Fig. 4.1, unless otherwise shown on design drawings.
Circumferential welds are not permitted within cones and node stubs unless specified on design or approved shop drawings.
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75
75
75
3
0
75
75
150
75
75
150
2
a) Circumferential welds on chords and longitudinal seams on stubs
b) Longitudinal seams on chords

1
2
3
e
longitudinal seams not permitted in these areas

circumferential welds not permitted in these areas
circumferential welds should be avoided in these areas
minimum distance: two times the chord thickness or 150 mm whichever is less
Fig. 4.1
B.9.5
Prohibited locations of welds in tubular joints
Beams
Segments of beams with the same cross-sections may be spliced. Either straight or staggered splices
may be used for beam or plate splices.
Splices in plate girders and sections shall not be less than one meter or twice the depth of the beam apart
whichever is greater.
Longitudinal stiffeners shall be spaced at least 100 mm from longitudinal seams.
For staggered splices, splices in girder and column flanges shall be spaced at least 100 mm from the web
splice.
B.9.6
Piles
B.9.6.1
General
The surface of piles and followers shall be bare metal, free from mill varnish, oil and paint, except for specific markings. The area of the surface used for markings shall be the minimum required consistent with
adequate identification.
B.9.6.2
Pile-to-sleeve connections
If forces to be transferred from steel member to steel member across the steel to grout interfaces and
through the grout, specific preparations of sleeves and piles to be performed and certain shear keys to be
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welded outside of the piles and inside of the sleeves. The spacing between both shall be about 40 mm,
depending of the type of grout used; details see Figures 4.2a and 4.2b.
Welding and testing requirements see C.3.9.
Ds
Dg
Dp
4
2
3
ts
tp
tg
1
inner steel tubular member
outer steel tubular member
grout
shear keys (if present)
outside diameter of outer tubular member
outside diameter grout annulus
outside diameter of inner tubular member
wall thickness of outer tubular member
nominal thickness of grout annulus
wall thickness of inner tubular member
centre to centre spacing of the shear keys
1
1
2
3
h
w
Grouted connections
Fig. 4.2a
1
2
3
4
Ds
Dg
Dp
ts
tg
tp
s
weld bead
square bar with fillet beads
round bar with fillet beads
shear key height
shear key width
Fig. 4.2b Type of shear keys
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B.10
Fitting and assembly
B.10.1
General
Excessive jamming is to be avoided during fitting and assembly. Major deformations of individual members are to be faired prior to further assembly. The welding-on of assembly aids is to be restricted to a
minimum. For weld preparation, assembly and tack welding, see C.6.3.
B.10.2
Spliced components
Components which are to be spliced shall be aligned as accurately as possible. Special attention shall be
paid to the alignment of (butting) members, which are interrupted by transverse members. If necessary,
such alignment shall be facilitated by drilling check holes in the transverse members which are later sealwelded. The fit-up is to be checked before welding.
For allowable tolerances, see B.15.
B.10.3
Slotted members
When members are slotted to receive gusset plates, the slot should be 305 mm or twelve times the member wall thickness, whichever is greater, from any circumferential weld. To avoid notches the slotted
member should be drilled or cut out and ground smooth at the end of the slot with a diameter of at least
3 mm greater than the width of the slot. Where the gusset plate passes through the slot, the edge of the
gusset plate should be ground to an approximately half round shape to provide a better fit-up and welding
condition.
B.10.4
Trial fitting, maximum root gaps
All components should be trial fitted before welding and grinding or buttering of the weld preparation at
the installation site should be avoided for special and primary steel fabrication. Where root gaps are out of
tolerance, the joint shall be dismantled to permit local grinding or buttering following by grinding, back to
the required profile see also C.6.8. For special and primary members the maximum build-up shall be
8 mm and the maximum root gap 10 mm. For parts outside of the areas specified in A.1.3 the maximum
root gap may be applied in accordance to IACS REC. No.47, i.e. 1.5t or max. 25 mm for butt joints and
16 mm for T-joints. Alternatively the requirements of B.6.1 may be applied to establish an appropriate
repair procedure.
B.10.5
Joining of different thicknesses
Where butt welds are to be made between members of different thickness, a transition using a taper of
1 : 4 shall be provided. This taper may be wholly or partially within the width of the weld. When necessary, the thicker member shall be tapered, details to be given in relevant drawings and/or standards, see
also both Figs. 4.30 and 4.31.
B.10.6
Joints in the deck plating
Joints in grating and mechanical joints in deck plates shall be at support points unless the design includes
other appropriate details. Welded joints in deck plate should preferably offset from welds to the supporting
structures. Mismatches greater than 2 mm at grating and deck plate joints shall be ground down and recoated.
B.10.7
Cope-holes (rat-holes), penetrations and other cut-outs
Cope-holes, penetrations and other cut-outs shall be avoided wherever possible. Cope-holes may be
permitted provided they are approved on shop drawings and the following criteria shall apply:
Permanent cope-holes shall have a radius of 50 mm or twice the plate thickness, whichever is larger, and shall be ground smooth. Where cope-holes of these dimensions would jeopardize structural
integrity cope-holes less than this radius may be considered. Fillet welds shall be returned through
the cope-holes. The cope-hole corners to be sealed by continuous fillet weld.
Temporary cope-holes (those approved subject to their being reinstated or sealed) shall have a radius not less than twice the plate thickness and shall be reinstated to an approved procedure. Filling
with weld metal is not permitted.
The radius of any approved cut-outs other than cope-holes shall not be less than 100 mm. Where
necessary, the area shall be checked by ultrasonic testing before cutting to ensure that no cut is
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made within 300 mm of internal stiffeners. The original plate shall be clearly marked and shall be
welded back into the cut-out, unless other proposals are agreed.
B.10.8
Tubular structural members
Tubular members framing into joints shall be carefully contoured to obtain accurate alignment. The bevel
shall be formed providing a continuous transition from maximum to minimum bevel angel around the circumference. Generally, the fabrication shall be planned in such a manner that back welding can be performed to the largest extent possible.
B.10.9
Alignment and tack welds
Members to be welded shall be brought into correct alignment and held in position by clamps, other suitable devices or by tack welds until welding has been completed or progressed to a stage where the holding devices or tack welds can be removed without danger of distortion, shrinkage or cracking. Suitable
allowances shall be made for distortion and shrinkage, where appropriate.
Tack welds shall have a minimum length of 50 to 75 mm and number of tacks is to be sufficient to avoid
cracking. Temporary tack welds using bridging or bullets, shall only be performed using materials equivalent to the base material and using a WPS based on a qualified welding procedure. All such tack welds
and any spacer wedges shall be removed from the final weldment, see also C.6.3.
Tack welds to be fused into the weld shall be made in the weld groove only and the ends of the tack
welds shall have their ends ground.
B.10.10
Check of fit-up and before welding
The fit-up shall be checked for dimensional accuracy before welding. Surfaces to be welded shall be free
from mill scale, slag, rust, grease, paint etc. Edges are to have smooth and uniform surface. No welding
shall be performed when the surfaces are damp. Suitable protection shall be arranged when welding is
performed during inclement weather conditions. The groove shall be dry at the time of welding.
B.10.11
Bolting connection
Bolting material shall comply with the requirements in A.6 and GL Rules for Steel and Iron Materials (II-12), Section 6, C. Following requirements shall apply additionally to A.6:
all details including material specification and drawing to be approved by GL
holes shall be made by machine drilling
bolts and nuts shall not be welded under any circumstances
the hardness shall be verified by spot hardness testing of each delivery, batch and size of bolts used
for submerged applications phosphating shall be used
methods to prevent loosening of the fasteners shall be considered
threaded fasteners should normally be pre-tensioned
B.10.12
Seal/blind compartments
Crevices and areas which become inaccessible after fabrication or assembly shall be sealed-off from the
outside atmosphere. Seal welds have a throat thickness of at least 3 mm. Where steel items shall be hot
dip galvanized, hollow sections shall be ventilated.
B.10.13
Temporary cut-outs
Temporary cut-outs shall not be located in restricted areas as shown on design drawings. Temporary cutouts shall have a corner radius not less than 100 mm. Temporary cut-outs shall be closed by refitting the
same or an equivalent plate and employing the same welding, inspection and documentation procedures
and requirements that govern the structural part in question.
B.10.14
Doubler plates
All temporary attachments which shall be flame-cut or welded under water shall be attached to the structure by using doubler plates.
All attachments in the extended tidal zone shall be attached to the structure by using doubler plates.
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B.10.15
Industrial Services
Structural Design
Steel Structures
Grinding details for High Fatigue Utilisation
When grinding is specified on design drawings or instructed as a corrective action, the grinding shall be
performed according to a detailed procedure, see also A.4.5.4.4. Grinding tools, direction, surface roughness and final profile shall be specified.
B.11
Weather protection
Prefabrication is to be performed as far as possible in weather-protected workshops. For assembly the

components and in particular the areas, in which welding is performed, are to be protected by provisional
coverings against the effects of weather (e.g. rain and wind). For welding under low ambient temperatures and pre-heating, see C.6.4.
B.12
Removal of temporary attachments and auxiliary materials
B.12.1
Clamping plates, aligning ties, scaffolding and other auxiliary materials temporarily welded on
structural members, shall be limited as much as practicable.
B.12.2
Where attachments are necessary, the following requirements shall apply:
Temporary attachments shall not be removed by the hammering or arc-air gouging. Attachments to
leg joint cans, skirt sleeve joint cans, brace joint cans, brace stub ends and joint stiffening rings shall
be flame-cut to 3 mm above parent metal and mechanically ground smooth flush to the parent metal.
The ground area shall be visually inspected and MT shall be performed in accordance with the inspection category in question. If any further welding is required, the testing has to be executed before the permanent weld is executed, see also C.6.3.6.
Attachments to all other areas, not defined above, shall be removed by flame cutting just above the
attachment weld (maximum 6 mm above weld); the remaining attachment steel shall be completely
seal welded.
Attachments to aid in the splicing of legs, braces, sleeves, piling, conductors, etc. shall be removed
to a smooth and flush finish.
Attachments on all areas that will be painted shall be removed as above, prior to any painting.
B.12.3
If during rough-planning the surface of the structural members is damaged, the areas concerned are to be ground both flat and notch-free and subsequently checked for cracks by MT. Where
possible, repair by welding is to be avoided; otherwise, approval by the GL Surveyor is required.
B.13
Flame straightening
B.13.1
Flame straightening shall neither impair the properties of the materials nor of the welded joints
and shall be avoided completely, where practicable. In case of doubt, proof of satisfactory performance of
thermal treatment may be demanded.
B.13.2
Members distorted by welding shall be straightened according to a detailed work instruction.
B.13.3
The following flame-straightening temperatures for normalized, thermo-mechanical rolled and
quenched and tempered delivery conditions are recommended maximum values, see Table 4.18.
Table 4.18 Flame-straightening temperatures
Delivery condition
Normalized
Edition 2013
Short superficial
heating
Short full section

heating
Full section heating

with longer holding time
[C]
[C]
[C]
900
700
650
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Thermo-mechanical
rolled up to S460
900
700
650
Thermo-mechanical
rolled S500 to S690
900
600
550
Quenched and tempered

B.14
Tempering temperature applied to the original product 20 C

(generally below 550 C)
Heat treatment
If heat treatment is required, it is to be performed in accordance with a written procedure specification,

listing in detail:
structural member, dimensions, material and supply condition
heating facilities and insulation
control devices and recording equipment
heating and cooling rates (temperature gradients)
holding range of temperature and time
The specification is to be submitted to GL for approval. For post-weld heat treatment, see C.6.9.
B.15
Fabrication tolerances
B.15.1
General
B.15.1.1 Allowable fabrication and construction tolerances shall be specified depending on the significance of the structural members and the loads acting on them. They shall be submitted to the
Owner/Purchaser for acceptance. The resulting specification is to be submitted to GL for approval. A general guidance for allowable tolerances is given in B.15.2 to B.15.19.
For weld imperfections, see C.6.6 and Fig. 4.1. In case of fatigue assessment the detail classification of
the different welded joints as given in Table 3.14 is based on the assumption that the fabrication of the
structural detail or welded joint, respectively, corresponds in regard to external defects at least to quality
group B according to ISO 5817 and in regard to internal defects at least to quality group C.
B.15.2
Length tolerances
The length tolerances are defined in Table 4.19.

Table 4.19 Length tolerances according to ISO 13920
Nominal length
[mm]
Special and primary

structures [mm]
Secondary structures
[mm]
2 30
120 - 400
401 1000
1001 2000
2001 4000
4001 8000
8001 12000
10
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12001 16000
12
16001 20000
14
Above 20000
16
B.15.3
Misalignment of butt joints
The misalignment e shall not exceed the following, whichever is less, see Fig. 4.3:
e 0.10 t1
for special structures, max. 3 mm
e 0.15 t1
for primary structures, max. 4 mm
e 0.30 t1
for secondary structures, max. 6 mm, tapering 1 : 4 required
e, t
: Dimensions [mm]
t1
Fig. 4.3
B.15.4
t1 t2
t2
Definition of misalignment at butt joints
Misalignment of cruciform joints
The misalignment e shall not exceed the following, see Fig. 4.4
e 0.15 t
for special structures
e 0.30 t
for primary structures
e 0.50 t
for secondary structures
t is the smallest thickness of t1, t2 and t3.

e, t1, t2, t3 : Dimension [mm]
t1
t2
t3
Fig. 4.4
B.15.5
Definition of misalignment at cruciform joints
Roundness of tubular members
B.15.5.1 The external circumference shall not differ from the design or calculated circumference by
more than +0.3 % of the specified external diameter.
B.15.5.2 The difference between the measured maximum and minimum diameters (out of roundness)
shall not exceed 1 % of the specified diameter or 6 mm, whichever is less.
B.15.5.3 The maximum deviation from the nominal diameter, measured at a stiffener or a bulkhead
shall not exceed 0.5 %.
B.15.5.4 Lower values and/or additional limitations may be required for masts, crane pillars and similar
components of lifting appliances.
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B.15.5.5 The global and local tolerances for circular cylinder shells (e.g. of flotation tanks, buoyancy
structures, etc.) exposed to outer pressure are to be calculated and specified in each single case depending on maximum pressure, diameter to wall thickness ratio and stiffener distance to diameter ratio.
B.15.5.6
For limitations regarding buckling, see Section 3, H
B.15.5.7
For deviations of longitudinal stiffeners, see both B.15.10 and B.15.11.
B.15.5.8
Local deviations out of roundness and out of straightness
The measuring length Am of a straight rod or of a curved template shall be according to both Fig. 4.5 and
4.6.
The deviation out of the straightness or out of roundness shall be e 0.01 Am.
Where for straight rods:
Am = 4 r t
for curved template Am is the smallest of:
Am = s
Am =
or:
2.3 r
r
Am = r
with:
r
: radius of shell curvature
: unsupported length (i.e. length between bulkheads or ring stiffeners)
: stiffener spacing of longitudinal stiffeners
: plate thickness of shell
s, e, A, Am, r, t : Dimensions [mm]
Shell
Weld
e
m
measuring rod
Fig. 4.5
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measuring template
t
Fig. 4.6
B.15.6
Measuring length Am of curved template
Straightness of (prefabricated) tubular members, girders or beams
The deviation of straightness e shall be 0.001 L or 3 mm, whichever is greater, for compression members, e.g. columns, primary truss members and girders or beams with non-hollow cross sections, see Fig.
4.7.
The deviation of straightness shall be e 0.002 L or 5 mm, whichever is greater, for girders or beams
with hollow cross sections and for all other applications.
: unsupported length [mm]
e
Fig. 4.7
B.15.7
Definition of straightness
Deviation from the theoretical axis in tubular nodes
If the specified (designed) eccentricity x is less D/4, the deviations are defined as follows, see Fig. 4.8:
x as built < x designed (x1 in Fig. 4.8):
e1 x1, but separation requirement of 50 mm minimum to be observed, see Fig. 4.8
x as built > x designed (x2 in Fig. 4.8):
e2 0.1 x2 [mm], maximum 50 mm
If the specified (designed) eccentricity x > D/4, which has to be considered in the strength calculations,
the deviations are:
e1,2 < 0.1 x1,2 [mm], maximum 50 mm
separation requirement of 50 mm minimum to be observed, see Fig. 4.8.
seperation
50 mm min.
as built axis
theoretical
axis
e1
x1
Fig. 4.8
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e2
x2
Deviations at tubular nodes
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Industrial Services
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Bulges in plating
The deviation e of bulges in plating from straight line are defined as follows, see Fig. 4.9:
e 0.004 s
s = stiffener distance
e, s
: Dimensions [mm]
e
e
Fig. 4.9
B.15.9
Definition of bulges in plating
Deformation of plane, stiffened plating
The permissible deviation e of deformations in plane, stiffened plating from straight line is defined as follows, see Fig. 4.10:
e 0.0015 L
e, L
: Dimensions [mm]
e
Fig. 4.10
B.15.10
Definition of plating deformation
Lateral miss-positioning or deflection of stiffeners between supporting members
The permissible lateral miss-positioning or deflection of stiffeners between two supporting members is
defined as follows, see Fig. 4.11:
e1 1 + 0.015 L[mm],
maximum 5 mm
e2 1 + 0.010 h [mm],
maximum 3 mm
e1, e2, L, h : Dimensions [mm]

Smaller values may be required for reasons of buckling strength.
e1
e2
e1
e2
Fig. 4.11
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Deviation and/or distortion of girders
The permissible deviation and/or distortion of girders is defined as follows, see Fig. 4.12:
e1, e2, h
e1 1 + 0.01 h [mm],
maximum 3 mm
e2 0.01 h [mm],
maximum 2 mm
: Dimensions [mm]
The permissible deflection of the face plate to the girder plane is defined as follows, see Fig. 4.12:
e3, e4, b
e3 1 + 0.01 b [mm],
maximum 3 mm
e4 0.01 b [mm],
maximum 2 mm
: Dimensions [mm]
Smaller values may be required for reasons of buckling strength.
b
e1
e3
e4
e2
a)
Fig. 4.12
B.15.12
b)
Definition of deviations of girders
Lateral deflection and inclination of (as built) columns
The lateral deflection e1, see Fig. 4.13, shall be in accordance with the requirements defined in B.15.6, if
L = H [mm].
The permissible deflection e2 shall be less or equal 0.0015 H.
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e2
e1
11h,
1h,h,
00mm
0mm
mm
55t5t t
(all
(all
(all
ddd
Fig. 4.13
B.15.13
Definition of column deviations
Deviation of box girders
The tolerances for both box girders and box girder stiffeners shall comply with the following additional
requirements, see Fig. 4.14 a) to d):
Maximum deviation:
e1 = + 3 mm (see Fig. 4.14a))
Out of straightness:
e2 = + 0.0015 L; max. 10 mm (see Fig. 4.14b))
Buckling of plates:
e3 = + 0.005 W or (0.005 H); max. 10 mm (see Fig.4.14 c))
Twisting of girder:
e4 = + 0.005 H; max. 6 mm (see Fig.4.14 d))
e1, e2, e3, e4, H, L, W
: Dimensions [mm]
e1
Z
e2
e1
e2
L
b)
a)
H
W
e3
e4
c)
d)
a) At end section
b) and c) Out of straightness and buckling
d) Twisting of girder
Fig. 4.14
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B.15.14
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Global horizontal tolerances
Following main tolerances for leg spacing at plan bracing levels shall apply, see Fig. 4.15 a) and b):
the horizontal centre to centre distance between adjacent legs at the top of a structure where a deck
or other structure is to be placed (stab-in-nodes) shall be within 10 mm of the design values
the horizontal centre-to-centre distance between legs at other locations shall be within 20 mm of
the design values
the horizontal centre-to-centre diagonal distances between legs at the top of a structure where a
deck or other structure is to be placed (stab-in-nodes) shall be within 10 mm of the design values
the horizontal centre-to-centre diagonal distance between legs at other locations shall be within
20 mm of the design values
: Dimension in [mm]
L 10 mm
L 20 mm
20
10
mm
mm
a) Top elevation for deck stab-in
Fig. 4.15
B.15.15
b) Other elevations
Global horizontal tolerances
Global vertical tolerances
Following vertical tolerances for plan bracings shall apply, see Fig. 4.16:
the elevation of the top of legs shall be within 13 mm of the design values
the vertical level of braces within a horizontal plane shall be within 13 mm of the design values
the vertical distance between plan bracing elevation shall be within 13 mm of the design values
each leg shall be straight to within 10 mm over the entire length
all Dimensions [mm]
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0 13
4 3
L 13
0 13
2 1
0 10
1
2
3
4
theoretical centreline
actual centreline
theoretical top of legs
actual top og legs
Fig. 4.16
B.15.16
Vertical tolerances
Tolerances on straightness of tubular members assembled into structure
Following tolerances for the straightness of tubular members, when assembled into the structures, shall
apply, see Fig. 4.17:
brace members shall be straight to within e 0.12 % of the nominal length between work points L1
chord members shall be straight to within e 0.10 % of the nominal length measured between the
work points of major framing members L2
L1, L2: Dimensions [mm]
WP
L1
L2
WP
WP
WP = Working point
WP
a) Brace member
Fig. 4.17
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b) Chord member
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B.15.17
Industrial Services
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Leg alignment tolerances at plan bracing level (structures with more than 4 legs)
Following tolerances for the alignment and straightness of legs shall apply, see Fig. 4.18:
at each plan bracing level the legs shall be aligned horizontally within 10 mm of the design location
each leg shall be straight to within 10 mm over the entire length, see both B.15.15 and Fig. 4.16
all Dimensions [mm]
1
2
0 10
1 theoretical centreline
2 actual centreline
Fig. 4.18
B.15.18
Leg alignment tolerances at plan bracing level (structures with more than 4 legs)
Conductor guide alignment tolerances
Following tolerances for conductors, pile guides, pile sleeves and other appurtenance supports shall apply, see Fig. 4.19:
the distance e1 to the best-fit line shall be less than 10 mm at the top guide
for vertical spacing between guides of less and equal than 12 m, the distance e2 to the best-fit shall
be less than 10 mm
for vertical spacing between the guides of more than 12 m, the distance e3 to the best-fit shall be
less than 13 mm
e1, e2, e3 : Dimensions [mm]
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2
1
2
e1
e2
2
1
2
e2
2
1
e3
1
2
3
4
plan bracing levels

centres of conductor guides at each level
theoretical centreline
best-fit line
Fig. 4.19
B.15.19
Conductor guide alignment tolerances
Tolerances for trusses
Tolerances for trusses are to be specified analogously to those given in B.15.7 (deviation from the theoretical axis in tubular nodes), B.15.11 (deviation and/or distortion of girders) and B.15.12 (lateral deflection and inclination of as built columns). Special consideration is to be given to areas of introduction or
deviation of forces, e.g. at stabbing points or connections of crane pedestals.
Welding
C.1
General requirements
C.1.1
Scope, welding rules
These Rules define the general conditions for the preparation and performance of all welding work including quality assurance measures. It is taken for granted that all further details of welding (not listed here)
will be laid down in the welding specifications analogously to the GL Rules II Materials and Welding,
Part 3 Welding, in the following referred to as GL Welding Rules, or to other codes, standards, etc.
recognized by GL.
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C.1.2
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Codes and standards
C.1.2.1
The codes, standards, etc. mentioned below or in the GL Welding Rules constitute an integral
part of these Rules and require no special consent. The version current at the time when these Rules are
issued shall apply. New editions of the codes, standards, etc. may be used in agreement with GL.
C.1.2.2
The application of other codes, standards, etc. may be agreed by GL. They are to be listed in
the construction particulars, e.g. in the welding specifications, and presented to GL on request. The actual
version of these standards shall apply; otherwise the year of publication shall be indicated.
C.1.2.3
If any of these codes, standards, etc. contradict these Rules, the latter shall take precedence
over all the others. Any deviations require approval by GL from case to case.
C.1.3
Terms and definitions
The terms and definitions as contained in recognized codes, standards, etc. are to be employed. The
code or standard used is to be indicated in the design and/or construction documentation and presented
to GL on request. Any other deviating terms and definitions are to be separately explained in the welding
specifications.
C.1.4
Welding works equipment
The manufacturers shall have suitable equipment and plant for the satisfactory performance of welding
work. Apart from perfectly functioning cutting and welding machines and tools, this equipment shall include dry, heatable storage facilities, baking ovens and heated quivers for the welding consumables, and
equipment for preheating, heat treatment, calibration and temperature control.
C.1.5
Welding supervision
The preparation and performance of welding operations shall be supervised by specially trained and experienced welding supervisors. Proof of their professional qualifications is to be furnished to GL; their
tasks and responsibilities are to be defined and made known to GL. For more details, see GL Welding
Rules.
C.1.6
Welding processes
The welding processes in accordance to ISO 15614-1 shall apply unless otherwise specified.
C.1.7
Performance of qualification tests
Welding qualification tests are to be performed under the supervision of GL on the manufacturers premises. Fabrication conditions shall be simulated as far as possible. Non-destructive and destructive tests
may in agreement with GL be performed on the premises of another independent, neutral testing
body.
C.1.8
Documentation
The manufacturer shall both produce and submit to GL prior to production a documentation covering the
main aspects of welding work as follows:
drawings showing all weld details
welding procedure specifications (WPS)
welding consumables handling procedures
non-destructive testing specifications
welding procedure qualification records (WPQR)
welding supervisors qualification in acc. to ISO 3834-2
welder's qualification Certificates acc. to to EN 287-1 and/or ISO 9606-4
welding operator's Certificate acc. to ISO 14732
welders identification system
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C.2
Welding consumables
C.2.1
Approval of welding consumables
C.2.1.1
All welding consumables and auxiliary materials (covered electrodes, wire electrodes, wiregas combinations or wire-flux combinations) intended to be used on offshore steel structures shall be
approved by GL in accordance with GL Welding Rules for the respective range of application (base materials, welding positions, heat treatment condition, etc.).
C.2.1.2
Welding consumables and auxiliary materials not approved by GL according to GL Welding
Rules may be qualified with special agreement by GL in the course of the welding procedure qualification tests. In this case, one round tensile test specimen is to be additionally taken lengthwise, mainly from
the weld metal of the butt welds.
Such qualifications are, however, limited to the users work in the range of application, according to the
approved welding procedure specifications, and remain valid for not longer than one year, unless repeat
tests are carried out in accordance with GL Welding Rules.
C.2.2
Selection of welding consumables
C.2.2.1
The welding consumables and auxiliary materials are to be chosen such that in the weld connection, including heat affected zone (HAZ) at least the same mechanical properties as those specified
for the base materials are achieved. When different steels are to be joined, the welding consumables and
auxiliary materials are to be chosen based on the lower yield strength.
C.2.2.2
Welding consumables and auxiliary materials with a controlled low hydrogen content in the
weld metal, e.g. H5 according to ISO 3690, shall be used for welding of higher and high strength steels
(yield strength > 275 MPa), for all steel having a carbon equivalent > 0.42 % and are recommended for all
highly stressed and thick walled components exposed to low temperatures as well as for steel forgings
and castings.
Welding consumables and auxiliary materials other than low hydrogen types may only be used with special agreement by GL, except for secondary structures.
C.2.3
Storage and re-drying of welding consumables
C.2.3.1
All welding consumables and auxiliary materials (except shielding gases) are to be stored, as
far as possible in the following way:
in original packages
in a storage room, where a minimum temperature of 18 C and a humidity of the atmosphere of less
than 60 % is maintained
air circulation of the room is required
storage of packages preferably in shelves or on pallets, but not directly on the bottom
the welding consumables and the auxiliary materials shall be properly identifiable up to their final
use
general storage time not longer than 2 years
special packages (tin or vacuum) are without any time limitation
the manufacturers recommendations are to be prevailed
Prior to use, low hydrogen covered electrodes, folded flux core wire electrodes and fluxes are to be redried (baked) in accordance with the manufacturers instructions (observing the maximum baking time
specified).
Unless otherwise specified, the baking temperature should be 250 C to 350 C, the baking time >
2 hours, but not longer than 12 hours in total. Repeated baking is permissible, as long as the maximum
drying period of 12 hours is not exceeded for basic type.
C.2.3.2
At the working area, the welding consumables and auxiliary materials are to be protected
against the effects of weather (moisture) and contamination. Low hydrogen covered electrodes and fluxes
are to be kept in heated quivers at temperatures between 100 C and 150 C. All unidentifiable, dam-
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aged, wet, rusty or otherwise contaminated welding consumables and auxiliary materials are to be discarded.
C.3
Welding procedure specification and qualification
C.3.1
General
Detailed welding procedures shall be prepared for all welding covered by these Rules. The welding procedure may be based on previously qualified welding procedures provided that all the specified requirements can be fulfilled.
C.3.2
Welding procedure specification (WPS)
A welding procedure specification (WPS) is a specification based on a welding procedure qualification

record (WPQR) and accepted in accordance with those requirements. The WPS is the preliminary welding procedure specification (pWPS) revised to reflect the welding and variables qualified by the welding
procedure tests. All production welding shall be performed in accordance with a WPS.
WPS are to be prepared and submitted to GL for review. The WPS are to contain all essential variables
on the preparation and performance of welds, such as:
applicable standards
materials (grade, standard, delivery condition, CEV-ranges, thickness range, outside diameter)
which range of structural categories shall apply (above or below LAT)
joint and grove design (joint type, single or multiple, root opening, root face, groove angle)
joint preparation (cutting method) and tacking
cleaning method
welding process and parameters (for root, hot, fill and cap layers)
welding consumables and auxiliary materials (manufacturer, trade name, classification)
gas shielding, flow rate
welding positions and progressions
preheating, interpass temperatures
heat input
weld build-up (welding sequence)
root treatment (back gouging)
post-weld (heat) treatment
if the WPS shall be used for submerged parts, that may be exposed to cathodic protection (below
LAT), than this fact shall be noted, see A.3.5.
It is recommended to prepare a list with all welding procedure specifications used in the project and all
procedures to be attached with detailed information for new as well as for repair welds. Inspection requirements are subject to the relevant specifications and/or ITPs, see also F.4.2.
C.3.3
Preliminary welding procedure specification (pWPS)
A preliminary welding procedure specification (pWPS) shall be prepared for each new welding procedure
qualification. The pWPS shall specify the ranges for all relevant parameters.
The pWPS shall be submitted for review and acceptance by the Owner/Purchaser prior to commencing
the welding procedure qualification, see also C.3.10.3.
C.3.4
Welding procedure qualification (WPQ)
C.3.4.1
The manufacturers shall prove their ability to apply the specified welding procedures in a sufficient manner and with satisfactory results, in conjunction with the materials and welding consumables
actually used. Such proof is to be provided prior to start of fabrication.
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C.3.4.2
Unless otherwise agreed, a welding procedure qualification (WPQ) shall be proved by a welding procedure qualification test (WPQ-Test) under actual or simulated fabrication conditions and witnessed by GL.
C.3.4.3
In exceptional cases, GL may recognize in part or in whole existing welding procedure qualifications based on tests witnessed and approved by another competent and independent Authority. Therefore, adequate documentation, including complete test reports, to be submitted to GL.
C.3.4.4
The approval for a welding procedure qualification is restricted to the manufacturer and to the
welding works or working unit (e.g. platform, jacket, barge, etc.), where the test welds were performed.
The approval is valid within the limitations of the essential variables according to C.3.7.
C.3.4.5
The approval for the use of the qualified procedure is normally valid for the fabrication period
of the structure. Where the fabrication has been interrupted for more than 3 months, GL may require production tests or repeated welding procedure qualification tests.
C.3.4.6
Production tests or repeated welding procedure qualification tests may also be required if the
conditions under which the approval was granted (e.g. personnel premises) do not longer apply, or in the
event of doubts as to satisfactory execution of the welding.
C.3.5
Welding procedure qualification tests
Welding procedure qualification tests are to be carried out in accordance with ISO 15614-1 and the additional requirements of this Section, specified in both Tables 4.20 and 4.21, or with the consent of GL
subject to other recognized codes or standards (e.g. AWS D 1.1, NORSOK M-101 or EEMUA No.158).
Table 4.20 Welding procedure qualification tests - types and number of tests
Joint type
Butt welds
(plates and
tubes)
Thickness
[mm]
Visual
100 %
+
specified
NDT
t 30
Transverse
tensile
test
specimen
Transverse
bend
test
specimen
Charpy
impact
test specimen
Macro
etchings/
hardness
test specimen
100 % RT or
UT 9 + MT or
PT 10
21
2 face 2
2 root
4 3 3,5
1/2 rows 6
t > 30
100 % UT or
RT + MT or
PT10
t 30
100 % UT 9 +
MT or PT 10
t > 30
100 % UT + MT
or PT 10
all
100 % MT or
PT 10
2/2 rows 6
t 30
100 % UT 9 +
MT or PT 10
4 3 3,5,8
1/2 rows 6
t > 30
100 % UT + MT
or PT 10
T-joints (full
penetration)
T-joints
(fillet welds)
Tubular
joints
(nodes)
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63
3,4,5
4 3 3,5,8
63
63
3,4,5,8
3,4,5,8
1/3 rows
6,7
Others
PWHT
(CTOD)
see A.4.5
2/2 rows 6
2/3 rows
1/3 rows
6,7
6,7
PWHT
(CTOD
see A.4.5
PWHT
(CTOD)
see A.4.5
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1 Additional round tensile test specimen to be taken longitudinally from weld metal, if welding consumables are not approved
by GL, see C.2.1.2.
2 For t > 12 mm, 4 side bend test specimens may be chosen instead of 2 face and 2 root bend test specimens.
3 Charpy impact test specimen to be sampled approximately 1 mm below base material surface at the capping side, notch
positioned perpendicular to the surface:
in the centre of the welding
on the fusion line (50 % weld metal, 50 % heat affected zone)
2 mm from fusion line in the heat affected zone
5 mm from fusion line in the heat affected zone
see sketch below, both T- and tubular joints analogously, see Fig. 4.20
4 Additional Charpy impact test specimens to be sampled in the root region with the notch positioned perpendicular to the
surface:
in the centre of the welding
on the fusion line (50 % weld metal, 50 % heat affected zone,see sketch below, both T- and tubular joints analogously,
see Fig. 4.20)
5 If different welding consumables or welding processes are used for the same joint, impact testing shall be performed for all
related areas of the weld.
6 One hardness measurement row 2 mm below each surface, measuring points concentrated near fusion line in the heat
affected zone with some spots in the weld metal and base material, details see ISO 9015-1 Figures 3, 4 and 5.
7 Additionally 1 row in the root area.
8 If the Charpy test specimens can't be taken out of the T-joints the qualification shall be done on butt welds.
9 UT shall not be used for t < 8mm.
= =
10 PT shall be selected according to F.3
Fig. 4.20
Location of charpy test specimens
Table 4.21 Welding procedure qualification tests - acceptance requirements

Type of test
Acceptance requirements
Non-destructive testing
The soundness of the welds is to comply with the acceptance requirements

laid down in ISO 15614-1, Chapter 7.5.
All weld metal tensile

tests 1
Minimum yield strength and tensile strength as specified for the base material
to be welded. 2
Transverse tensile tests In accordance to ISO 15614-1.

Face/root and side bend
Bending angle 180. Mandrel diameter 4 t in accordance to ISO 15614-1.
tests
Charpy V-notch impact
tests
Edition 2013
Average and minimum absorbed energy for each notch position (centre of
weld, fusion line and heat affected zone) shall meet the base material requirements, see A.4.4.2, Table 4.10. Test temperature shall be one exposure
level lower than for the base material, see A.4.4.2, Table 4.11.
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Hardness tests
The maximum hardness shall not exceed 350 HV10 above the submerged
zone, i.e. LAT (see Section 5) and in the submerged zone that may be exposed to cathodic protection the maximum hardness shall be 325 HV10.
Macro etchings
According to ISO 15614-1, and the hardness indents shall be clearly shown
and a scale shall be added to the macro.
CTOD or PWHT
See A.4.5
1 If required according to C.2.1.2

2 The tensile strength of all weld metal for welding high strength steels may be up to 10 % below the minimum tensile strength
of the base material, provided that the results obtained with the transverse test specimen across the weld meet the requirements. Special consideration is to be given for material/wall thickness 50 mm.
C.3.6
Welding procedure qualification record (WPQR)
The welding procedure qualification record (WPQR) shall be a record of all welding data, such as:
manufacturer, place and date
applicable standard
joint preparation (root opening, root face, groove angle drawn in a sketch)
welding sequences with sketch and pass-nos.
welding process(es)
welding position and progression
plate/tubular wall thickness/diameter
base material specification and heat-no., material Certificate
welding consumable(s), code designation, trade name, lot-no., consumable(s) Certificate(s)
welding parameters for root, hot, fill and cap layers (pass-no., diameter, gas composition, gas flow
[l/min], current polarity, amperage, voltage, travel speed, heat input)
preheat temperature
interpass temperature for each layer
PWHT, if required
other information like weaving, backing, gouging, grinding, etc.
manufacturer's signature
Third Party's signature
The WPQR shall be submitted for review and agreement prior to start of production. The complete WPQR
with satisfactory test results qualifies a pWPS to a WPS.
C.3.7
Limit applications of qualified welding procedures
C.3.7.1
General
Changes in the variables as specified in C.3.7.3 to C.3.7.14, respectively, are to be considered as being
essential and in general require performance of a new or additional procedure qualification test unless
otherwise agreed. When a combination of welding processes is used, the variables applicable to each
process shall apply, see also AWS D 1.1 and ISO 15614-1.
C.3.7.2
Essential variables
Approved welding procedures may be used within the limitations of these essential variables regarding:
details of base materials
thickness
tube diameter (if applicable)
joint configuration (butt, fillet, etc.)
bevel configuration incl. backing (if required) and/or back gouging
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welding process and/or multiple processes

welding positions and progression
type of welding consumables (classification acc. to code and trade name)
welding parameters
preheating and working temperatures
number and sequence of layers
post-weld heat treatment, if required
as laid down in the following for welding above water.
For CTOD, see also A.4.5.5.3 and for welding under water see C.3.10.5. GL may specify other limits if the
peculiarities of a welding procedure, the material, the joint configuration and thicknesses or other parameters have a considerable effect on the properties of a weld.
C.3.7.3
Details of base material
Changes beyond the ranges given in ISO 15614-1, Chapter 8.3. Additional items shall apply:
A change from wrought (rolled, forged) steel to cast steel or vice versa shall require a new welding
procedure qualification.
For special and primary members an increase of the carbon equivalent value (CEV) greater than
0,03 % or an increase in the carbon equivalent parameter for cracks (PCM) greater than 0,02 %,
with respect to the values specified in the procedure qualification test.
For special and primary members a change in the delivery condition (normalized, thermomechanical controlled process or quenched and tempered).
Note:
General classification of material with its groups is mentioned in CEN ISO/TR 20172.
C.3.7.4
Thickness
Changes in plate/wall thicknesses beyond the ranges given in ISO 15614-1, Chapter 8.3.2.
C.3.7.5
Tube diameter
Changes from diameters beyond the ranges given in ISO 15614-1, Chapter 8.3.2.
C.3.7.6
Joint configuration
Changes beyond the ranges given in ISO 15614-1, Chapter 8.4.3.

C.3.7.7
Groove design
A decrease in groove angle more than 10:

For groove angles less than 30 the limitation is + 20/- 0.
C.3.7.8
Welding process
Any changes beyond the ranges given in ISO 15614-1, Chapter 8.4.1 and 8.5.
C.3.7.9
Welding position and progression
Change from one principal welding position and progression to another, unless covered by the inclusions
given in Table 4.22.
Furthermore additional changes shall apply:
change from weaving to stringer bead technique or vice versa
change of stringer to weave ratio outside the tolerances specified in the agreed WPS
changes beyond the ranges given in ISO 15614-1, Chapter 8.4.2.
Welding procedures may be qualified in two positions which represent the highest heat input and the lowest heat input. Then all positions are qualified.
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Table 4.22 Qualified welding positions

Test weld positions 1
Joint configuration
Plates, butt
welds
Tubes, butt
welds 3
Fillet welds
Qualified positions 1
Plate or tube position
Fillet welds, plates

or tubes
Butt welds
ISO 6947
AWS
Plates
Tubes
PA
PC
1G
2G
PA/1G
PC/2G
PF
PG
PE
3G
3G
4G
PA/1G and PF/3G

PG/3G
PA/1G, PC/2G and PE/4G
PA
PC
PH
PJ
H-L045
J-L045
H-L045
1G
2G
5G
5G
6G
6G
6GR 4
PA
PA
PB
PB
PC
1F
1FR
2F
2FR
2F
Plate
Pipe rotating
Plate and pipe
Pipe rotating
Plate and pipe
PF
3F
Plate
PG
PD
3F
4F
Plate
Plate
PH
PJ
5F
5F
Pipe fixed
Pipe fixed
PA/1G 2
PA/1G and PC/2G 2
-
PA/1G
PA/1G and PC/2G
PA/1G, PE/4G and PH/5G
PA/1G, PE/4G and PJ/5G
All except PG/3
All except PF/3
-
PA/1F
PA/1FR
PA/1F and PB/2F
PA/1F and PB/2F
PA/1F,PB/2F and
PC/2F
PA/1FPB/2F and
PF/3F
PG/3F
All except PF/3F
and PG/3F
All except PG/5F
All except PC/2F
and PH/5F
1 Welding positions according to ISO 6947 and AWS A3.0

2 Qualifies also for butt welding tubes with diameter > 500 mm
3 Tubular joints (node sections) are to be qualified separately
4 To be applied for welders qualification tests only
C.3.7.10
Welding consumables
Changes beyond the ranges given in ISO 15614-1, Chapters 8.4.4, 8.4.5 and 8.5.
C.3.7.11
Welding parameters
Changes beyond the ranges given in ISO 15614-1, Chapter 8.4.8. Additional item shall apply:
A change greater than 25 % in the heat input of the welding passes from the average value calculated in
the supporting procedure qualification test. Heat input average shall be calculated separately for root, hot,
fill and cap passes.
C.3.7.12
Preheating and interpass temperatures
Changes beyond the ranges given in ISO 15614-1, Chapter 8.4.9 and 8.4.10.
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Sequence of layers
Change from welding with temper beads to welding without temper beads. Sequence of deposition of
different consumables required.
C.3.7.14
Post-weld heat treatment
Change from as welded condition to post-weld heat treated condition and vice versa. Change beyond
specified temperature range, holding time and heating/cooling rates (temperature gradients).
C.3.8
Qualification for tubular node connections
C.3.8.1
For full penetration groove welds between tubes and/or plates or girders (T-, K- or Y-joints)
forming node connections, welding procedure qualification tests are to be performed analogously to the
requirements stated above and following the indications given in C.3.8.2 to C.3.8.4. A detailed test programme is to be prepared by the manufacturers in agreement with GL from case to case.
C.3.8.2
The test programme shall cover the different joint configurations, tube diameters and wall
thicknesses, angles included between the axis of the tubes as well as the different welding positions for
each individual groove type. If not otherwise required, the test pieces may be formed as a brace to can
connection according to Fig. 4.21.
C.3.8.3
When the diameter D (of the can) exceeds 500 mm, this tube may be replaced for the test
weld by a plate of same or equivalent steel grade and of relevant size and similar thickness, but not less
than 25 mm. When other types of welding (double side, partial penetration groove or fillet welds) are intended and approved for fabrication, these types are to be qualified separately. Double side welding may
be covered by single side welding qualification with GLs consent in each individual case.
30 - 45
min. d
or 300
Fig. 4.21
m
or in.
30 d
0
Tubular node test piece
C.3.8.4
The joint is to be tested by ultrasonic and magnetic particle method. From each position
marked with a circle (A, B, C) in Fig. 4.21 one set of test specimens as required in Table 4.20 is to be
prepared and tested. Charpy V-notch impact test specimens are to be taken from positions A and C
only and those from fusion line and heat affected zone shall be placed on the bracing side, if not required
otherwise. The acceptance requirements given in Table 4.21 apply.
C.3.8.5
In addition to the limitations and essential variables given in C.3.7 for tubular node connections the following limitation shall apply:
Change of more than 5 from the included angle between the axis of the tubes or girders to smaller angles requires re-qualification when the included angle between 45 and 30. Below 30 the limitation is
+20/-0, see C.3.7.7.
C.3.9
Qualification of grout beads
C.3.9.1
Type of shear key
The test programme shall cover the different types shear keys used, see Fig. 4.2b.
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A welding procedure qualification is required for the specific shear key type used in the project. This
WPQR shall be conducted as follows: depositing of a full circumferential bead on a can, with material of
the diameter and thickness shown on the drawings, using appropriate production welding equipment.
C.3.9.2
Testing programme
Following tests to be performed:

visual inspection in compliance with the drawing (height, width and toe profile)
VT + MT 100 %
macro-examination 2 sections, minimum distance of 1 m:
external defects quality group B and internal defects group C acc. ISO 5817
hardness indents shall be made as follows and shall not exceed 325 HV10:
1. weld bead (Fig. 4.2b), key type 1) according to Fig. 4.22
2. square and round bar with fillet beads (Fig. 4.2b), key types 2 and 3 according to Fig. 4.22b.
H2
measurements in millimeter
L=1
0.5
2
1
1 base metal
2 heat affected zone
3 weld metal
1
1
2
3
h
w
Fig. 4.22a Hardness indents for shear key type 1
weld bead
square bar with fillet beads
round bar with fillet beads
shear key height
shear key width
Fig. 4.22b Hardness indents for both shear key types 2 and 3
C.3.10
Qualification for underwater welding
C.3.10.1 Underwater welding, to be used for construction or repair, is to be qualified by a test, following
the scheme given for welding above water, conducted under actual welding conditions at the welding site
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or simulated at a test facility. The test is to be carried out at the same water depth or at similar conditions
as for the actual welding operation.
C.3.10.2 For underwater welding generally a low hydrogen process shall be used, carried out in a dry
chamber under pressure equivalent to the water depth or under one atmosphere pressure (habitat welding).
Underwater wet welding, where the arc is working in the water or in a small gas-filled cavern, is normally
restricted to minor or temporary repair work in shallow waters and requires GLs consent in each individual case.
C.3.10.3 Prior to the qualification test, a detailed preliminary welding procedure specification (pWPS) is
to be prepared by the manufacturer and submitted to GL for review. In addition to the particulars mentioned in C.3.2, the following data are to be specified:
maximum and minimum water depth
chamber (habitat) atmosphere (gas composition and pressure)
maximum humidity in the chamber (habitat)
temperature fluctuations inside the chamber
electrode transport and monitoring system
inspection schedule and methods
C.3.10.4 Based on the preliminary welding procedure specification (pWPS) according to C.3.10.3 a
welding procedure qualification test programme is to be established by the manufacturer and submitted to
GL for approval. The manufacturer shall also document his previous experience with similar welding
works, otherwise an extended testing may be required by GL. Testing and acceptance requirements
given in C.3.5 apply analogously.
C.3.10.5 In addition to the limitations and essential variables given in C.3.7 for underwater welding the
following variations are considered to be essential:
change from habitat welding to wet welding and vice versa
change in water depth (working pressure) beyond the agreed range
change in habitat atmosphere (gas composition)
change in welding consumables
change in welding current/polarity
change in welding parameters (amperage, voltage, travel speed) of more than 10 % of mean values
Regarding production tests to be performed prior to actual welding, see both C.6.10 and C.6.11.3.
C.3.11
Evaluation of test results, requirements, repeat test specimens, test reports
C.3.11.1
Designation of test results
To ensure that the description and evaluation of welding processes and positions, test results, etc. are as
clear and uniform as possible, use shall be made of the terminology and symbols in the relevant standards (e.g. ISO 857, ISO 6947, ISO 6520, ISO 5817, ISO 10042). The position of a defect or fracture
shall be indicated and may be designated as follows:
WM
: weld metal
FL
: fusion line
HAZ
: heat-affected zone of base material
BM
: base material
C.3.11.2
Requirements, repeat test specimens
C.3.11.2.1 The requirements are specified in Table 4.20.

C.3.11.2.2 Repeat test are according to ISO 15614-1 Chapter 7.6
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Reports, storage times
C.3.11.3.1 Reports shall be prepared of all trial welds and tests and submitted to GL in duplicate, signed
by the tester and the testing supervisor, see GL Rules for General Requirements, Proof of Qualifications,
Approvals (II-3-1), Section 4 and Annex D.
C.3.11.3.2 The debris of test pieces, specimens and the test documentation are to be kept until all the
tests and inspections are concluded by the confirmation of approval issued by GL. For the storage time of
documents relating to the non-destructive testing of welds (e.g. radiographs), see D.1.8.
C.3.12
Range and period of validity
All new welding procedure tests are to be carried out in accordance with this Rule from the date of its
issue.
However, this Rule does not invalidate previous welding procedure test made to previous issues of this
Rule.
Where additional tests have to be carried out to make the qualification technically equivalent, it is only
necessary to do the additional test on a test piece, which should be made in accordance with this Rule.
C.4
Welders qualifications
C.4.1
Qualification requirements
The welders shall be certified by an accredited body according to AWS D.1.1, EN 287-1 and /or ISO
9606-4. Welding operators shall be certified according to ISO 14732/EN 1418.
C.4.2
Qualification of underwater welders
C.4.2.1
For underwater welding only those welders may be qualified, who are well trained, experienced and qualified for relevant welding above water. Prior to the qualification tests under water, the
welders are to be given sufficient training to get familiar with the underwater welding conditions such as
pressure, atmosphere, temperatures, etc.
C.4.2.2
The test welds are to be performed using materials comparable in chemical composition
(weldability) and strength to those used in the actual welding job, and with the welding process in question under actual or simulated diving conditions.
C.4.2.3
Type and scope of testing are to be based on the actual welding job analogously to those
given above and will be decided from case to case. Limitations given above apply analogously, the limitation of applicable (greater) water depth for welding will be decided in each single case.
C.4.3
Validity of qualification Certificates
C.4.3.1
The validity of a welders qualification Certificate is generally two years, details see in the mentioned standards in C.4.1, provided that during this period the welder has been working under the supervision of GL and the welders work is monitored by visual and/or non-destructive testing. GL may demand
annual repeat tests if monitoring mainly takes the form of visual inspections or if the results of NDT cannot be correlated to the welder.
C.4.3.2
A repeat test is required where a welder, who has been tested in more than one welding process, has not used the process in question for a period exceeding six months but has meanwhile used
another process. A repeat test is also required if a welder has not performed any welding work as defined
in C.4.1 for a period exceeding three months.
GL may demand a repeat test at any time if reasonable doubts should arise as to a welders performance.
C.5
Design of weld connections
C.5.1
C.5.1.1
The shop drawings, etc. shall provide clear and complete information regarding location, type,
size and extent of all welds. The drawings shall also clearly distinguish between shop and field welds.
Symbols and signs used to specify welding joints shall be in accordance with recognized codes or stanEdition 2013
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dards (to be mentioned in the drawings, specifications, etc.) or shall be explained in these documents.
Special weld (groove) details shall be shown by sketches and/or relevant additional remarks.
C.5.1.2
It is recommended that standard welding details, symbols, etc. including any workmanship or
inspection requirements, are to be laid down in standard drawings submitted to GL for general approval.
Dimensions of welding should not form a part of those standard drawings, but shall be designated in the
contract or shop drawings for each individual structural part or welding respectively.
C.5.1.3
All welds shall be planned and designed in such a way that they are readily accessible during
fabrication and can be executed in an adequate welding position and welding sequence, see also C.6.5.
Welded joints which are subject to NDT inspection shall be placed and designed to facilitate application of
the required inspection procedure, so that tests offering reliable results may be carried out.
C.5.1.4
Welds of special and primary structural members shall have unique weld numbers. Welds of
secondary structural members may be group numbered, but only within the same drawing sheet. The
shop drawings shall have all information to select the correct WPS.
C.5.2
Weld shapes and dimensions
C.5.2.1
Weld shapes (groove configurations) shall be in accordance with ISO 2553 or ISO 9692 or
AWS D 1.1. As far as possible, full penetration butt or T-joints shall be designed as double side welds
with the possibility of sufficient root treatment (gouging) instead of single side welds. Fillet welds shall be
made on both sides of the abutting plate or web.
C.5.2.2
Weld shapes shall be designed to ensure that the proposed weld type and quality (e.g. full
penetration) can be satisfactorily achieved under the given fabrication conditions. Failing this, provisions
shall be made for welds which are easier to execute. The (possible lower) load-bearing capacity of these
welds shall be taken into consideration in the dimensional design. According to Fig. 4.23, the effective
throat thickness of a partial penetration groove weld shall be the depth of bevel less 3 mm, if not otherwise proved in way of welding procedure qualification tests and agreed by GL.
C.5.2.3
Special weld shapes, differing from those laid down in the above Rules and standards (e.g.
single side, full penetration groove welds in tubular T-, K- or Y-connections) or weld shapes for special
welding processes shall have been proved in connection with the welding procedure qualification tests
according to both C.3.3 and C.3.5 and are to be approved by GL. Typical welds of tubular T-, K- and Yconnections with and without back welding are shown in both Figs. 4.24 and 4.25.
Welding details to be observed, especially for Fig. 4.25, see both Tables 4.23 and 4.24
Table 4.23 Minimum weld thicknesses for tubular joints
Weld angle
Weld thickness tw [mm]
Over 130
To continue line of brace/stub, except that tw need not exceed 1.75 t
60 to 130
1.25 t
40 to 60
1.50 t
Under 40
1.75 t
Remark:
Smooth profile required between brace/weld/chord generally
t = wall thickness of brace or stub [mm]
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Table 4.24 Root gap requirements for tubular joints

Groove angle
Root opening g [mm]
Over 90
05
45 to 90
25
Under 45
3 6.5
Remark:
Details of welding process to be considered.
C.5.2.4
The weld contour is to be designed with smooth transitions tangent to the parent material in
order to achieve the actual calculated fatigue life. The requirements regarding the weld contour, including
additional treatment, such as grinding of weld toes to a smooth profile depending on the actual detail
category, see Section 3, I.2.8, are to be laid down in the drawings and/or specifications. A typical improved weld contour of a T-joint is shown in Fig. 4.26. The cap layer should be made with single passes
(no excessive weave technique), starting at base material and making the last passes in temper bead
technique on top of the weld to avoid excessive hardness in the heat affected zone.
C.5.2.5
Dimensions (effective throat thicknesses and lengths) of welds are to be determined in context
with the static and fatigue strength calculations and are to be specified in the drawings submitted to GL
for approval.
C.5.2.6
The effective throat thickness of a complete penetration groove weld shall be the thickness of
the thinner part to be joined. For partial penetration groove welds, the drawings shall specify the groove
depth applicable to the effective throat thickness required for the welding procedure to be used, see both
C.5.2.2, Fig. 4.23 and Fig 4.27, as well as the calculated effective throat thickness.
The throat thickness of fillet welds is the size a in Fig. 4.27. In the drawings, fillet weld dimensions may
be specified by the throat thickness a or by the leg length A, which is A = a 2 .
The throat thickness of fillet welds shall be as follows:
amax
: 0.7t1
amin
t1
: lesser (e.g. the web) plate thickness [mm]
t2
: greater (e.g. the flange) plate thickness [mm]
t1 + t 2
[mm], but not less than 3 mm
3
epth
ve d
groo
a
f
Fig. 4.23
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epth
ve d
groo
a
f = deduction for incomplete
root penetration 3 mm
(see 5.2.2)
Effective throat thickness a of partial penetration groove welds
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t
45
45
rmin t
rmin t
2
Area D
a > 60
Area A
a > 130
Area C
60 < a 90
Area B
90 < a 130
b1
45
a
rmin t
2
rmin t
2
b2
Fig. 4.24
180 - a
2
a
b
t
b1 a
2
rmin t
2
rmin t
2
weld angle
groove angle
wall thickness of brace
b2 45
Typical tubular weld connections with back welding
a
t
b 45
1:2
b = 15
tw
tw
Area A
a > 130
a 40
Area D
t
40 < a 60
b = a/2
Area B
90 < a 130
g
tw
Area C
60 < a 90
b 45
b/2
g
a
tw
b = a/2
g
smooth profile between brace

- weld and weld - chord required
a weld angle
b groove angle
t wall thickness of brace
tw weld thickness (see Table 4.23)
g root gap (see Table 4.23)
Fig. 4.25
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tw
Typical tubular weld connections without back welding
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t
ch m
thin ember
ner
part or
undercut not to
exeed 0.3 mm
bran
temper beads
re-entrant
angle 135
theoretical radius
body
135
grinding line tool radius

(tool radius 8 mm min.)
cap passes
0.05 t or 0.8 mm max.

0.3 mm max. without
MPI - indications
Fig. 4.26
Typical improved weld contour
convex
weld
concave
weld
45
45
Fig. 4.27
C.5.3
Effective throat thickness a and leg length A of fillet welds
Details of welded joints
C.5.3.1
All welded joints on special and/or primary members shall be designed to provide a stress flow
as smooth as possible without major internal or external notches, discontinuities in rigidity and obstructions to strains.
The transition between differing component dimensions, e.g. of girders or stiffeners, shall be smooth and
gradual. The length of the transition should be at least 4 times the difference in depth, see Fig. 4.28.
loads
4
notch - free ground
where necessary
1
Fig. 4.28
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improved shape
Transitions between components with differing dimensions
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C.5.3.2
The requirements given in C.5.3.1 apply in analogous manner to the welding of secondary
members onto primary (or special) supporting members. The ends should have smooth transitions to the
main structure, see Fig. 4.29.
End of weld with smooth

transitions to the main structure
(to be ground if necessary)
Fig. 4.29
Ends of secondary members welded on the main structures
C.5.3.3
Where the plate or wall thickness differs more than 3 mm at joints mainly stressed perpendicularly to the (butt) weld direction, the difference shall be smoothed by bevelling and/or buttering according
to Fig. 4.30 prior to butt welding. Differences in surface levels up to 3 mm may be equalized within the
weld.
up to
3 mm
up to
3 mm
up to
3 mm
1
1
1
1
Fig. 4.30
Transition in butt welds of different thickness
C.5.3.4
If a misalignment due to component or plate respective wall thickness tolerances cannot be
eliminated by adjusting (e.g. in case of circumferential butt welds in tubes) and the difference X is not
greater than one quarter of the thinner plate or all thickness, the misalignment may be equalized by
chamfer or built-up welding according to Fig. 4.31. Where the difference is greater and/or highly fatigue
stressed joints are involved, equalization is to be decided and agreed upon with GL in each individual
case.
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Equal plate thickness

4x *
edge chamfered
4x
1:4
edge built up
1:4
4x
4x
1:4
edge chamfered
edge built up
4x *
1:4
4x
edge built up
4x
4x *
4x
edge chamfered
edge chamfered
4x
1:4
Different plate thickness
edge built up
* but at least till end of chamfered part on opposite side

Fig. 4.31
Equalization of misalignment in butt welds
C.5.3.5
Where plates (including girder web and flange plates) or tube walls are subjected locally to
increased stresses, thicker plates are to be inserted in preference to doubler plates. This applies analogously to flanges, stuffing-boxes, hubs, bearing bushes or similar components to be welded into plates.
The minimum size of those reinforcement plates shall be:
Dmin
: 170 + 3 (t - 10), but not less than 170 mm
: the diameter of round inserts or the length/breadth of angular inserts [mm]
: plate thickness [mm]
The corner radii of angular reinforcing plates shall be at least 50 mm. The welding between those reinforcement plates or inserts and the plating shall be full penetration butt welds, and the transition shall be
in accordance with C.5.3.3.
C.5.3.6
Doubler plates (cover plates) may be used to reinforce girder flanges or similar components in
the area of maximum bending moments. Doubler plates shall be limited to one per flange, and their thickness t shall not exceed 1.5 times the thickness of the flange, their width w should not exceed 20 times
their thickness. The ends of doubler plates shall be extended beyond the calculated, theoretical start or
end conforming to Fig. 4.32. The fillet welds connecting the doubler plate to the flange shall be continuous welds. The welds at the end of the doubler plates shall conform to Fig. 4.32.
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t 25
tR 25
tR
w/2
r 3t
tR
t > 25
1.5w
1.5w
tR 25
tR
t 25
calculated, theoretical
starts or ends of doubler
plates on flanges
0.5tR
w/2
0.5tR
Steel Structures
0.5t
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t > 25
Rules
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t : thickness of doubler plate

tR : thickness of reduced (chamfered) doubler plate
w : width of doubler plate
Fig. 4.32
Configuration and welding of ends of doubler plates on flanges
C.5.3.7
Local clustering of welds and short distances between welds are to be avoided. Adjacent butt
welds should be separated from each other by a distance of at least:
50 mm + 4 t
t
: plate thickness [mm]
Fillet welds should be separated from each other and from butt welds by distance of at least:
30 mm + 2 t
The width of sections (strips) of plate to be replaced should, however, be at least 300 mm or 10 t, whichever is greater.
C.5.3.8
Where tubular joints (node sections) without overlapping requires increased wall thicknesses
and/or special steel in the main member (chord, can) and/or in the branch members (bracing stubs), the
separation of the welds shall be in accordance with both Figures 4.33a) and 4.33b). The greater measures apply, see also B.15.7.
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1/s
1
/4
50
d1
4:1
d 600
d2 600
g 50
d
6 2
0
d 0
1 2 /4
50
d2/4 150
D/4
300
d2
1
of:
ser
les 5 0
1 t
2
d
6 2
00
4:1
d1
4:1
4:1
d2
a)
b)
1
seam weld
2
can circumferential weld
s
slope of conical transion (s = 4for D/t < 30; flatter slope necessary for higher D/t ratios)
t
wall thickness of chord
g
gap between of braces
D outer diameter of can or chord
d1 outer diameter of brace
all Dimentions [mm]
Fig. 4.33
Separation at tubular joints and weld seams
C.5.3.9
In overlapping tubular joints (node sections), in which part of the load is transferred directly
from one branch member (bracing) to another through their common weld, the overlapping of the welds
shall be at least in accordance with both Figures 4.33a) and 4.33b). The greater measure applies. The
actual length of the overlapping weld is to be determined by calculation. The heavier brace shall preferably be the through brace with its full circumference welded to the chord.
C.6
Performance of welding, workmanship
C.6.1
C.6.1.1
All welding is to be performed observing the applicable paragraphs of this Section as well as
the common actual standard of welding technology to achieve the required quality. Detailed recommendations are given in relevant parts of EN 1011 series. Compliance with these Rules and with any other
conditions, which may be agreed or stated in the drawings, specifications and other related documents or
imposed in connection with approvals as well as with good workmanship, is the responsibility of the
manufacturers. Inspections performed by GL do not relieve the manufacturers of this responsibility.
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C.6.1.2
The preparation and performance of all welding operations shall be supervised by manufacturers welding supervisors, see C.1.5. Regarding the qualification and the functions of the welding supervising personnel, see GL Welding Rules. In the event of any deviations from the above stated operating
conditions, the welding supervisory personnel shall, in agreement with GL, take steps to ensure the constant and adequate quality of the welds. For inspection personnel see F.5.
C.6.2
Overweldable shop primers
C.6.2.1
Overweldable shop primers which are applied to plates, sections, etc. prior to welding and are
not removed shall be tested and approved in accordance with GL Rules for General Requirements, Proof
of Qualifications, Approvals (II-3-1), Section 6.
C.6.2.2
By suitable checks on the thickness of the coating especially on and by sample production
tests in the course of normal fabrication welding, shops shall ensure that the welded joints suffer no unacceptable deterioration, see GL Rules for General Requirements, Proof of Qualifications, Approvals (II3-1), Section 6, C.
C.6.3
Weld preparation assembly, tack welding
C.6.3.1
Machining, oxygen cutting, air carbon arc gouging, oxygen gouging, chipping or grinding may
be used for joint preparation, back gouging or the removal of unacceptable work or metal, except that
oxygen gouging shall not be used on normalized or quenched and tempered steels.
C.6.3.2
When preparing and assembling components, care shall be taken to ensure compliance with
the weld shapes and root openings (air gaps) specified in the drawings and specifications. With single
and double-bevel T-joints, especially, attention shall be paid to an adequate root opening in order to
achieve sufficient root penetration.
C.6.3.3
The root opening shall not exceed the specified gap. If the gap exceeds this value locally over
a limited area, the gap may be reduced by build-up welding of the groove edges, subject to the prior consent of the Surveyor. Details see also both B.10.4 and C.6.8.
With fillet welds, the a dimension shall be increased accordingly, or a single or double-bevel weld shall
be made, if the air gap is large. Inserts and wires shall not be used as fillers.
C.6.3.4
With the Surveyors agreement, large gaps except in highly stressed areas of special structural members may be closed by means of a strip of plate with a width of at least 10 times the plate
thickness or 300 mm, whichever is the greater.
C.6.3.5
Members to be welded shall be brought into correct alignment, see also B.10, and held in position by bolts, clamps, wedges, guy lines, struts and other suitable devices or by tack welds until welding
has been completed. The use of jigs and fixtures is recommended, where practicable. Suitable allowances shall be made for warpage, shrinkage and for expansion due to ambient changes, e.g. direct
sunlight.
C.6.3.6
Clamping plates, temporary ties, aligning pins, etc. shall be made of structural steel of good
weldability and should not be used more than necessary. They are to be carefully removed to prevent
damage to the surface of members when the components have been permanently welded, see also B.12.
C.6.3.7
Clamping plates, temporary ties, aligning pins, etc. shall not be welded to components or areas subject to particularly high stresses, nor shall they be welded to the edges of flange plates of girders
or similar members. The same applies to the welding of handling lugs and other auxiliary fixtures.
C.6.3.8
Tack welds should be used as sparingly as possible and shall be performed by qualified welders using qualified welding procedures and consumables.
The preheating temperature shall not be less than for welding the joint.
Where their quality does not meet the requirements applicable to the subsequent welded joint, they are to
be carefully removed before the permanent weld is made. All tack welds which will form part of the permanent weld shall be cleaned, ground down to a feather edge at both ends and visually inspected prior to
welding of the root pass.
Any cracked tack weld shall be completely removed by grinding and not incorporated into the weld, see
also B.10.9.
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C.6.3.9
Particularly with mechanized welding processes and invariably when end craters and defects at the start and end of the weld have to be avoided run-in and run-off plates of adequate section
shall be attached to components and cleanly removed on completion of the weld.
C.6.3.10 Surfaces to be welded shall be visually examined, to ensure freedom from laminations, cracks,
slag inclusions and cutting notches and additionally clean and dry.
Any scale, rust, cutting slag, grease, paint or dirt is to be carefully removed before welding or dressed out
by grinding. If the depth of excavation exceeds 5 mm, a weld repair shall be made, using an approved
WPS.
Moisture is to be removed by preheating. Edges (groove and root faces) are to have a smooth and uniform surface.
Bevels are to be ground after weld preparation by acetylene cutting.
For overweldable shop primers, see C.6.2.
C.6.4
Weather protection, preheating, heat input during welding
C.6.4.1
Weather protection, welding at low temperatures
C.6.4.1.1 The area in which welding work is performed has to be sheltered from wind, damp and cold,
particularly outdoor. Where gas-shielded arc welding is carried out, special attention is to be paid to ensure adequate protection against draughts. When working in the open under unfavourable weather conditions it is advisable to dry welding configurations by heating.
C.6.4.1.2 At ambient temperatures below +5 C, additional measures shall be taken, such as shielding
of components, extensive preliminary heating and pre-heating, especially when welding with a relatively
low heat input (energy input per unit length of weld), e.g. when laying down thin fillet welds or in the case
of rapid heat dissipation, e.g. when welding thick-walled components. Wherever possible, no welding
should be performed at ambient temperatures below -10 C.
C.6.4.2
Preheating for the welding of ferritic steels
C.6.4.2.1 The need for preheating of ferritic steels and the preheating temperature depend on a number
of factors. Among these are especially important:
the chemical composition of the base material (carbon equivalent) and the weld metal/consumable
the thickness of the work piece and the type of weld joint (two or three dimensional heat flow, see
combined thickness in EN 1011-2)
the welding process and the welding parameters (energy input per unit length of weld)
the shrinkage and transformation stresses
the temperature dependence of the mechanical properties of the weld metal and the heat affected
zone
the diffusible hydrogen content of the weld metal
C.6.4.2.2 The operating temperature to be maintained (minimum preheating temperature and maximum
interpass temperature) for structural steels may be determined in accordance with EN 1011-2.
C.6.4.2.3 Preheating is always necessary for following duties:
tack welds generally
welding of lugs or other auxiliary welds
during erection of major components
welding of large wall thicknesses
welding of castings and forgings
during repair welding should be minimum 50 C higher than the preheat used for the original weld
A detailed procedure shall be available, where all items mentioned for the project used.
Additional information is required from the steel manufacturer.
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C.6.4.2.4 Preheating shall be applied uniformly throughout the thickness of the plate or component over
a distance of four times the plate thickness, minimum of 100 mm, on both sides of the weld.
Preheating above 50 C should be achieved by electric heating elements. Cutting torches are not allowed
for preheating.
C.6.4.2.5 To prevent cold cracks in higher-strength and high strength (quenched and tempered) steels,
thick-walled components or components of complex design, it is advisable to use measures which give
the hydrogen induced into the weld metal during welding sufficient time to escape. The following methods
are well established:
maintenance of a specific minimum preheating and interpass temperature throughout the welding
operation
delayed cooling after welding
holding at approx. 230 250 C for about 2 hours prior to cooling (hydrogen-reducing heat treatment
or soaking)
heat treatment immediately after welding (without cooling in between)
further information required from the steel manufacturer
C.6.4.2.6 Where structural steels or fine-grained structural steels have undergone thermo-mechanical
processing (TMPC steels), the need for and degree of preheating shall be decided separately on the basis of the carbon equivalent and the results of the approval or welding procedure tests as applicable. Drying of the areas to be welded by heating may be sufficient.
C.6.4.3
Monitoring of interpass temperatures
The guide values contained in EN 1011 or AWS D.1.1 for the interpass temperatures relating to the various steels shall not be significantly exceeded.
The minimum interpass temperature shall not drop below the minimum required preheat temperature.
C.6.4.4
Welding with controlled heat input per unit length of weld
In addition to controlling the preheating and interpass temperature, the heat input per unit length of weld
shall be controlled during welding, especially in the case of weldable, high strength (quenched and tempered) fine-grained structural steels. The heat input per unit length of weld shall not fall below or exceed
the values indicated by the steel manufacturer or those used in the welding procedure tests and specified
in the welding procedure specifications (WPS) by any significant amount.
C.6.4.5
Preheating and heat input during the welding of other steels or metallic materials
C.6.4.5.1 Preheating is not normally required for austenitic materials. Preheating may be necessary for
austenitic-ferritic materials. A maximum permitted interpass temperature which is normally between 150
C and 180 C shall be complied with in order to prevent hot cracking.
C.6.4.5.2 Ferritic and stainless martensitic steels shall be adequately preheated and welded using controlled heat input per unit length of weld. Guide values for the preheating and interpass temperatures are
prescribed in EN 1011-3.
C.6.4.5.3 Preheating is not normally required for welding of aluminium alloys, but should not exceed
50 C. A maximum permitted interpass temperature of 100 C to 120 C shall be complied with in order to
prevent undesirable phase dispersion. EN 1011-4 contains guide values for both the preheating temperature to be applied and the interpass temperature.
C.6.5
Welding positions, welding sequence
C.6.5.1
Welding should be performed in the optimum welding position, and welding in unfavourable
positions is to be limited to the indispensable minimum. For similar and repetitive welding operations it is
advisable to use a (rotary) jig enabling all welds, as far as practicable, to be made in the downhand position. Vertical-downward welding may not be used to join special and primary structural members.
C.6.5.2
The welding sequence shall be chosen to allow shrinkage to take place as freely as possible
and to minimize shrinking stresses. In special cases, GL may require to set down the assembly procedure
and welding sequence in an appropriate schedule.
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C.6.5.3
It is recommended to prepare welding sequence plans for special designs. This shall be attached to the relevant WPS used.
C.6.6
Weld quality requirements
C.6.6.1
The requirements to be met by the weld, e.g. seam geometry, surface quality, admissible external and internal flaws, depend on the significance of the respective welds for the overall integrity of the
structure. The operability of individual components as well as the kind of loads (static/dynamic) and the
stress level shall also be considered.
C.6.6.2
The requirements to be met by the welds are to be laid down in the plans for production, inspection and testing, e.g. drawings, specifications etc., see also F.4.4, and on the basis of relevant codes
and standards, see ISO 5817 Table 1, and contractual matters and taking into account the criteria as
stated in C.6.6.1. These particulars are to be presented to GL for review and approval. For inspection and
testing of welds, see D to F.
C.6.7
Repairs
C.6.7.1
General
For repair welds generally the requirements are identical to those applicable to the original weld, nevertheless a repair procedure to be qualified. Welds containing cracks shall not be repaired, until the reason
for the cracking has been determined. Prior to carrying out extensive repair welds or the repetition of repair welds, e.g. owing to inadequate results of non-destructive inspections, consultation with the GL Surveyor shall be sought. The kind and scope of envisaged repair measures have to be agreed with him. For
examination of repair welds, see both F.4.4 and F.4.5.
C.6.7.2
Correction of welds containing defects
Repair welding shall be qualified by a separate welding repair qualification test based on WPQRs for the
type of weld repair to be applied, see C.6.7.5.
If necessary, the defective part of the weld shall be cut out for further examination. Crater cracks may be
repaired by grinding followed by NDT and subsequent repair welding according to an accepted repair
welding procedure.
Other defects shall be corrected by grinding, repair welding or re-welding.
When weld defects are removed by grinding only, the final weld surface and the transition to the base
material shall be smooth. Removal of defects shall be verified by local visual inspection, aided by applicable NDT methods. If applicable, the remaining thickness in the ground area shall be measured. Repair
welding is required, if the remaining thickness is less than that specified.
C.6.7.3
Repair by welding
Repair of welded joints shall be carried out by completely removing the unacceptable portion of the weld
without substantial removal of the base material.
The excavated area shall have smooth transitions to the metal surface and allow good access for both
NDT after excavation and subsequent repair welding. After excavation the defect shall be confirmed by
MT.
The excavated groove shall be minimum 50 mm long, measured at defect depth even if the defect itself is
smaller. Defects spaced less than 100 mm shall be repaired as one continuous defect.
If in one seam section several flaws requiring repair are located close to each other, the whole seam section has to be gouged out and welded new.
After repair welding the complete weld, i.e. the repaired area plus at least 100 mm on each side, shall be
subjected at least to the same NDT as specified for the original weld.
C.6.7.4
Preheating and interpass temperature
Preheat for repair welding shall normally be 50 C above minimum specified preheat for production welding.
The interpass temperature shall be maintained until the repair has been completed.
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C.6.7.5
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Steel Structures
Repair welding procedure
Repair and re-repair may be performed in accordance with the WPS of the original weld, or a separately
qualified procedure, if the repair process or/and consumable are different.
Qualification of repair welding procedures shall be made by excavating a repair groove in an original
weld, welded in accordance with a qualified welding procedure, e.g. partial and through thickness repair.
For the mechanical testing the excavated groove shall be of a sufficient length to obtain the required
number of test specimens + 50 mm at each end.
Mechanical testing may be limited to HAZ Charpy V-notch testing in the original weld, see both Figs. 4.34
and 4.35.
WM FL
FL+2 mm
FL+5 mm
FL+5 mm FL+2 mm FL
FL+2 mm
Fig. 4.34
FL
Charpy-V notch impact test specimen positions full thickness repair
The FL specimen shall sample 50 % WM and 50 % HAZ

The FL+ 5mm sample is applicable to WPQT only.
FL
: fusion line
WM
: weld metal
HAZ
: heat affected zone

FL FL+2 mm
FL+5 mm
FL+5 mm FL+2 mm FL WM
Fig. 4.35
C.6.7.6
Charpy-V notch impact test specimen positions partial thickness repair
NDT methods
MT, UT or other suitable methods shall be used to verify the complete removal of the defects. PT is only
allowed after consultation with the Surveyor.
Repair welding in the same area may be carried out twice. Further repairs shall be evaluated in each
individual case.
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C.6.7.7
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Post-weld heat treatment
In general, major repair welds, at parts which have already undergone post weld heat treatment, necessitate another heat treatment of the whole part. GL may agree to local post weld heat treatment or in the
case of minor repair welds dispense with it completely; this has to be decided in each individual case.
C.6.7.8
Correction of distortion
Improperly fitted parts should be cut apart and re-welded in accordance with the applicable qualified
WPS.
Parts distorted by welding, beyond the tolerances, should be straightened. Material properties are to be
observed, see also B.13.
C.6.8
Buttering
When the gap of weld joint exceeds the limitations a buttering of the weld groove be qualified by a separate WPQT and the largest gap in production shall be used.
For special and primary members the maximum build-up shall be 8 mm and the maximum root gap 10
mm. Further details, see both B.10.4 and C.6.3.3.
No weaving is allowed on this welding procedure.
After welding MT shall apply before filling the groove and no surface linear indications are accepted.
C.6.9
Post weld heat treatment
Note
Stress-relief annealing will be dealt with in the following under the heading of post weld heat treatment.
Should other kinds of post weld heat treatment be intended, agreement shall be sought from GL, who will
consider the conditions on a case to case basis.
C.6.9.1
Post weld heat treatment should generally be performed at structural welds of joint thicknesses of 50 mm and over, unless adequate fracture toughness can be proved in the as welded condition. For restrained joints of complicated design, post weld heat treatment may be required for thicknesses less than 50 mm, see A.4.5.
C.6.9.2
Any heat treatment is to be performed in accordance with a procedure specification, to be
prepared by the manufacturers and submitted to GL for approval. This specification shall detail heating
facilities, insulation, control devices and recording equipment, as well as heating and cooling rates, temperature gradients, holding temperature ranges and times.
C.6.9.3
Wherever possible, post weld heat treatment is to be carried out in an enclosing furnace.
Where this is impractical, local heat treatment may be performed with the consent of GL. When local heat
treatment is performed, an area extending over at least 3 times the material thickness on both sides of
the weld is to be kept at the specified temperature.
C.6.9.4
Any heat treatment cycle is to be recorded using thermocouples equally spaced externally and
whenever possible internally throughout the heated area. The heat treatment records are to be submitted to the GL Surveyor. Regarding inspections and tests after heat treatment see F.4.
C.6.10
Production tests
C.6.10.1 Production tests, i.e. tests with test pieces welded simultaneously at specified intervals during
fabrication may be called for where the base material, the welding process or the loading conditions require that proof be provided of the sufficient mechanical characteristics of the welded joints produced
under fabrication conditions.
C.6.10.2 Production test pieces shall be welded and tested in a manner analogously to that prescribed
in C.3.5. The scope of the tests and the requirements to be met shall be determined on a case to case
basis.
C.6.10.3 If a production test fails, the reason for the failure shall be determined and remedial action
implemented.
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Welding should be suspended until the cause of cracks and defects has been identified and measures to
be taken to prevent their occurrence. Cracks or other persistent weld defects may lead to a revision
and/or a re-qualification of the WPS.
C.6.11
Underwater welding
C.6.11.1 Underwater welding is generally to be carried out in a large chamber from which the water has
been evacuated (habitat welding). Underwater wet welding characterized by the arc working in the water
or in a small gas-filled confinement, is normally restricted to minor repair work at secondary structures
only in shallow water and requires the special consent of GL from case to case.
C.6.11.2 Underwater welding is to be performed in accordance with a detailed procedure specification
to be prepared by the manufacturers and submitted to GL for approval. It is to be carried out using especially qualified welding procedures (see C.3.10) and by special qualified welders (see C.4.2). The transfer
and handling of welding consumables as well as baking and storage in the welding habitat shall be considered in the welding procedure specification.
C.6.11.3 Production test welds are to be carried out prior to commencing the underwater welding at the
site in a manner which, as far as possible, reproduces the actual welding conditions, thus checking that
all systems are properly functioning, and results in sound welds. The production test welds are to be
visually inspected and non-destructively tested prior to production welding. Subsequently they are to be
subjected to mechanical and technological tests. Type and number of test pieces and tests are to be
specified and agreed by GL from case to case.
C.6.11.4 Visual inspections and non-destructive testing are to be carried out on the actual production
welds by qualified operators, applying qualified and approved procedures, see also F. The methods and
extent of inspections and testing are to be specified and agreed by GL from case to case. The finished
welds shall fulfil the requirements specified for the individual structural parts or welds respectively.
C.6.11.5 All underwater welding work, including qualifications, production tests, actual welding data and
inspection and test results shall be recorded. The records are to be submitted to GL for review and shall
be kept for 5 years, see D.1.8.
Survey, Inspection and Testing
D.1
D.1.1
Inspection and testing shall be performed by the manufacturers in accordance with an approved inspection and test plan (ITP) by the Owner/Purchaser, to confirm that all project requirements
meet the demands of these Rules, the approved specifications and drawings or any other requirements
stated or agreed upon.
ITPs to be submitted to GL for acceptance.
D.1.2
Inspection and testing are to be carried out during fabrication, construction and erection
phases and shall cover following items:
correct identification and documentation and use of materials
qualification and acceptance procedures and qualified/certified personnel
inspection of preparatory work (assembly, fit-up form work, reinforcements, etc.)
welding inspection
inspection of fabrication work for compliance with specifications and procedures
witnessing of NDT, control and testing
inspection of repairs
inspection of corrosion protection systems
D.1.3
For the quality control required during fabrication and construction, see B.4.
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D.1.4
Manufacturers will be responsible for the due performance of the inspections and testings as
required, as well as for compliance with the requirements laid down in the documents. Inspections and
testings performed by GL do not relieve manufacturers of their responsibility.
D.1.5
The GL Surveyor shall have the opportunity of witnessing and observing the inspections and
tests conducted, or of conducting inspections and tests himself. To this effect the Surveyor shall have
permission to enter production areas and building sites and be assisted, wherever possible.
D.1.6
Following inspection and testing by the manufacturers the structures or parts thereof are to be
presented to the GL Surveyor for final checking. Parts are to be presented in suitable sections enabling
proper access for inspection generally before painting. The Surveyor may reject components that have
not been adequately inspected and tested by the manufacturers, and may demand their resubmission
upon successful completion of such inspections and corrections by the manufacturers.
D.1.7
Assessments of defects (e.g. weld defects), which are identified by their nature, location, size
and distribution, shall take due account of the requirements applicable to the welded joints, see also F.4.
Inspection or testing results respectively shall be evaluate by the testing department and/or the welding
supervisory staff and submitted to GL for review. The final assessment, together with the right of decision
as to the acceptance or repair of defects in the material or weld, shall rest with the GL Surveyor.
D.1.8
Reports shall be prepared on all (initial and repeat) inspections and tests, and these shall be
submitted to the GL Surveyor together with other documentation (e.g. radiographs etc.) for review. The
reports shall contain all the necessary details relating to the particular test method used, see F.7.2, G.7,
H.11, I.13, J.15, K.9, and the position at which the test was performed and the results obtained. The reports shall at any time, during fabrication and construction, as well as during erection and installation,
permit the irrevocable tracing of tested areas and test results. Test reports and documentation shall be
kept for minimum 5 years.
D.1.9
Welds shall be subject to NDT in progress with fabrication. The results of these activities shall
be consecutively reported to the Owner/Purchaser.
D.2
Codes and standards
D.2.1
The codes, standards and other relevant Rules and Regulations mentioned in the following
constitute an integral part of these Rules and require no special consent. The version in force on the date
of publication of these Rules shall be applied. New editions of the codes, standards, etc. may be used in
agreement with GL.
D.2.2
The application of other equivalent standards, codes etc. (e.g. AWS D 1.1 Structural Welding
Code-Steel and API RP 2X Recommended Practice for Ultrasonic and Magnetic Examination of Offshore Structural Fabrication and Guidelines for Qualification of Technicians) may be agreed by GL. They
are to be listed in the construction particulars, (e.g. in the inspection and testing plans, specifications or
other contractual Rules and Regulations) and presented to GL on request.
D.2.3
Where the codes, standards, etc. are contradictory to these Rules, the latter shall automatically take precedence. Any deviations from these Rules require approval by GL on a case to case basis.
D.2.4
Generally the latest edition of the codes and standards shall apply due to the contractual date
for the whole fabrication and construction phase.
D.2.5
use.
Mandatory principles and/or recommendations are subjected to the responsible Authority in
D.3
Terms and definitions
The terms and definitions as contained in recognized codes, standards, etc. are to be employed. The
code or standard used is to be indicated in the inspection and testing documentation and presented to GL
on request. Any other deviating terms and definitions are to be explained separately in the inspection and
testing specifications and/or procedures.
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D.4
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Testing equipment
D.4.1
The testing facilities and equipment employed have to meet the latest technical standards and
have to be in good condition.
The manufacturer has to ensure functionally of examination or testing equipment and of recording and/or
measuring devices vital for correct functioning of equipment and machinery used in fabrication.
If manufacturers do not possess equipment of their own, they may use test equipment of third parties,
e.g. testing institutes.
D.4.2
on hand.
The equipment has to be calibrated and/or gauged and the respective Certificates have to be
D.4.3
GL may check the equipment or insist on having the equipment checked in the presence of
the Surveyor. Ultrasonic testing equipment and accessories may be checked within the scope of examining the testing personnel.
D.5
Vendor inspection
Such components have to comply with the relevant specifications. The grade of supervision depends on
the type of component. A type approval of special components to be performed by GL HO or another
authorized agency. Statutory Rules and Regulations have to comply with.
Survey and Inspection Scheme
E.1
General
E.1.1
The survey and inspection plan has the task to all areas of concern:
Granting of human live and avoiding of death

Protection of the environment
Saving of properties, operating interests and other economic aspects
E.1.2
This survey and inspection scheme gives an overview of periodical and non-periodical surveys
and inspections. The periodical surveys to be performed on an annual basis, except the underwater survey to be carried out 3 months later after installation of the jacket. The next underwater survey to be performed after 9 months and is subject to the regular annual survey. Periodical inspections of Offshore
Wind Turbines and Transformer substations is specified in BSH StandardDesign of Offshore Wind Turbines.
E.2
Periodical surveys
E.2.1
Above water
General components:
stairs, ladders and other access facilities
boat landing
walkways
Structural components:
steel members for both jacket and topside (dents, deformations, fatigue cracks, bolt pre-tension)
corrosion protection (painting)
foundation structures
E.2.2
Splash zone
denting of the structure
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missing and deformed structural members

pittings
marine growth
E.2.3
Submerged zone
Structural components:
general damages
jacket structure incl. boat landing, mud plates, pile guide supports, incl. grouting
J-tubes incl. cable entrances
cathodic protection system
Other requirements:
marine growth
scour protection and scouring of the sea bed
build-up of cuttings or sediments
movements in bottom sediments
biological activities
E.2.4
Initial condition survey
During the first year of operation of the installation, an initial condition survey should be carried out in
order to enable an overall assessment of the ability of load bearing structures to meet the redefined acceptance criteria. The condition survey will be able to disclose damage or defects if any at an early stage
such that corrective measures can be initiated as needed.
This activity may be included as part of the first periodic survey program.
E.3
Non-periodical survey
General such surveys are required after extreme/accidental events or as a result of operational changes.
A non-periodical inspection, subject to evaluation, be advanced or delayed to coincide with a scheduled
inspection program, if reasonable. Following surveys are subject to non-periodical matters:
Damage and repair of structural components
List of possible damages:
structural
excessive deformations
fabrication or installation
due to overloading
due to man-made hazards
corrosion, etc.
Non-Destructive Testing
F.1
General
F.1.1
Prior to commencement of fabrication the manufacturer shall submit a plan for NDT and NDT
procedures.
F.1.2
Welds shall be subject to NDT in progress with the fabrication. The results of these activities
shall be consecutively reported to Owner/Purchaser.
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F.1.3
Methods of NDT shall be chosen with due regard to the sensitivity of the method and the
methods ability to detect defects likely to occur as a consequence of the welding process.
F.1.4
Final inspection and NDT of structural steel welds shall not be carried out before 48 hours
after completion, except where PWHT is required. The time delay may be reduced to 24 hours for steel
grades with SMYS of 355MPa or lower, and for steel grades with SMYS of 420 MPa or lower for plate
thickness below 40 mm, provided delayed have not been observed for the materials and/or welding consumables in question.
F.1.5
When heat treatment is performed, the final NDT shall be carried out when all heat treatments
have been completed.
F.1.6
All NDT shall be properly documented. The reports shall identify all defects exceeding the
acceptance criteria unless more stringent reporting requirements have been agreed. All weld repair shall
be documented.
F.1.7
The reporting system shall ensure that there is no doubt what is examined and where it is
examined. The system shall give a clear and exact description of reportable defect location.
F.1.8
Nevertheless, where defects requiring repair are located by the discretionary inspection a detailed report shall be submitted to the Owner/Purchaser.
F.2
NDT procedures
NDT procedures shall be performed in accordance with agreed written procedures, that as a minimum
are in accordance with GL Rules and give detailed information on the following aspects:
applicable codes and/or standards
materials, dimensions and temperature of tested material
periodically verification of equipment requirements
joint configuration and dimensions
technique (sketches / figures) to be referenced in the NDT report
equipment and consumables
both calibration techniques and references
testing parameters and variables
assessment of imperfections and the surfaces from which the examination has been performed
reporting and documentation of results
personal qualifications
acceptance criteria
F.3
Selection of NDT - Methods for different materials
For different types of materials following selection of NDT methods shown in Table 4.25.
Table 4.25 Minimum scope of non-destructive inspections and testing [%]
Welds
NDT
method
Material
Plate
Butt
Tjoint
T-joint
partial
Fillet
Castings
Forgings
Clad
weld
plate
VT
All
MT
Ferromagnetic steels/
Duplex 1
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PT
Aluminium/Cu
alloys/
SS/Duplex 2
RT
All
x4
UT 5
All excl. Cu
ET 3
All
1 Methods are applicable with limits for Duplex, shall be approved case by case
2 May be used for other materials also after special approval in each case
3 May be approved after special approval in each case
4 Recommended for t 40 mm
5 Only applicable for welds with t 8 mm
F.4
Extent of NDT
F.4.1
The required minimum extent of testing is given in Table 4.26. For the categorization of structural members, see A.2; the relevant weld connections are to be subdivided accordingly.
The extent shall be based on type and level of design stresses and on the importance of the connection
in question. The welds shall be assigned inspection categories equal to be highest structural category of
the two components.
All welds which will become inaccessible or very difficult to inspect in-service to be non-destructive tested
over their full length, according to the scope of non-destructive inspections and testing, see Table 4.26.
The specified percentage to be tested in Table 4.26 refers to the total length of welds for each structural
member category.
Table 4.26 Minimum scope of non-destructive inspections and testing [%]
Category of structural members/ Type of inspection
Special structural
members
Type of
connection
Primary structural
members
VT
RT
UT 4
MT or
5
PT
VT
RT
UT 4
100
10 1
100
100
100
10 1
T-joints (full pene100

tration)
100
100
100
T-joints (partial
penetration)
100
100
Fillet welds
100
100
Butt welds
Secondary structural
members
MT or
RT UT 4
MT or
VT
100
100
100
spot 3
100
100
100
spot
100
100
100
spot 3
100
100
100
spot 3
PT
PT
The radiographic testing may be replaced by ultrasonic testing, if the weld thickness is 40 mm
Where partial penetration T-joints are admissible in highly stressed areas, an ultrasonic inspection to determine the size of
incompleteness and the soundness of the welds may be required
Approximately 2 to 5 %
Ultrasonic examination shall be replaced by RT for plate thickness < 8 mm
Selection according to Table 4.25
F.4.2
The respective inspection and testing plans as well as relevant specifications shall be compiled by the manufacturers for each structure, taking into consideration their individual design and stress
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conditions. These plans and specifications shall contain the scope and methods of inspection and testing
as well as the acceptance limits for surface and internal weld defects. These limits are intended to be
used for the assessment of the welds in accordance with common standards, e.g. ISO 5817, details see
C.6.6.
Particular attention is to be paid to materials and processes (possibilities for faults) besides the stresses.
When partial testing is defined for welds in an area, the testing shall be done in areas of welds most susceptible to weld defects, like on the transition of different thickness or crossing of longitudinal and/or
circumferential welds.
Specifications and plans shall be submitted to GL for approval.
F.4.3
All non-destructive testings of complicated and heavy structures (e.g. tubular node joints and
other, thick-walled T-, K- and Y-connections) or of higher-strength and especially high-strength structural
steels shall be performed not earlier than specified in F.1.4 after weld completion in order to be able to
detect delayed cracking. Where components are subjected to post-weld heat treatment, the nondestructive testings shall be performed after this heat treatment.
F.4.4
Should the inspections and tests reveal defects of any considerable extent, the scope of the
tests shall be increased. Unless otherwise agreed, tests shall then be performed on two further sections
of weld of the same length for every weld section tested and found to be in need of repair. Where it is not
certain that a defect is confined to the section of weld under test, the adjoining weld sections shall be
additionally tested. GL may stipulate further inspections and tests, especially in the event of doubts as to
the professionally competent and satisfactory execution of the welds.
F.4.5
Repaired welds shall be re-inspected. Where welds have been completely remade, retesting
at least equal in scope to the initial inspections shall be performed in accordance with the Surveyors instructions. Re-inspections are to be identified as such in test reports and on radiographs, e.g. by a letter
R(= repair) placed next to the reference of the radiograph.
F.4.6
The repair rate shall be submitted regularly on a weekly basis to the Owner/Purchaser.
F.4.7
Frequent repairs shall result in increased extent of NDT. The extent of NDT shall be increased
in a manner such that all relevant defects are discovered in the areas of concern and representative sampling is carried out on all welds.
A reduction of examination can be agreed with the Owner/Purchaser after the quality level has been restored.
F.4.8
If severe defects (i.e. cracks, other planar defects or excessive slag lines) occur repeatedly, all
welds made with the same welding procedure during the period in question, shall be examined full length.
F.4.9
NDT shall cover start and stop points of automatically welded seams, except in the case if runon, run-off tabs are used.
F.5
Inspection personnel, supervisors
F.5.1
Inspection personnel (inspectors)
F.5.1.1
The non-destructive weld tests shall be performed by persons trained in the use of the test
method concerned, possessing adequate practical experience and qualification according to the type of
testing/inspection applied, see both EN 473 and ISO 9712. GL shall be supplied with appropriate documentary proof of such training and experience, e.g. conforming to both EN 473 and ISO 9712.
F.5.1.2
Inspection of welds by NDT shall only be performed by inspectors holding a Level II of EN
473, ISO 9712 or ASNT SNT-TC-1A. Moreover personnel who inspect tubular nodes shall be especially
qualified in accordance with API RP 2X.
F.5.2
Inspection supervisors
F.5.2.1
An appropriately qualified works inspection supervisor shall be available for scheduling and
monitoring the performance of the non-destructive weld tests and evaluating the results. Personnel re-
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sponsible for all NDT activities shall be qualified to EN 473, ISO 9712 or ASNT SNT-TC-1A, Level III.
Additional qualification in accordance to API RP 2X is required.
F.5.2.2
The inspection supervisor is responsible for ensuring that the non-destructive weld tests are
competently and conscientiously carried out and recorded by suitable inspectors in accordance with these
Rules, the relevant codes, standards and the approved inspection schedule.
F.5.2.3
When using the services of outside inspection bodies, the works shall ensure that the above
conditions are satisfied and shall inform GL accordingly.
F.6
Acceptance criteria for NDT
F.6.1
All welds shall show evidence of good workmanship. For primary and special members the
visual inspection and NDT acceptance criteria level shall comply with ISO 5817 level B for surface imperfections (5817, Table 1, item no. 1 and 3) and level C for internal imperfections (ISO 5817, Table 1, item
no. 2). Welds of category secondary shall comply with ISO 5817 level C, unless otherwise stated in specifications, drawings, etc. For aluminium and aluminium alloys ISO 10042 shall apply, see also ISO 17635:
NDT of welds.
F.6.2
Acceptance of defects exceeding the given limits may be granted based on fracture mechanics testing and appropriate calculations. If this approach is considered, the inherent inaccuracy of the
NDT method shall be considered when the critical defect size is determined.
F.6.3
The soundness of welds shall comply with the acceptance criteria for each of the NDT method
used. Defects exceeding the limit shall be repaired and after repair welding has been performed, the complete weld, (i.e. the repaired area plus at least 100 mm on each side) shall be subjected to at least the
same NDT methods as specified for the original weld.
F.7
Final report
F.7.1
General
All NDT shall be properly documented in such a way that the performed testing can be easily retraced at
a later stage. The report shall identify the unacceptable defects present in the tested area, and a conclusive statement as to whether the weld satisfies the acceptance criteria or not.
The report shall include a reference to the applicable standard, NDT procedure and acceptance criteria.
F.7.2
Minimum requirements shall be stated:
object and drawing references

place and date of examination
material type and dimensions
post-weld heat treatment, if required
location of examined areas, type of joint
welding process used
name of the company and operator carrying out the testing including certification level of the operator
surface conditions
temperature of the object
number of repairs, if specific area repaired twice or more
contact requirements, e.g. order no., specifications, special agreements, etc.
sketch showing location and information regarded detected defects
extent of testing
testing equipment used
description of the parameter used for each method
description and location of all recordable indications
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examination results with reference to the acceptance level/criteria

number of repairs to be specified in the report, such as once or twice repairs in the same area
Visual Inspection
G.1
General
The testing shall be performed during fit-up (see APIRP2X, Chapter 7.6) and in the as-welded condition in
accordance to ISO 17637, in case of post-weld heat treatment after the treatment. The results of the visual inspection during the fit-up shall be reported to ascertain areas likely to result in poor weld quality or
areas where the root location has been modified.
G.2
Testing conditions
Details see ISO 17637, Chapter 2

G.3
Testing volume
Details see Table 4.26.

G.4
Evaluation of indications
The weld shall be examined to determine whether it meets the requirements of the acceptance criteria in
accordance to F.6.1.
Details see ISO 17637, Chapter 4.4.1 to 4.4.5.
Additional requirements:
any attachments temporarily welded to the object shall be removed. The area where the attachment
was fixed shall be checked to ensure freedom of unacceptable imperfections
all sharp corners adjacent to the weld are to be rounded. Preparation of edges/structural shapes to
be prepared to an acceptable surface finish.
Non-ferreous materials:
Weld zones in stainless steels, Nickel and Titanium alloys shall be visually inspected and fulfil the criteria
for oxidation levels (surface colour).
G.5
Visual testing of repaired welds
When welds fail to comply wholly or in part with the acceptance criteria and repair is necessary, the following actions shall be made:
If removal of metal is required and the remaining thickness is less than that specified repair welding
shall be done according to an approved procedure
If the weld is partly removed it shall be checked that the excavation is sufficiently deep and long to
remove all imperfections. It shall also be ensured, that there is a gradual taper from the base of the
cut to the surface of the weld metal at the ends and sides of the cut. The width and profile of the cut
must be prepared such that there is adequate access for re-welding, see also C.6.7.3.
It shall be checked that, when a cut has been made through a faulty weld and there has been no serious loss of material, or when a section of materials containing a faulty weld has been removed and
a new section is to be inserted, the shape and dimensions of the weld preparation meet the requirements, see also C.6.3.4.
In case where part of a weld is gouged out the excavated area shall be ground and magnetic particle
testing should be carried out prior to re-welding in order to ensure that the imperfection is removed,
see also C.6.7.6.
G.6
Acceptance criteria
The quality shall comply with the requirements of F.6.1.

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G.7
Reporting
The information specified in F.7.2 shall be included in the report.
Magnetic Particle Inspection
H.1
Scope
Magnetic particle testing (MT) techniques apply for the detection of surface imperfections in ferromagnetic
steels, forgings, castings and welds including the heat affecting zones using continuous wet or dry
method.
MT shall be carried out in accordance with ISO 17638.
H.2
Information
Required information prior to testing, see F.3.

H.3
Equipment
Unless otherwise agreed the following types of alternating current-magnetizing equipment shall be used:
electromagnetic yoke
current flow equipment with prods
adjacent or threading conductors of coil techniques
This equipment shall be in accordance to ISO 9934-3.
H.3.1
Alternating current
The use of alternating current gives the best sensitivity for detecting surface imperfections and an AC
electromagnetic yoke shall be used. Each AC electromagnetic yoke shall have a lifting force of at least
45 N (10 lbs.) at the maximum pole space that will be used.
H.3.2
Direct current
Current flow equipment with prods and adjacent or threading conductors or coil techniques shall be specially approved by the Society in each case. Each DC electromagnetic yoke shall have a lifting force of at
least 174 N (40 lbs.)
Unless otherwise agreed, use of permanent magnets shall be avoided due to limitations of the different
equipment and the difficulty to obtain sufficient magnetic field/strength for several configurations.
Where prods are used, precautions shall be taken to minimize overheating, burning or arcing at the contact tips. Removal of arc burns shall be carried out where necessary. The affected area shall be tested by
a suitable method to ensure the integrity of the surface. The prod tips should be lead, steel or aluminium
to avoid copper deposit on the part being tested. Prods should not be used on machined surfaces.
When black light is used the black light must be capable of developing the required wavelengths of 330 to
390 nm with an intensity at the examination surface of not less than 1000 W/cm when measured with a
suitable calibrated black light meter.
H.4
Overall performance test
Before testing begins, a test is recommended to check the overall performance of the testing. The test
shall be designed to ensure a proper functioning of the entire chain of parameters including equipment,
the magnetic field strength and direction, surface characteristics, detecting media and illumination.
H.5
Surface preparation
The testing surfaces shall be free from loose scale, rust, weld spatter and other impurities (i.e. oil, grease,
dirt, heavy and loose paint). Notches, grooves, scratches, edges and other surface irregularities which
can produce false indications, are to be removed by grinding or machining prior to the test. The surface
shall be in accordance to acceptance level 1 of ISO 23278, see H.10.
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When testing of welds is required, the surface and all adjacent areas within 20 mm has to be prepared as
described above.
There shall be a good visual contrast between the indications and the surface under test. For nonfluorescent technique, it may be necessary to apply a uniform thin, adherent layer of contrast paint. The
total thickness of any paint layer shall normally not exceed 50 m.
H.6
Testing
Testing shall be done in accordance to ISO 17638

H.7
Detecting media
H.7.1
General
The detecting media shall be in accordance with ISO 9934-2.

H.7.2
Dry powder
The colour of the dry particles shall provide adequate contrast with the surface being examined and it
may be of fluorescent or non-fluorescent type. Dry particles shall only be used if the surface temperature
of the test object in the range from 57 C to 300 C.
H.7.3
Wet particles
The colour of the wet particles shall provide adequate contrast with the surface being examined and they
are available in both fluorescent or non-fluorescent type. These particles are suspended in a suitable
liquid medium such as water or petroleum distillates. The temperature range of wet particle suspension
and the test object surface shall be in the range between 0 C and 57 C. For temperature below 0 C or
above 57 C, procedures approved in accordance with recognized standard for this purpose shall be
used. For temperatures exceeding 57 C dry powder shall be used.
H.7.4
Fluorescent particles
With fluorescent particles the testing is performed using an ultraviolet light, called black light. The testing
shall be performed in darkened area where the visible light is limited to a maximum at 20 lx.
The test surface shall be viewed under a UV-A radiation source. The UV-A irridiance at the surface inspected shall not less than 10 W/m2 (1000 W/cm2).
H.7.5
Visible light intensity
The test surface for colour contrast method shall be inspected under daylight or under artificial white luminance of not less than 500 lx on the surface of their tested object. The viewing conditions shall be such
that glare and reflections are avoided.
H.8
Application of detecting media
After the object has been prepared for testing, magnetic particle detecting medium shall be applied by
spraying, flooding or dusting immediately prior to and during the magnetization. Following this, time shall
be allowed for indications to form before removal of the magnetic field.
When magnetic suspension are used, the magnetic field shall be maintained within the object until the
majority of the suspension carrier liquid has drained away from the testing surface. This will prevent any
indications being washed away.
H.9
Evaluation of imperfections
Certain indications may arise from spurious effects of scratches and change of section, which create a
boundary between regions of different magnetic properties. These are defined as false indications and
not as real imperfections. The operator shall carry out any necessary testing and observations to identify
such false indications.
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Acceptance criteria
The quality for welds shall comply with the requirements of F.6.1, i.e. linear indications in accordance to
ISO 23278 are not acceptable. Any linear indications shall be ground and re-examined.
H.11
Reporting
Additionally to the items listed in F.7.2, following details have to be included in the testing report:
type of magnetization equipment
type of current
detection media
viewing conditions
demagnetization, if required
lifting force
other means of magnetic field strength verification.
Penetrant Testing
I.1
Scope
This part describes penetrant testing (PT) used to detect imperfections which are open to the surface of
the tested material. PT in accordance with ISO 3452-1 should be used for non-magnetic materials.
I.2
Equipment / testing material
Details see ISO 3452-1, Chapter 5.4 and 6.1, Table 1.

I.3
Compatibility of testing materials with the parts to be tested
Details see ISO 3452-1, Chapter 7.1.

I.4
Preparation, pre-cleaning and testing

I.5
Application of penetrant
Details see ISO 3452-1, Chapter 8.3.1 to 8.3.3

I.6
Excess penetrant removal
The application of the remover medium shall be done such that no penetrant is removed from the defects/
discontinuities.
The excess penetrant shall be removed using a suitable rinsing technique. Examples: spray rinsing or
wiping with a damp cloth. The temperature of the water shall not exceed 50 C.
General, the excess penetrant shall be removed first by using a clean lint-free cloth. Subsequent cleaning
with a clean lint-free cloth lightly moistened with solvent shall then be carried out.
Any other removal technique shall be approved by the contracting parties particularly when solvent remover is sprayed directly on to the object to be tested.
First the excess water washable penetrant shall be removed with water. Subsequent cleaning with a
clean lint-free cloth, lightly moistened, with solvent shall be then carried out.
I.7
Drying
Details see ISO 3452-1, Chapter 8.4.7.
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Application of developer

I.9
Development time
Details see ISO 3452-1 Chapter 8.5.7

I.10
Viewing conditions

I.11
Acceptance criteria
The quality shall comply with the requirements of F.6.1,

i.e. cracks, laps and lack of fusion , which open to the surface, are not acceptable.
These linear indications shall be ground and re-examined.
I.12
Post cleaning and protection
After final inspection, post cleaning of the object is necessary only in those cases where the penetrant
testing products could interfere with subsequent processing or service requirements.
If required a suitable corrosion protection shall be applied.
I.13
Reporting
Additionally to the general terms in F.7.2, following items to be included:

penetrant system used, e.g. coloured or fluorescent
penetrant product
application methods
penetration and development time
viewing conditions
test temperature
Radiographic Testing
J.1
Scope
This part applies to the radiographic testing (RT) of fusion welded joints in metallic materials. RT shall be
carried out in accordance with ISO 17636, Class A.
J.2
Radiation sources
Details see ISO 17636, both Chapters 7.2.1 and 7.2.2

J.3
Films and intensifying screens
Details see ISO 17636, Chapter 7.3.

For different radiation sources, the minimum film system classes and type and thickness given in both
Tables 3 and 4 of ISO 17636 shall be used.
J.4
Radiographic parameters
J.4.1
Surface preparation
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Film identification
Details see ISO 17636, both Chapters 6.4 and 6.5.

J.4.3
Overlap of films

J.5
Types and position of Image Quality Indicator (IQI)
Details see both ISO 19232-1 or 19232-2, Chapter 6.7

J.6
Test arrangement
The radiographic techniques in accordance with ISO 17636-1, Chapter 7.1.1 to 7.1.9 shall be used.
J.7
Choice of tube voltage and radiation source
J.7.1
X-ray devices up to 500 KV
Details see J.2.

J.7.2
Other radiation sources
Details see both, J.2 and ISO 17636-1, Chapter 7.2.2.

J.8
Film systems and screens
Details see both, J.3 and ISO 17636-1, Table 2.

J.9
Alignment of beam

J.10
Reduction of scattered radiation
J.10.1
Filters and collimators

J.10.2
Interception of back-scattered radiation

J.10.3
Source to object distance
Details see ISO 17636-1, Chapter 7.6

J.11
Density of radiographs
Details see ISO 17636-1, both Chapter 7.8 and Table 5.

J.12
Film processing
Details see ISO 17636-1, Chapter 7.9

J.13
Viewing conditions

J.14
Acceptance criteria
Details see F.6.1
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Reporting
Additionally to the general terms in F.7.2, following items to be included:

radiographic technique and class
type and position of image quality indicator
IQI sensitivity
test arrangement in accordance with ISO 17636-1, Chapter 7.1
system of marking used
film position plan
radiation source
etc.
Further details see ISO 17636-1, Chapter 8.
Ultrasonic Testing
K.1
Scope
This part specifies techniques for the manual ultrasonic testing (UT) of fusion-welded joints in metallic
materials of thickness greater than or equal to 8 mm. It is primarily intended for use on full penetration
welded joints where both the welded and parent material are ferritic.
UT of welds in plate and tubular butt welds and double side welded joints shall be performed in accordance with ISO 17640 or API RP 2X and in tubular nodes (see Figs. 4.24 and 4.25) in accordance with
API RP 2X. This part specifies especially node joint testing not specified in ISO 17640. Testing in accordance to ISO 17640 shall be performed on examination level C.
Alternative detection and sizing methods, e.g., Time-of- Flight Diffraction (TOFD), Automated UT, AUT
Imaging, Computerized UT, or Computerized Imaging may be used to supplement the recommended
manual UT methods. However, TOFD shall not be used as the sole method of sizing. Where these methods have not been reduced to routine practice, they shall have demonstrated an acceptable track record
of verification, as well as having been represented in successful practical tests for personnel qualification.
K.2
Applicability of UT to offshore structures
Offshore structures require extensive use of T, K and Y tubular member intersections and ring and diaphragm-stiffened tubulars. Considering the limitations of alternate methods, ultrasonic examination is
recommended for the detection of internal discontinuities and MT for surface imperfections. Therefore in
accordance to F.4, Table 4.26 butt welds and T-Joints (full penetration) in special and primary structural
members shall be 100 % UT and 100 % MT inspected and only 10 % RT in case of butt welds.
K.2.1
Advantages and limitations of UT of welds
UT has a heavy dependence on the skill and training of personnel, therefore UT inspection personnel
who inspect tubular nodes shall be especially qualified in accordance with API RP 2X. This section defines the major attributes and limitations of the ultrasonic technique.
K.2.1.1
Detection
Radiography is most sensitive to three-dimensional discontinuities, such as lack-of-penetration, slag inclusions, and porosity. Other discontinuities, such as cracks and lack-of-fusion, are less reliably detected,
especially when oriented askew of the radiation beam. In order to be readily discernible on the film, the
thickness of the discontinuity parallel to the radiation beam must be on the order of two percent of the
weld thickness. As the thickness of the weld increases, the quality of the discontinuity image decreases
due to radiation scattering within the weld. Therefore RT may be completely replaced by UT, if the weld
thickness is > 40 mm (see note 1 of Table 4.26).
In contrast to RT, the UT is highly sensitive to two-dimensional discontinuities and less sensitive to threedimensional ones. Tight cracks and lack-of-fusion discontinuities are also difficult to detect with UT; however, the threshold limit for UT is considerably smaller than for RT.
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After limitation in the use of shear wave UT is the failure to detect large two-dimensional (planar) discontinuities as a result of the inherent direction of the reflected beam. Large flat discontinuities reflect the
acoustical energy away from the receiving transducer and therefore often go undetected in single-angle
or single-transducer examination. Conversely, small discontinuities produce a scattering of reflected energy over a broad angular envelope, increasing the chance of detection.
The direction of the ultrasonic beam also causes difficulty in detection of certain types of discontinuities.
For example, single pores or randomly dispersed porosity is particularly difficult, if not impossible, to detect at sensitivities recommended for the detection of planar discontinuities significant to service performance. Spherical discontinuities (and to a lesser extent those of cylindrical shape) have only a fraction of
their area perpendicular to the acoustic beam and therefore do not return acoustical energy proportional
to their physical size.
In most cases, this limitation should not be cause for great alarm since the influence of such internal imperfections is limited as stress raiser.
Based on the high influence of surface imperfections to the fatigue strength reference value the required
quality levels for such imperfections are higher than for internal imperfections. Therefore the quality level
B of ISO 5817 is required for surface imperfections detected by VT, MT and UT in some cases, like root
imperfections in tubular node joints without back welding and level C for internal imperfections detected
by UT and in case of butt welds 10 % RT (see Section 3, I, B.15.1.2 and F.6.1)
K.2.1.2
Evaluation
Evaluation implies the identification and sizing of detected discontinuities since some discontinuities, such
as porosity and isolated slag, are of little significance. It is worthwhile to identify the character and source
of each anomaly, not only to effect removal of those of rejectable size but also to permit preventive corrective action.
The information yielded by UT is only a portion of that required for identification. To reach a reasonable
conclusion as to indication type, qualified UT personnel must be thoroughly familiar with the welding process and the degree of perfection in fit-up, and have accurately located the reflector within the weld profile.
Combining this information with that obtained by secondary manipulations of probe angle and beam,
qualified UT personnel are able to reliably identify only three geometric discontinuity configurations with
spherical, cylindrical, and planar. The technique is inherently incapable of differentiation between such
discontinuities as lack-of-fusion at the root and incomplete penetration or, more importantly, the coincidental presence of cracks radiating from these fusion defects.
For UT discontinuity size measurement are two techniques commonly practiced, each with its own advantages.
The first, called amplitude measurement, is rather simple and particularly suited to measuring discontinuities of small size that can be completely contained within the cross section of ultrasonic beam. Accuracy
of the technique deteriorates rapidly as discontinuities increase in size and approaches a limit of applicability when the discontinuity exceeds 6 mm. The major disadvantage of the technique lies in the fact that
the total reflecting area is responsible for the echo height, rendering it impossible to differentiate between
length and width of the reflector.
The second, called beam boundary intercept technique, offers greater advantage in determining both the
length and width of most discontinuities of significance. Theoretically the technique is accurate when used
properly. However, the unavoidable variations in probe characteristics plus the requirements for precalibration of equipment and the need for exceptionally skilled personnel somewhat diminish the accuracy
of results (seldom better than 1.6 mm).
K.2.1.3
Influence of material properties, thickness, surface finish and curvature
Some steel manufacturing processes, such as control rolled and thermo-mechanical controlled process
(TMCP= TM) steels, can cause minor variations in acoustic properties. This effect on velocity may cause
changes to the transducer beam angle in comparison to the reference standard.
The physical condition of the weld and base metal significantly influence the detection and evaluation of
weld flaws. The acoustical characteristics of the base metal will determine the amount of sound lost
through scattering and absorption to interception with the weld discontinuity. Inclusions and lamination in
the base metal will misdirect shear wave beams away from intended areas of examination and produce
reflections from unknown und unidentified areas.
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Therefore where ultrasonic testing is to be performed on steel produced by control rolled or TMCP calibration (reference) blocks shall be produced both perpendicular to, and parallel to, the direction of rolling.
The rolling direction shall be clearly identified.
The reference block shall be either:
1. a block of the same acoustic properties, and specified surface finish, and having a thickness within
+/- 10 % of the test object;
or
2.
a block of the same acoustic properties, surface finish, shape and curvature as the test object.
In the case of Type 1), correction for any differences in attenuation, curvature and coupling losses is required before equipment performance checks and Distance Amplitude Curve (DAC) can directly applied.
K.3
Procedure Qualification and Approval
The following applies to procedure qualification and approval:

Written UT-Procedure shall be prepared by the UT supervisor.
The following list of essential variables shall be detailed in the written procedure and employed during trial and subsequent weld examinations. Significant variations from the proven procedure shall
be cause for requalification.
Type of weld configuration and surface temperature range
Acceptance Standard/Criteria
Type of UT instrumentation
Use of electronic gates, suppression, alarms, and the like
Equipment calibration and frequency (time intervals in acc. to API RP 2X, Table 1)
Equipment performance checks and frequency (min. requirements see API RP 2X, Table 2 und
K.4.1)
Length of coaxial cable
Transducer frequency, size and shape, beam angle and type of wedge an angle beam probe
Surface preparation
Couplant (shall be in accordance with EN 583-1 or equivalent)
Base metal examination
Transfer correction (shall be in accordance with API RP 2X, Chapter 7.7.4, EN 583-2 or equivalent)
Scanning sensitivity
Scanning pattern
Triangulation methods for determining effective beam angle, indexing of root area, and flaw location.
Method of discontinuity length determination
Method of discontinuity width determination
Computer hardware and software used for locating and sizing reflectors.
Reporting and retention
K.4
UT Equipment
The equipment used for ultrasonic testing has to:

be applicable for the pulse echo technique and for the double probe technique
cover the frequency range from 2 to 6 MHz
allow echoes with amplitudes of 5 % of full screen amplitude to be clearly detectable under test conditions
include straight beam transducers, and angle beam transducers of 45, 60 and 70
see also API RP 2X, Chapter 7.5.1 and 7.5.2
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Equipment performance checks
Since determination of the reflector location and size is the primary intent of an ultrasonic examination, it
is essential for the instrumentation to yield accuracy commensurate with the examination requirements.
Before any new instrument or component is employed for weld examination, it shall be examined to determine its performance characteristics with respect to the requirements of these rules.
A standard operating procedure and quality control manual shall detail the method adapted to assure
traceability based on the following requirements:
Equipment Performance Checks (Standardization) shall be performed with the Standards (e.g. calibration blocks) of API RP 2X, table 2 considering the following requirements
The IIW and IOW calibration blocks shall be fabricated from material to be examined (see K.2.1.3)
Transducer beam angle:
Beam angle determination using the large hole (for angles of < 70) in the IIW block may contain a
significant error, therefore, transducers employed for evaluating discontinuity position and size be
further calibrated using the IOW block (see Fig. 4.36).
Beam Profile:
The IOW block should be employed to determine the characteristics and shape of each beam profile. The intensity of any echo signal rise from a secondary axis should not exceed 10 % of the major
axis intensity.
Determining the Beam Spread:
The beam boundary is defined as the surface of a cone where the echo intensity from a small reflector intersecting the beam will be some predetermined percent of the maximum echo obtained from
the same reflector on the beam axis. Commonly defined boundaries are those where the intensity is
6 dB and 20 dB below the maximum signal.
The IOW block is designed to facilitate the measurement of the cone angle at varying distances from
the index point for plotting the profile in both the vertical and horizontal plan.
Resolution:
The IOW block is employed to assess the resolution capabilities of each instrument-transducer combination. The ability to independently resolve two closely spaced reflectors on the sound path is a
mandatory requirement for accurate weld-quality assessment. For example, the differentiation of a
root discontinuity from the root protrusion of an acceptable weld is required when examination must
be conducted from one side only (see Fig. 4.25).
Using the five 1.5 mm resolution holes as reflectors, one should be able to clearly separate the individual holes on 4 mm spacings with a 45 transducer oscillating at 2.25 MHz.
50
83
13
Surface A
75
5 - 1.5 mm holes 22 mm
deep on 10 slope
3 at 2.5 mm and
2 at 4 mm centers
10
25
19
63
Additional holes
63
25
32
48
Surface B
10
35
22
50
305
Dimensions in millimeters, tolerance 0.1 mm.

Grind surfaces A and B to indicated surface
roughness in microinches.
Fig. 4.36
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Preparation for examination
Prior to attempting evaluation of a weld in the structure, UT personnel should become thoroughly familiar
with the design by reference to the specification and construction drawings. The nominal thickness of
specific connections should be noted and compared to values obtained by measurement during the weld
examination.
The results of the visual inspection during the fit-up should be reviewed to ascertain areas likely to result
in poor weld quality or areas where the root location has been modified.
A final visual inspection of the weld should be performed for detection of undercut, incomplete fill or excess roughness which would interfere with a meaningful ultrasonic examination.
K.5.1
Index of weld root
Subsequent to the weld bevel preparation, including any field trimming during fit-up, and prior to welding
of the root pass, the member from which scanning is to be performed should be scribed or punch-marked
at a specific distance from the root face to ensure an exact index of the root face location after completion
of welding (see Fig. 4.37).
This marking is particularly important for T, K, and Y connections where measurement from other index
points becomes difficult or impossible after completion of welding. These marks provide an exact location
of the root face during the ultrasonic examination and aid in differentiation of root defects from acceptable
root protrusions.
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Branch
member
Scribe or punch mark
before fitup
Detail "D"
Details "C" or "D"

Details
"A" or "B"
Detail "B"
x
x
Detail "A"
Detail "B"
Detail "C"
Detail "D"
Note
The "x" dimension may have to be greater
at this point to insure retention after welding.
Fig. 4.37
K.5.2
Weld root index
Surface preparation
The surface from which scanning is to be achieved should be cleaned to remove all scale or coating (for
example by grit-blasting or power brushing) to assure continuous coupling during the examination, particularly if flaw sizing is based on amplitude technique. Regardless of the quality of the surface finish, it is
recommended that transfer corrections be utilized in all cases (see EN 583-2, Chapter 8 and Annex E).
K.5.3
Thickness measurement
The thickness of each member from which scanning is to be achieved should be determined and recorded for use in the flaw location determination. Thickness should be ascertained at four points around
the circumference on tubular members and every 2 m along welds in flat plate connections.
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Base metal examination
The entire area from which scanning is to be achieved should be examined by the longitudinal wave technique to assure freedom from lamination or other laminar-type flaws which could interfere with sound
wave propagation. If defects or considerable variation in attenuation are found, it is important that their
influence on the weld examination be taken into account and the scanning technique adjusted to ensure
complete examination of the weld.
K.6
Scanning techniques
Probe manipulations employed to detect discontinuities in the weld area are termed scanning und the
success of the entire examination depends on the selected probe, instrument sensitivity, and transducer
movements employed during this phase of the examination.
K.6.1
Probe selection
The selection of a scanning probe is generally a compromise between sensitivity, coverage, resolution,
and mechanical coupling stability. Large high-frequency probes produce a narrow ultrasonic beam of
high-resolution capabilities and a reduced sensitivity to detection of discontinuities obliquely oriented to
the sound beam.
Consequently, examination of welds in thick sections with miniature and small dimension probes generally will require two or more scans at different sensitivity levels and base line adjustments to ensure that
all discontinuities of interest will reflect sufficient energy to be visible on the cathode ray tube.
For angle beam scanning of weld discontinuities of the size of interest in offshore structural fabrication, a
probe with a transducer element of 12 mm round or square, operating between 2 MHz and 2.25 MHz is
suggested as a good compromise of all desirable attributes. The beam produced from this probe will
permit examination of thick sections with moderate beam decay, resolve most discontinuities of interest
without indicating the presence of fine inclusions within the steel, and exhibit a beam profile included angle sufficiently broad to ensure that discontinuities at all orientations between the nominal 45, 60, and
70 angles will yield a significant echo signal. Other transducer frequencies and sizes may be desirable
for specific applications.
K.6.2
Sensitivity
Scanning must ensure the detection of all discontinuities of interest; therefore, a sensitivity greater than
that required to produce a full-scale echo signal from the reference reflector is always employed. An increase in sensitivity 6 dB above that required to produce a full-DAC (Distance Amplitude Correction: A
method of correcting for the changes in the ultrasonic wave caused by attenuation or divergence) echo
signal from the reference reflector will ensure full- DAC echo signals for discontinuities oriented 7 to 10
from perpendicular when scanning with the recommended probe. An increase of 12 dB above the reference will aid in detection of transient reflectors at high scanning speeds.
K.6.3
Extent of coverage
K.6.3.1
The complex geometry of welded connections on offshore structure particularly T, K, and Y
connections, typically requires the use of nominal angle transducers (i.e. 45, 60, and 70) in multiple
scans of the entire circumference and almost always from the brace side of the weld only. Thick wall diagonal braces with full- throated weld connections may also require the use of an 80 transducer to ensure that the sound beam intercepts the root area.
In all scans the transducer cant angle is continually adjusted to maintain the beam perpendicular to the
length of the weld. See Fig. 4.38 for definitions of nomenclature associated with tubular member intersections. The recommended effective probe angle for examination of the root area should be that which produces an incident angle nearest to perpendicular to the anticipated weld discontinuity.
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Transducer oriented
normal to weld
Chord or
main leg
A
A
Cant
angle
Skew angle
Transducer
Weld
Flaw
B
f
Brace
Beam
angle
Local dihedral angle

T
Main fusion zone
Brace fusion zone
Weld root
Fig. 4.38
Section A - A
Parameters associated with geometry of pipe intersection
K.6.3.2
Examination of the weld root areas separately from the remainder of the weld is recommended. If the probe is moved parallel to the toe of the weld at the intercept distance (see K.5.1 index of
weld root) to the root protrusion, any change in the root geometry can be ascertained by a lateral movement on the horizontal scale of the Cathode Ray Tube (CRT). The generally continuous echo from the
root protrusion indicates a sound weld-whereas, an interruption or shift in echo signal position indicates a
change in root geometry and the presence of a discontinuity. Detection of the metal path distance shift is
enhanced by expanding the horizontal scale to include only the region of interest (see Fig. 4.39)
Banding strap
or bar
Shift
Indication
of root
discontinuity
Position "A"
5
Indication of root discontinuity position "A"
Banding strap
or bar
4.5
Sound root
Position "B"
5.0
5.5
1" full screen

0
Sound root position "B"
Fig. 4.39
Weld root examination
K.6.3.3
After examination of the root area, the remainder of the weld is scanned using a back-andforth motion accompanied by a slight rotational movement (see Fig. 4.40). The length of the transverse
movement must be sufficient to ensure that the center of the beam crosses the weld profile in two direc-
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tions, a full-vee path, or a surface distance equivalent to approximately one and one-fort times the skip
distance (see Fig. 4.41)
Weld axis
Movement
F
Movement
0
Movement Movement
A
B
Movement
C
Fig. 4.40
A
Movement
E
Scanning patterns
B
Fig. 4.41
" S
Weld scanning
K.6.3.4
Additional, axial weld scanning is recommended for welded connections in material with 355
MPa SMYS and above and thickness of >= 25 mm for the detection of transverse planar discontinuities
(see Fig. 4.40). Scanning coverage should be parallel to the weld axis in two directions and include transverse scanning atop the weld reinforcement surface, where practical. If scanning atop the reinforcement
is not practical, all efforts for axial weld scanning should be performed from the adjacent base material,
each side of the weld. A 45 probe angle is recommended as the primary scan for the detection of transverse planar discontinuities.
K.6.3.5
As a minimum, the welds shall be examined through the entire volume of the weld and the
heat-affected zone.
K.7
Discontinuity evaluation
Evaluation consists of the various steps required to assess the unknown character, orientation, and size
of discontinuities whose presence has been established during scanning. Characterization and orientation
are reasonable reliable determinations of a well-executed ultrasonic examination. The methods of evaluation are described in the following section.
K.7.1
Characterization and orientation
Weld imperfection geometries corresponding to the cylindrical shape are hollow beads, some slag lines,
and un-fused slugs. Single pores and widely spaced porosity produce reflections similar to the ideal
spherical reflector.
The group of weld imperfections identified by planar configurations are lack of fusion, un-fused root faces,
fusion line slag, undercut, and cracks.
To differentiate between the spherical or cylindrical reflectors from the planar, it is necessary to employ
several different angles (see API RP 2X, Chapter 7.9).
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K.7.2
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Size evaluation
Three methods which produce useful information on sizing are recommended for use on offshore structures:
The amplitude comparison technique
The beam boundary intercept technique
The maximum amplitude technique
In some instances, it will be necessary to employ all three using best judgment for the final estimation of
size. However, if the reflector is large with respect to the sound beam, the methods of sizing will generally
be restricted to the beam boundary intercept and maximum amplitude techniques.
K.7.2.1
Amplitude comparison technique
Size determination by the amplitude comparison technique is achieved by comparing the discontinuity
reflection to the reflection obtained from an artificial reflector in reference blocks. In order to improve the
accuracy of sizing of weld discontinuities, which generally are elongated parallel to the weld length, a
multitude of artificial reflectors of various widths and lengths should be available for comparison with the
discontinuities detected during scanning. Selection of the proper length artificial reflector requires prior
determination of the length of the unknown by one of the alternate methods of sizing.
Since the amplitude of a reflector diminishes with increased distances from the probe, it is necessary to
construct a DAC curve, e.g. in accordance to EN 583-2, Chapter 6.3 for reflector comparison when the
unknown reflector fails to fall at the same distance on the display-screen horizontal scale as the reference
reflector.
The inaccuracy is considered too great to qualify a procedure meeting the minimum standards recommended herein if the comparison technique is to be the sole method employed (for more details see API
RP 2X, Chapter 7.9.3.1).
K.7.2.2
Beam boundary intercept technique
Determination of the transverse dimension of a reflector by the beam boundary intercept technique is
accomplished by manipulating the probe to obtain the maximum signal from the reflector and adjusting
the echo signal to some convenient screen height, for example, 75 % of full scale. The sensitivity is then
increased 20 dB using the calibrated gain control and the probe moved forward until the echo signal returns to the original maximized value, that is, 75 % of full scale. At this point, the bottom edge of the 20
dB beam boundary determined by the procedures outlined in K.4.1, will be intercepting the top edge of
the reflector (see Fig. 4.42).
The bottom of the reflection is located by moving the probe backward through the maximum position until
the echo signal again returns to 75 percent of full screen indicating that the top of the 20 decibel beam
profile is intercepting the bottom edge (see Fig. 4.42).
The beam boundary intercept technique is best suited to members approximately 20 mm and thicker and
evaluation on the first traverse (half skip) of the thickness.
Multiple determinations should be obtained from the edges of the reflector in order to minimize errors due
to coupling variations and contact pressure. At least three attempts should be made from each edge, and
the results for all three should fall within 1.6 mm of the same location.
The method yields uncertain results when applied to measuring the depth of corner reflectors, such as
lack of penetration in single-sided welds. Alternate methods are suggested for that type of reflector. More
about Beam Boundary Intercept Technique see API RP 2X, Chapter 7.9.3.2.
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0"
0"
0"
Top
1
Height
Bottom
2
0
45
Fig. 4.42
K.7.2.3
45
60
Beam boundary plotting
Maximum amplitude technique
The maximum amplitude technique utilizes the fact that most of the energy in the ultrasonic beam is concentrated near the center of the beam in a very narrow band. This characteristic is employed to find the
top of reflectors by maximizing the reflection as in the beam boundary technique and moving the probe
forward until the echo signal just begins to trop from the peak value. The bottom edge is determined by
moving the probe backward until the echo signal just begins to drop. Measurements of the sound beam
path lengths, A1 and B2, and surface distances for each probe position D1 and D2 see Fig. 4.43.
Best results from the maximum amplitude technique occur when the instrument pulse length is very short
and the probes have high-resolution capabilities. Probes of a high diameter-to-wave-length ratio produce
a sharply defined central beam and are preferred for this technique. These conditions dictate the use of
frequencies above that for normal scanning and the largest practical diameter for the surface conditions
of the examination. Probes with a frequency of 4 MHz and diameters of 12.5 mm or larger are recommended.
This technique can also be used to determine the diameter of cylindrical shaped defects. More about
Maximum Amplitude Technique, see API RP 2X, Chapter 7.9.3.3.
D2
D1
A1
B2
Nominal or
measured angle
Fig. 4.43
K.7.2.4
Maximum amplitude technique
Inaccuracies in size elevation
All three of the described techniques are capable of yielding accurate results on flat plate weld examinations within the limitations described, but all three suffer significant loss of accuracy when examining tubular members. In the absence of a large number of curved-reference standards of the same geometry as
the members to be examined, the accuracy of all techniques diminish due to a spreading of the beam at
the coupling interface and the opposite curved wall of tubulars. The inherent broadening of the beam
results in reduction of the centerline intensity and alteration of intensity to the beam edge. The magnitude
of the error increases with the difference in diameters between reference and examined member.
When scanning in the circumferential direction or at a cant angle to the pipe axis (see Fig. 4.38), the
sound beam also changes dimensions depending on the area of contact and the thickness-diameter ratio
of the member. Fig. 4.44 illustrates the increase in divergence after the beam has struck the back wall of
a tubular during a circumferential scan. The effect is to alter the angular position of the 6 dB, 20dB, or any
other constant intensity ray of the beam. This invalidates the beam intercept technique and diminishes the
accuracy of the amplitude comparison technique. When possible, the size measurements should be
made in the first half-skip distance of the sound beam to minimize the effects of beam spreading at the
intercept with the back wall.
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Approx.
55
35
Approx. 45
beam spread
10
beam
spread
Fig. 4.44
K.7.2.5
Modified
beam profile
Original
beam profile
Circumferential beam profile
Recommended techniques
In practice the three sizing techniques should be performed in an organized sequence from simplest to
most difficult usually in the following order. First, the amplitude comparison technique should be performed during initial characterization and orientation assessment with the discontinuity compared to
known size implants. The maximum amplitude technique can usually be performed concurrently while the
discontinuity remains at the maximized amplitude. The beam boundary technique should be performed if
there is uncertainty in the previous sizing estimates or if characterization and orientation suggest using
this technique.
The amplitude comparison technique is recommended for evaluating corner reflectors if the anticipated
width is not much greater than 3 mm. Length should be approximated by the maximum amplitude technique. For all other circumstances, all possible means should be employed. From the results, a best estimate should be offered with considerations to the effects of curvature and configuration.
K.8
Acceptance criteria
The appropriate level of examination is an integral part of the overall fracture control plan, which maintains a quality level consistent with the design performance. For example, Figs. 4.45 and 4.46 show weld
surface profile qualities and fatigue S-N curves which are consistent with each other. For offshore platforms designed to fatigue performance Level C (curve X), with as-welded surface profiles, Level C provides a compatible internal examination criteria.
Level C Experience-based fitness-for-purpose quality is based upon generalized consideration of
fatigue, brittle fracture, and tensile instability modes of failure, and intended for use in applications where
the design stress, fatigue analysis, and minimum toughness meet the requirements of API RP 2A-WSD.
This also requires consideration of the fracture toughness of welds and heat-affected zones.
"F"
As-welded - without profile

control
"C"
"A"
As-welded - profile approx. T/2 radius

with undercut restrictions
Ground - microscopic stress

approx. equals hot-spot
stress measured by strain gauge
Fig. 4.45
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10.000
Typical data from small polished
unwelded laboratory specimens
5.000
50
2.000
A
C
F
1.000
20
500
10
5
C
Curves A&C from AWS D1.1
Curve F from British STD.153
X
F
200
eTR Total strain range - m
Total stress range - KSI
100
100
2
1
102
Fig. 4.46
K.8.1
103
104
105
106
107
108
Design S-N curves for different weld profiles, curves X from API RP 2A-WSD
Level C acceptance criteria
The following applies concerning Level acceptance criteria:

K.8.1.1
Discontinuities are evaluated using a combination of beam boundary techniques and amplitude calibration utilizing the transfer and distance amplitude corrections addressed in K.2.1.3 and K.7.2.4.
The reference level calibration for root reflectors are the 1.6 mm notches shown in the reference block for
Level C examination (Fig. 4.47). The reference level for internal reflectors is the side hole with a diameter
of 1.6 mm.
Evaluation of a discontinuity is to be based on the ultrasonic operators best determination of actual flaw
dimensions, bearing in mind that interior planar flaws which are poorly oriented with respect to the ultrasonic beam may return a smaller echo than a surface (root) notch of the same size.
Flaw size is to be given in terms of width and length as illustrated in Fig. 4.48. In addition, the reflector
shall be classified as spherical, cylindrical, or planar and its position within the weld cross section be accurately determined. Identification as to type (such as, crack versus incomplete fusion) is not required.
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notch
2"
(50.8 mm)
drilled
hole
1-"
(38 mm) min
Plan
1-"
(38 mm)
1/16 " (1.6 mm) hole
1-"
(38 mm)
1/16 " deep buttress notch

(1.6 1.6 mm)
See slot details below
(four blocks required)
5-" T min
Elevation
Note
Simulated references for rejectable flaws established by the Operator's ultrasonic specialist should be
added to these blocks for calibration of internal refelctors, that is, in. side-drilled hole. A minimum
of four blocks should be prepared, each with a minimum of one notch described below. The ultrasonic
specialist should determine the value of T based on the material and equipment that will be used.
45
3/32" max.
(2.38 mm)
1/16"
(1.6 mm)
0.044"
(1.12 mm)
30
Anticipated
reflective side
20
0.054"
(1.37 mm)
Fig. 4.47
Edition 2013
Tolerance - Angle 1
- Inches 0.001
- Milimeters 0.025
Anticipated
reflective side
0.059"
(1.49 mm)
Reference for level C examination block
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Chord
member
Width (W)
Brace
member
Notes
Aligned discontinuities separated
by less than L1 + L2 divided by 2
and parallel dicontinuities separated
by less than W1 + W2 divided by 2
shall be evaluated as continuous.
Direction of
applied stress
Accumulative flaws are evaluated

over 6 inches or D/2 length of weld
(whichever is less)
Weld throat thickness = T
Tube diameter = D
Length (L)
L and W based on a rectangle which

totally enclosed indicated discontinuitly
Fig. 4.48
Definitions for reporting
K.8.1.2
All reflectors 6 dB smaller than the reference level (that is 50 % DAC) may be disregarded
(DRL = disregard level). Reflectors above the DRL shall be further evaluated as described in the following
sections. The operator may elect to decrease the DRL based on the criticality of a particular component.
K.8.1.3
Isolated, random, spherical reflectors are acceptable, regardless of signal amplitude.
K.8.1.4
Clustered multiple reflectors with indications above 50% DAC curve and two times the branch
thickness in length should be evaluated in terms of their encompassing with and length using the limits of
Figs. 4.49 and 4.50.
Reject
Width, in.
" or T/4
Accumulative
flaws
1/8
1/16
Individual
flaws
Accept
Any*
Length, in.
Fig. 4.49
Edition 2013
6 or D/2
Notes
Near-surface reflectors:
Discontinuities that are within Width W or T/6 (T, W see
Fig. 4.48) of the outside surface shall be sized as if exending
to the surface of the weld. Near-surface reflectors in TKY welds
should also be evaluated by other means (for example grinding).
Reflectors less than 1/16 in. in size, but above disregard level:
In-line discontinuities where the sum of greatest dimentions
exceeds 6 times the branch thickness in any 12 times the branch
thickness of weld length are rejectable. All other randomly
spaced discontinuities below reference level A (1/16 in. side
drilled hole) are to be disregraded up to D/2 length (D being
the tube diameter).
Internal reflectors and all other welds
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Reject
Width, in.
" or T/4
Accumulative
flaws
1/8
1/16
For complete penetration welds in one-sided T, K & Y

tubular connections made without backing discontinuities
in the root bead of details C and D of fig. 4.37 are to be
disregarded.
Individual
flaws
Accept
6 or D/2
Length, in.
Fig. 4.50
T, K and Y root defects
K.8.1.5
Cylindrical or planar reflectors whose dimensions exceed the limits of Figs. 4.49 and 4.50 (depending on location) are rejectable.
K.8.1.6
Internal reflectors near the fusion line of a weld shall be evaluated with various probe angles
while making an effort to obtain a beam path perpendicular to the fusion line.
K.8.1.7
Reflectors within the base metal of the main member (joint can) at welds shall be evaluated as
described in the following. In addition, any such reflector that exceeds the disregard level shall be reported to the operator:
1. Individual reflectors exceeding the limits of Fig. 4.49 are rejectable.
2. Accumulated reflectors exceeding 8 % of the area under the weld in any 150 mm or D/2 (D = Outside diameter of the main member) length (whichever is less) are rejectable.
3. Rejectable base metal reflectors shall be reviewed by the operator prior to any excavation or attempted repair. Consideration should be given to the risk of causing further problems (such as lamellar tearing) with the additional thermal strain cycles such excavation and repair would entail.
K.9
Reporting
Additional to the items listed in F.7.2, following details have to be included in the testing report:
The details of the examination shall be documented in sufficient detail to permit repetition of the examination at a later date.
Details of acceptable discontinuities shall be documented to acknowledge their presence (e.g. incorporated tack welds, porosity material imperfections)
Full-scale sketches and drawings are desired to augment descriptions of the weld or material and
locations of all rejectable discontinuities.
The form shown in API RP 2X, Appendix D provides the required details of documentation
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Section 5
A
B
C
D
General ....................................................................................................................... 5-1

Material Selection ....................................................................................................... 5-6
Coating Selection...................................................................................................... 5-11
Cathodic Protection................................................................................................... 5-14
General
A.1
Scope
A.1.1
This Section covers corrosion protection of fixed or mobile steel and concrete structures. Design, calculation methods, material selection, fabrication, installation and commissioning of the corrosion
protection system are subject to approval by GL in connection with the overall Certification procedure.
A.1.2
The DIN 81249 and ISO 15156 series standards shall apply to the selection of materials and
the design of offshore structures and equipment components in case the technical designer has to consider the corrosion behavior of an unprotected metallic material in sea water or sea atmosphere and if this
metallic material is listed in one of these standards.
A.1.3
The corrosion protection of fixed offshore steel structures, including platforms (jackets), tension leg platforms (TLPs) and subsea templates shall be conform to EN 12495 or NACE SP0176 supplemented with the requirements listed below.
A.1.4
The corrosion protection of mobile floating structures which are static during their usual operation conditions include barges, jack-ups, semi-submersible platforms, storage tankers, buoys and appurtenances, such as chains shall be conform to EN 13173 or NACE SP0176 supplemented with requirements below. It does not cover the cathodic protection of ships.
A.1.5
The corrosion protection of steel in concrete shall be conform to NORSOK M-503.
A.2
Terms, definitions
A.2.1
General
The basic terms and definitions for corrosion of metals and alloys in ISO 8044 and ISO 15156, the general principles of cathodic protection in EN 12473 and paint systems in NACE SP0108, ISO 12944 and
NORSOK M-501 shall be applied. For the different special structure types the terms and definitions in
according with EN 12495, EN 13173 and NORSOK M-503 shall be used.
A.2.2
Anode
Anode is an Electrode at which anodic reaction predominates. (ISO 8044)

A.2.3
Anodic reaction
Anodic reaction is an electrode reaction equivalent to a transfer of positive charge from the electronic
conductor to the electrolyte. An anodic reaction is an oxidation process. An example common in corrosion
is: Me Men+ + ne (ISO 8044)
A.2.4
Atmospheric zone
Zone located above the splash zone, i.e. above the level reached by the normal swell, whether the structure is moving or not. (EN 12495)
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Back e.m.f.
Back Electro Motive Force = Voltage produced in a conductor that tends to neutralize the present voltage. The back e.m.f. is also the naturally occurring open circuit potential difference between the anode
and the cathode in sea water.
A.2.6
Boot topping
Boot topping is the section of the hull between light and fully loaded conditions, which may be intermittently immersed. (EN 13173)
A.2.7
Bracelet anode
Anode shaped as half-rings to be positioned on tubular items. Two half-ring anodes will have to fit together to become a bracelet anode. (EN 12496)
A.2.8
Buried zone
Zone located under the mud line. (EN 12495)

A.2.9
Calcareous deposits
Calcareous deposits are minerals precipitated on the steel cathode because of the increased alkalinity
caused by cathodic polarization. Well formed calcareous deposits reduce the rate of diffusion of dissolved
oxygen in the sea water to the steel surfaces and thereby reduce the current density necessary to maintain cathodic polarization. (EN 12473)
A.2.10
Cathode
Cathode is an electrode at which cathodic reaction predominates. (ISO 8044)

A.2.11
Cathodic disbonding
Failure of adhesion between a coating and a metallic surface that is directly attributable to the application
of cathodic protection. (EN 12473)
A.2.12
Cathodic protection
Cathodic protection is an electrochemical protection by decreasing the corrosion potential. (ISO 8044)
A.2.13
Cathodic reaction
Cathodic reaction is an electrode reaction equivalent to a transfer of negative charge from the electronic
conductor to the electrolyte. A cathodic reaction is a reduction process, e.g.: Ox + ne Red. (ISO 8044)
A.2.14
Coating breakdown factor
The coating breakdown factor is the anticipated reduction in cathodic current density due to the application of an electrically insulating coating when compared to that of bare steel. (EN 12473)
A.2.15
Conductor pipes
Conductor pipes form the first installed casing of an offshore well. (EN 12495)
A.2.16
Corrosion protection
Corrosion protection means modification of a corrosion system so that corrosion damage is reduced. (ISO
8044)
A.2.17
Corrosion resistant alloy (CRA)
Alloy intended to be resistant to general and localized corrosion of oilfield environments that are corrosive
to carbon steels. (ISO 15156)
A.2.18
Crevice corrosion
Locally more intensified corrosion in crevices. It results from corrosion cells caused by differing concentrations within the corrosive medium, especially by differences of the oxygen concentration between the
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crevice and the environment. As a result of the corrosion cell formation pH value reductions as well as
increased chloride concentrations occur within the crevices (DIN 81249-1).
A.2.19
Critical crevice temperature (CCT)
The CCT is that temperature at which, in a 6 % FeCl3 solution, crevice corrosion first occurs (see ASTM G
48).
A.2.20
Critical pitting temperature (CPT)
CPT is that temperature at which, in a 6 % FeCl3 solution, pitting corrosion first occurs (see ASTM G 48).
A.2.21
Current density
Current density is the current per unit area of the electrode. (ISO 8044)
A.2.22
Current drain
Current drains are components which are not considered to require cathodic protection but will drain current from the system. (NORSOK M-503)
A.2.23
Dielectric shield
Alkali resistant organic coating applied to the structure being protected in the immediate vicinity of an
impressed current anode to enhance the spread of cathodic protection and minimize the risk of hydrogen
damage to the protected structure in the vicinity of the anode. (EN 12473)
A.2.24
Driving potential
The driving potential is the difference between the structure/electrolyte potential and the anode/electrolyte
potential. (EN 12473)
A.2.25
Duplex stainless steel
Duplex stainless steel is a stainless steel whose microstructure at room temperature consists primarily of
a mixture of austenite (Face-centred cubic crystalline phase of iron-based alloys) and ferrite (Bodycentred cubic crystalline phase of iron-based alloys). (ISO 15156).
A.2.26
Extended tidal zone
Extended tidal zone is a zone including the tidal zone, the splash and the transition zone. (EN 12495)
A.2.27
Ferritic steel
Ferritic steel is steel whose microstructure at room temperature consists predominantly of ferrite (bodycentred cubic crystalline phase of iron-based alloys). (ISO 15156)
A.2.28
Flush mounted anode
Flush mounted anodes are designed to limit hydrodynamic effects when fitted to the structure. (prEN
12496)
A.2.29
Galvanically induced hydrogen stress cracking (GHSC)
Cracking that results due to the presence of hydrogen in a metal, induced in the cathode of a galvanic
couple, and tensile stress (residual and/or applied). (ISO 15156)
A.2.30
Galvanic protection
Galvanic protection is an electrochemical protection in which the protecting current is obtained from a
corrosion cell formed by connecting an auxiliary electrode to the metal to be protected. (ISO 8044)
A.2.31
H.A.T.
Level of the highest astronomical tide. (EN 12495)
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Hydrogen (induced) stress cracking (HSC, also known as HISC)
Cracking that results from the presence of hydrogen in a metal and tensile stress (residual and/or applied).
HSC describes cracking in metals that are not sensitive to SSC (Stress Corrosion Cracking) but which
may be embrittled by hydrogen when galvanically coupled, as the cathode, to another metal that is corroding actively as an anode. The term galvanically induced HSC has been used for this mechanism of
cracking. (ISO 15156)
A.2.33
Holiday
As holiday a coating discontinuity is understood that exhibits electrical conductivity when exposed to a
specific voltage. (ISO 21809-1)
A.2.34
Immersed zone
Zone located below the extended tidal zone and above the mud line. In case of floating structures, zone
located below the waterline at draught corresponding to normal working conditions. (EN 12495)
A.2.35
Impressed current protection
Impressed current protection is an electrochemical protection in which the protection current is supplied
by an external source of electric energy. (ISO 8044)
A.2.36
Insert
Insert is the form over which the anode is cast and which is used to connect the anode to the structure
requiring protection (prEN 12496).
A.2.37
J-tube
Curved tubular conduit designed and installed on a structure to support and guide one or more pipeline
risers or cables. (EN 12495)
A.2.38
L.A.T.
L.A.T. is the level of the lowest astronomical tide. (EN 12495)

A.2.39
Marine sediments
Top layer of the sea bed composed of water saturated solid materials of various densities. (EN 12495)
A.2.40
M.T.L.
Mean tide level (also known as M.S.L or M.W.L.). (EN 12495)

A.2.41
Pitting corrosion
Type of corrosion with the anodic formed on the material surface being considerably smaller than the
cathodic regions. Pitting corrosion frequently occurs if the protective layer of a metal is locally damaged or
if the passive layer of a stainless steel is penetrated e.g. by chloride ions (DIN 81249-1).
A.2.42
Pitting resistance equivalent number (PREN)
PREN is a number, developed to reflect and predict the pitting resistance of a CRA, based upon the proportions of Cr, Mo, W and N in the chemical composition of the alloy.
PREN = % Cr + 3.3 (%Mo + %W) + 16x %N (ISO 15156-3)
A.2.43
Protection current density
Current protection density is the density that is required to maintain the corrosion potential in a protection
potential range. (ISO 8044)
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Reference electrode
Reference electrode is an electrode, having a stable and reproducible potential that is used as a reference in the measurement of electrode potentials. (ISO 8044)
A.2.45
Resistivity of an electrolyte
Resistivity is the resistance of an electrolyte of unit cross section and unit length. It is expressed in ohm
metres ( m). The resistivity depends, amongst other things, upon the amount of dissolved salts in the
electrolyte. (EN 12473)
A.2.46
Riser
Vertical or near vertical portion of an offshore pipeline between the platform piping and the pipeline at or
below the seabed, including a length of pipe of at least five pipe diameters beyond the bottom elbow,
bend or fitting. (EN 12495)
A.2.47
Salinity
Amount of inorganic salts dissolved in the sea water. The standardized measurement is based on the
determination of the electrical conductivity of the sea water. Salinity is expressed in grammes per kilogramme or in ppt. (EN 12495)
A.2.48
Splash zone
Height of the structure which is intermittently wet and dry due to the wave action just above the H.A.T.
(EN 12495)
A.2.49
Submerged zone
The submerged zone is a zone including the buried zone, the immersed zone and the transition zone. In
case of floating structures, the zone includes the immersed and the buried zones. (EN 12495)
A.2.50
Stand off anode
Stand off anodes are designed to be off set a certain distance from the object on which they are positioned. The distance is typically 0.3 metre. (prEN 12496)
A.2.51
Tidal zone
Zone located between the L.A.T. and the H.A.T. (EN 12495)
A.2.52
Transition zone
Zone located below the L.A.T. and including the possible level inaccuracy of the platform installation and
a depth with a usually higher oxygen content due to the normal swell. (EN 12495)
A.2.53
Underwater hull
Underwater hull is the part of the hull vital for its stability and buoyancy of a floating structure, i.e. below
the light water line. (EN 13173)
A.3
Structural design
A.3.1
Design parameters
Some factors that may influence the design of a corrosion protection system shall be outlined. More detailed information is given in each of the referred Standards in A.1 and A.2.1. When designing a corrosion
protection system, it is important to ensure that the whole structure is adequately protected and that e.g.
areas are not substantially over-protected, uniform distribution of current and restriction are placed on the
sitting of the anodes (e.g. in way of nodes) and it may be advantageous to use coatings. The detailed
design of offshore structures shall include corrosion protection. This shall involve:
type of production installation
material selection
specification of coating
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cathodic protection (sacrificial or impressed current)

selection of anode material and type
reliability
maintenance
monitoring
The major parameters affecting corrosion protection are:
dissolved oxygen content
wind
earthquake
vibrations
waves
currents
sand-, ice-loads, formation and accretion
temperature
marine growth
salinity
Material Selection
B.1
General
The intensity of corrosion of an unprotected steel structure in seawater varies markedly with position relative to the sea levels as shown in Fig. 5.1. The splash zone above the mean tide level (M.T.L) is the most
severely attacked region due to continuous contact with highly aerated sea water and the erosive effects
of spray, waves and tidal actions. Corrosion rates as high as 0.9 mm/y at Cook Inlet, Alaska, and 1.4
mm/y in the Gulf of Mexico have been reported. Cathodic protection in this area is ineffective because of
lack of continuous contact with the seawater, the electrolyte, and thus no current flows for much of the
time. Corrosion rates of bare steel are often also very high at a position just below M.T.L in a region that
is very anodic relative to the tidal zone, due to powerful differential aeration cells which form in the well
aerated tidal region.
Protection of a steel structure can be achieved by various means; each corrosion zone being separately
considered:
atmospheric zone
extended tidal zone
immersed zone
buried zone
Three generally accepted methods are
cathodic protection
painting or coating
and sheathing
Corrosion in the atmospheric zone is typically controlled by the application of a protective coating system.
For the extended tidal zone, with the highest damage/corrosion rates NACE RP0176-2003 provide a list
of Corrosion Control Measures, e.g. additional Corrosion Allowance, Steel Wear Plates, Alloy-clad and
diverse coatings.
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Atmospheric zone
Splash zone
Extended
tidal zone
H.A.T.
M.T.L.
Tidal zone
L.A.T.
Transition zone
Submerged zone
Immersed zone
Mudline
Buried zone
Zone designation
Relative loss metal thickness
Fig. 5.1 Schematic representation of levels, zones and thickness loss in sea water environment
This clause outlines some of the more important metals which may be protected by cathodic protection in
sea water and gives guidance for
metal sheathing of extended tidal zone with 65 % Ni-Cu alloy 400 and 90-10 Cu-Ni
Critical Pitting and Crevice Temperature (CPT and CCT) at which the CRAs are susceptible to chlorides in seawater
potentials recommended for protection of metals
However, in view of the wide range of alloys and applications it is essential that these values are used for
general guidance only and for more specific recommendations the standards of A.1, A.2.1 and literature
review may be necessary.
B.2
Metal sheathing
Metal sheathing with 65 % Ni-Cu alloy 400 and 90-10 Cu-Ni has proved to be a very successful approach
when applied to the legs and risers in the extended tidal zone.
B.2.1
65Ni-Cu (Alloy 400) is prone to pitting under stagnant conditions (0-0.6 m/sec) but becomes
passive in flowing seawater and high resistance even at 40 m/sec.
In early trials of 65Ni-Cu (Alloy 400) welded directly to the steel, it was assumed that corrosion of the anodic steel below the tidal zone would be accelerated because it is in direct contact with the more noble
sheathing alloy. On the contrary, steel below the tidal zone was found to be cathodic relative to the noble
alloy sheathing material, since the sheathing alloy became polarized to the potential of the adjacent steel
below. Hence the submerged steel below the sheathed pilling corroded at a lower rate than the submerged steel on unsheathed bare steel because the resulting galvanic current between the sheathed tidal
zone and the submerged steel below it is lower.
B.2.2
90-10 Cu-Ni is an established alloy for seawater systems and recognized for its unique combination of high resistance to corrosion and macrofouling.
Maximum resistance to biofouling relies on 90-10 Cu-Ni being freely exposed and not galvanically or cathodically protected by less noble materials. It is thought that this allows the availability of free copper ions
in the surface film to inhibit the growth of macrofouling although some microfouling will colonize. Attachment of the sheathing material to the steel structure by welding or mechanical fasteners will result in cathodic polarization of the sheath material and a reduction in the antifouling capability of the 90-10 Cu-Nialloy. Therefore it is necessary to electrically insulate the sheath from the steel jacket members to
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gain the full advantage of the biofouling resistance properties of the alloy. Electrical insulation can be
achieved by pumping cement or an epoxy into the annular space between the component and the sheath
or, more simply, by use of an elastomer or rubber-base insulator.
B.2.3
Long term data has shown complete protection of the steel behind the sheathing. The corrosion rate of the 65Ni-Cu (Alloy 400) and 90-10 Cu-Ni was very low and uniform; after 10 years no measurable loss of thickness of the sheathing itself in the case of the directly welded and insulated steel. Coating should be applied and maintained on the upper steel/65Ni-Cu or steel/90-10 Cu-Ni interface and any
steel area above in the atmospheric zone. The accumulation of biofouling on insulated Cu-Ni was 1-4 %
of the bare steel. In the case of directly welded sheathing, there were over 50 and 60% reduction in the
biofouling mass after 5 and 10 years exposure respectively representing a significant reduction in structure weight and wave loading (see also ISO 12473 Chapter 8.3.2.3 Cooper alloys).
B.3
High strength steel and corrosion resistant alloys (CRAs)
B.3.1
For deep water developments, high pressure, high temperature, sour gas and condensate
fields there is a need for high strength and corrosion resistant alloys (CRAs). Although CRAs are considered to be immune from corrosion, they are really only resistant to general corrosion in oil and gas production fluids compared to carbon and low alloy steels. Internal corrosion problems in steels are essentially related to corrosion by CO2 and H2S. ISO 15156 Part 3 lists the CRAs that are acceptable and the
conditions for which they may be used in terms of pH, H2S partial pressure and chloride levels. External
corrosion problems increases at the anode with
an increasing free corrosion potential difference
an increasing cathodic/anodic area ration
an increasing specific electrical conductivity and an increasing temperature of the sea water
The types of corrosion attack depend upon the material used, the component design, and the operating
conditions. Uniform corrosion and shallow pit formation usually occur on unalloyed steels and low- alloy
steels. Pitting and crevice corrosion generally occurs on materials that are passivatable and tend to form
a surface layer (high-alloy steels, aluminum and aluminum alloys as well as copper and copper alloys).
B.3.2
The pitting resistance equivalent number (PREN) is a measure of the pitting corrosion resistance of stainless steels as well as chrome and molybdenum nickel-base alloys. The larger the value of
the PREN, the better the resistance to pitting and crevice corrosion in seawater. Using the following formula, various materials can be ranked based upon their chemistry.
PREN = % Cr + 3.3 (%Mo + %W) + 16x %N (ISO 15156-3)
Crevice corrosion is very similar to pitting corrosion. However, since the tighter crevice allows higher concentration of corrosion products, it is more insidious than pitting. This drives the pH value lower. The end
result is that crevice corrosion can happen at temperatures 30 - 50 C lower than pitting in the same environment.
The Table 5.1 to 5.3 present some of the more important metals used for subsea collecting systems.
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Table 5.1
Reference materials
UNS, M-No.
Standard
Grade, class
Material-types
S32205
ASTM A 240
2205
Duplex 22Cr
1.4462
EN 10028-7
X2CrNiMoN 17-12-2
Duplex 22Cr
S32750
ASTM A 240
2207
Super-Duplex 25Cr
1.4410
EN 10028-7
X2CrNiMoN 25-7-4
Super-Duplex 25Cr
S30400
ASTM A 240
304
Austenic SS
1.4301
EN 10028-7
X5CrNi 18-10
Austenitic SS
S31603
ASTM A 240
316 L
Austenitic SS
1.4404
EN 10028-7
X2CrNiMo 17-12-2
Austenitic SS
625
Nickel-base- Alloy
NiCr22Mo9Nb
Nickel-base- Alloy
825
Nickel-base- Alloy
NiCr21Mo
Nickel-base- Alloy
N06625
2.4856
DIN 17744
N08825
2.4858
DIN 17744
Table 5.2
Chemical composition of the reference materials

Weight, %, max.
UNS
M-No.
Mn
Si
S32205
0.03
2.0
1.0
0.03
0.02
1.4462
0.03
2.0
1.0
0.035
S32750
0.03
1.2
0.8
1.4410
0.03
2.0
S30400
0.08
1.4301
Mo
Fe
others
22.0-23.0 4.5-6.5
3.0-3.5
Rest
N=0.1
0.015
21.0-23.0 4.5-6.5
2.5-3.5
Rest
N=0.1
0.035
0.02
24.0-26.0 6.0-8.0
3.0-5.0
Rest
N=0.2
1.0
0.035
0.015
24.0-26.0 6.0-8.0
3.0-4.5
Rest
N=0.2
2.0
0.7
0.045
0.03
18.0-20.0 8.0-10.5
Rest
N=0.1
0.07
2.0
1.0
0.045
0.015
17.0-19.5 8.0-10.5
Rest
N=0.1
S31603
0.03
2.0
0.7
0.045
0.03
16.0-18.0
10-14
2.0-3.0
Rest
N=0.1
1.4404
0.03
2.0
1.0
0.045
0.015
16.5-18.5
10-13
2.0-2.5
Rest
N=0.1
N06625
0.1
0.5
0.5
0.015
0.015
20.0-23.0
Rest
8.0-10.0
5,0
Nb4.1
2.4856
0.1
0.5
0.5
0.02
0.015
20.0-23.0
58
8.0-10.0
5,0
Nb,Co
N08825
0.05
1.0
0.5
0.03
19.5-23.5
38-46
2.5-3.5
Rest
Ti=1.2
2.4858
0.02
1.0
0.5
0.02
0.015
19.5-23.5
38-46
2.5-3.5
Rest
Co,Cu
Table 5.3
Cr
Ni
Mechanical properties, PREN, CPT and CCT
UNS
M-No.
R0,2
MPa min.
Rm
MPa
A5
%
PREN
CPT
C 1, 2
CCT
1, 2
C
S32205
450
640
25
31-37
~30
~20
1.4462
460
640
25
31-38
~30
~20
S32750
550
800
20
38-44
~50-60
~25-35
1.4410
530
730
20
38-46
~50-60
~25-35
S30400
210
515-690
45
20-22
<0
<0
1.4301
210
520-720
45
19-21
<0
<0
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S31603
220
515-690
45
18-20
<0
<0
1.4404
220
530-680
40
18-20
<0
<0
N06625
410
800-1000
30
46-56
~60-90
~40-60
2.4856
410
800
30
46-56
~60-90
~40-60
N08825
240
590-750
30
28-35
~20-40
< 0-15
2.4858
235
550
30
28-30
~20-25
<0
Notes
1 DIN 81249
2 Klwer, J., Schlerkmann, H., Ppperling, R.: H S Resistant Materials for Oil & Gas Production. Paper No. 01004-2001 by
2
NACE International
B.3.3
The potential susceptibility of some alloys used for jumpers, manifolds, valves, etc. to HISC
due to polarization from cathodic protection of carbon steel subsea flowlines or subsea structures shall be
considered. Within the potential range of cathodic protection by e.g. Al-anodes (i.e. 0.80 to 1.10V
Ag/AgCl/ seawater) the production of hydrogen increases exponentially towards the negative potential
limits. Forgings, casts and welds are more prone to HISC than wrought materials due to the course microstructure allowing HISC to propagate.
The potential susceptibility of HISC of ferritic and ferritic- pearlitic structural steels with specified minimum
yield strength above 700 MPa or 300/350 HV, ferritic-austenitic Duplex stainless steels and certain precipitation hardening nickel based alloys with hardness above 300/350 HV due to polarization from cathodic protection shall be considered. Whilst this is the subject of current research, guidance will be provided in Table 5.4 (see also EN 12473, Chapter 8.3, Other metallic materials).
Table 5.4
Summary of potential versus Ag/AgCl/ sea water reference electrode recommended

for the cathodic protection of various metals in sea water
Min. negative potential [Volt]
Max. negative potential [Volt]
High strength steel: ReH 700 MPa and 350 HV:

Aerobic environment
Anaerobic environment
-0.80
-0.90
-1.10
-1.10
High strength steel: ReH > 700 MPa or >350 HV:
-0.80
Material
Stainless steel:
Austenitic steel: PREN 40
Austenitic steel: PREN < 40
Ferritic-austenitic Duplex:
Al Mg and Al Mg Si alloys
Copper alloys without Al
Copper alloys with Al
Nickel base alloys
-0.95
-0.30
2
-0.60
2
-0.60
No limit
No limit
-0.90 3, 1
-0.80
-1.0
-0.45 to -0.60
-0.45 to -0.60
No limit
-1.10
0.20
Notes
1 For materials susceptible to HISC the simultaneous presence of at least two conditions is needed:
more negative than -0,83 V

high level of strain in the material (> 80 % of ReH for global and local stress; 67 % of ReH for regions influenced by residual stresses)
2 For most applications these potentials are adequate for the protection of crevices although higher potentials may be consid-
ered.
3 Forgings, casts and welds are more prone to HISC than wrought materials due to the course microstructure allowing HISC to
propagate preferentially in the ferritic phase.

4 High strength nickel copper and nickel chromium iron alloys can be susceptible to HISC and potentials that result in signifi-
cant hydrogen evolution should be avoided. Nickel based alloys in the solution annealed condition are generally considered
immune to HISC. For certain nickel based alloys (i.e. austenitic alloys including e.g. UNS N05500 and UNS N07750) precipitation hardening may induce sensitivity to HISC.
ReH = minimum specified yield strength
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Coating Selection
C.1
General
C.1.1
The most suitable form of coating depends on the type of structure and its environment. In the
selection of a coating, the aim should be to achieve overall economy in the combined cost of the protected structure and of the initial and running costs of the protection schemes. Due regard should be paid
to the design life of the structure and the economics of repairing the coating should this become necessary. More information is given in the respective Standards, see NACE SP0108, ISO 12944, ISO 20340
and NOSOK M-501.
C.1.2
While organic coatings are not entirely impermeable to oxygen and water they do restrict corrosion when applied to the surface of a metal. The bulk of the corrosion on a painted surface does not
occur beneath the intact coating but at the base of holidays and pin holes. If cathodic protection is applied
to a painted surface, the coating acts as a substantial resistive barrier to current flow and where the current flows, it is to the holidays or pin holes. In terms of cathodic protection the presence of a coating improves current distribution and reduces current demand and interference effects.
C.1.3
Coating on offshore structures can be divided into four major areas:
atmospheric zone
extended tidal zone
immersed zone
buried zone
Fig. 5.1 presents the levels, zones and profile of the thickness loss resulting from corrosion of an unprotected steel structure in seawater.
Corrosion in the atmospheric zone is typically controlled by the application of a protective coating system
(see NACE SP0108-Table 3A to Table 5 and ISO 12944-Corrosion Category C5-M). Table 5.5 illustrates
typical coating systems used in the atmospheric zone for a design life of more than 15 years.
For the extended tidal zone, with the highest damage/corrosion rates (until 100 times higher than in the
atmospheric zone and three times higher than in the immersed zone) NACE SP0108Table 6A provide
diverse coatings like Vulcanized Chloroprene Rubber (thickness of 6 to 13 mm), two layer glass flake
epoxy with 1 mm DFT and Thermal-sprayed Aluminum with epoxy sealer. Polyurethane topcoat does not
have good water resistance and shall not used in the splash zone.
In the past, conventional protective coatings were seldom applied to structure in the immersed and buried
zone. However, increased current requirement and anode weight restriction can affect the decision to
coat complex structures to be installed in deeper waters with higher current density requirements, in
shielded areas as large conductor bundles and/or on structures with extended design lives.
Table 5.6 illustrates typical coating systems used in the extended tidal and immersed and buried zone.
C.1.4
Organic coatings promote the formation of a dense calcareous deposit at coating holidays and
bare areas because the initial current density may be relatively high at such locations. However, the solubility of potential film- forming calcareous deposits normally increases with decreasing temperature such
that colder waters might not allow the formation of a protective calcareous deposit or could require higher
initial current density to achieve polarization. This includes deep water applications for which the formation of calcareous deposits may be slow.
C.1.5
The application of coatings may not be suitable for parts of submerged structures requiring
frequent inspection for fatigue cracks, e.g. critical welded nodes of jacket structures.
For components of materials sensitive to HISC by CP (see B.3), an organic coating should always be
considered as a barrier to hydrogen adsorption.
C.2
Coatings and coating breakdown factors
C.2.1
Coating breakdown factor is the anticipated reduction in cathodic current density due to the
application of an electrically insulating coating when com-pared to that of bare steel. If the Coating break-
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down factor is zero, the coating is 100 % electrically insulating, thus decreasing the cathodic current density to zero. Coating breakdown factor 1 means that the coating has no current reducing properties.
An initial coating breakdown factor (fci) related mainly to mechanical damage occurring during the installation of the structure should be considered and a coating deterioration rate shall be thereafter evaluated
in order to take into account the coating aging and possible small mechanical damage occurring to the
coating during the structure life.
C.2.2
Due to possible interactions between the cathodic protection and the coating, all coatings to be
used in combination with cathodic protection shall be tested beforehand to establish that they have adequate resistance to cathodic disbondment. Alkali is generated on the cathodically protected surface and
this may result in the cathodic disbondment of the coating in way of any coating defects.
C.2.3
The conventional coatings of the oleo-resinous or alkyd types are attacked by alkali, i.e. they
are subject to saponification and are not recommended for use in association with cathodic protection.
The use of polyvinyl butyral shop primers has also caused loss of adhesion when combined with cathodic
protection.
The Coating Categories I to VII of Table 5.6 und the recommended constants k1 and k2 of Table 5.7 are
based on recommended values of EN 12495, EN 13173, ISO 15589 and NORSOK M-503 as well the
acceptance criteria of the coating standards ISO 12944, inclusive ISO 20340 and ISO 21809-1.
Table 5.5
System
No. 1, 2
Typical coating systems used in the atmospheric zone (design life >15 years)
Subsequent
coat(s)
Primer coat (s)

Binder type
Type of
primer
No. of
coats
NDFT
[ym]
A5M.02
EP, PUR
Misc.
80
A5M.04
EP, PUR
Misc.
A5M.06
EP,PUR,ESI
Zn (R )
A5M.07
EP,PUR,ESI
Zn (R )
Binder type
Paint system
No. of
coats
NDFT
[ym]
EP, PUR 3
3-4
320
250
EP, PUR 3
500
60
EP, PUR 3
4-5
320
60
EPC
3-4
400
Notes
1 ISO 12944-5, corrosivity category C5-M
2 The systems shall be pre-qualified in accordance to ISO 20340 (Ageing resistance)
3 Polysiloxane provides better UV restistance than polyurethane ( see NACE SP0108)
EP
: Epoxy
PUR
: Polyurethane
ESI
: Ethyl silicate
EPC
: Epoxy combination
Zn (R )
: Zinc-rich
Misc.
: Primers with miscellaneous types of anticorrosive pigments.
NDFT
: Nominal dry film thickness
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Table 5.6
Typical coating systems used in the extended tidal, immersed and buried zone
fcf
Coat.
Cat.
(see
Table
5.7)
1,0 3
250
0,8 3
II
350
0,26 3
III
EP
600
0,26 2
IV
80
EPGF
800
0,26 2
IV
13004700 11
0,16 2
13003800 11
0,10 2
VI
600013000
0,07 2
VII
Subsequent
coat (s)
Primer coat (s)

System
No.
A6.05 Mod
1,3,5
A6.05
Mod. 1,3,5
A6.05
Mod. 1,2,4
A6.08 1,2,4
Binder
type
Type
of
primer
No.
of
coats
NDFT
[ym]
No.
of
coats
EP
Misc.
20
EP
Misc.
80
EP
EP
Misc.
80
EP
EP
Misc.
80
EP
Misc.
3LPECl.A/B 6
EP 7 or 8
Misc.
25 or
125 8
Adhesive
150 ym +PE 10
3LPPCl.C 6
EP 7 or 8
Misc.
25 7 or
125 8
Adhesive 9
Misc.
25
Rubber 2, 12
Paint system
EP
150 ym +PP 10
Adhesive 9
25 ym +PC
NDFT
[ym]
Notes
1 ISO 12944-5, corrosivity category Im1, Im2 and Im3 (for water and soil)
2
for extended tidal zone recommended
for immersed zone recommended
The system shall be pre-qualified in accordance to ISO 20234 (Ageing resistance, Cathodic disbonding, Sea water immersion)
The system shall be pre-qualified in accordance to ISO 20234 (Cathodic disbonding, Sea water immersion)
ISO 21809-1
Liquid
Powder (FBE= Fusion Bond Epoxy)
Powder sprayed or extruded
10 Applied by extrusion
11 Thickness is function of pipe weight
12 NACE SP0108, Polychloroprene (neoprene) rubber
EP
: Epoxy
EPGF
: Epoxy glass flake
PE
: Polyethylene
PP
: Polypropylene
PC
: Polychloroprene
Fcf
: Final coating breakdown factor for design life of 30 years
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Table 5.7
Recommended constants k1 and k2 for calculation of coating breakdown factors

Coating categories (Table 5.6)
Zones
(Fig.1)
Constants
II
III
IV
VI
VII
Extended
k1
0.10
0.05
0.02
0.015
0.01
0.01
0.005
Tidal
k2
0.10
0.025
0.012
0.008
0.005
0.003
0.002
k1
0.10
0.05
0.02
0.015
0.01
0.01
0.005
k2
0.05
0.015
0.008
0.005
0.003
0.002
0.0015
Immersed
C.2.4
Calculation of coating breakdown factors:
fci
= k1
(1)
fcm
= k1 + k2 x t/2
(2)
fcf
= k1 + k2 x t
(3)
If fcm or fcf exceeds 1, fcm = 1 or fcf = 1 shall be applied in the design. (Coating breakdown factor 1
means that the coating has no current reducing properties.)
k1
: constant for the initial condition of coating depending mainly on mechanical damage occurring during the installation of the structure mechanical damage
k2
: constant for coating damage depending mainly on marine growth (incl. cleaning operations
to remove such growth) and the erosion effects of waves and currents
: design life (years)
fci
: initial coating breakdown factor
fcm
: mean (or maintenance or average) coating breakdown factor
fcf
: final (or re-polarization) coating breakdown factor
Cathodic Protection
D.1
General
In order to achieve the cathodic protection criteria on the whole structure it is necessary to consider the
electrical current demand on each part of the structure.
The electrical current demand of each part of the structure is the product of its steel surface area multiplied by the electrical current density required.
The current density required is not the same for all parts of the structure as the environmental conditions
are variable. Therefore, the following areas and parts should be considered, referring to zones as defined
in Fig. 5.1.
areas located in the extended tidal zone (usually coated or cladded)
areas located in the immersed zone
areas located in the buried zone
wells to be drilled; a current allowance per well shall be considered, depending on projected size,
depth and cementing of the wells
Neighboring structures and pipelines in electrical contact with the fixed steel offshore structure to be
protected.
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Design current densities
The selection of design current densities may be based on experiences from similar structures in the
same environment or from specific tests and measurements.
The electrical current density required for cathodic protection depends upon the kinetics of the electrochemical reactions and varies with parameters such as listed in A.3.1.
For each particular set of environmental condition (see Table 5.8) and surface condition of the structure
(see Table 5.6 and 5.7), the following electrical current densities shall be evaluated:
initial electrical current density required to achieve the initial polarization of the structure, i.e. to
achieve the lowering of the steel potential down to value within the range recommended in Table 5.4
mean (or maintenance or average) electrical current density required to maintain this polarization
level on the structure
final (or re-polarization) electrical current density required for a possible re-polarization (i.e. for reestablishing the potential to the initial polarization level) of the structure after severe storms or cleaning operations (i.e. marine growth)
Table 5.8 presents a general guide to the design of CP systems in major offshore petroleum producing
areas and offshore wind farms for carbon steel, stainless steel, aluminum and other metallic materials.
These data may be used as a starting point for investigation prior to selection of final design parameters
for a specific application. For special cases and deep water Table 5.9 and 5.10 shall be used.
Table 5.8
Current
Density
levels
Very
high
High
Medium
Low
Typical design current density values of bare metal surface in immersed zone until
100 m water depth
Water
Temp.
(C) 2
Design current
density (mA/m2)
Geographic
area
Water
Resistivity
(ohm-m)
NACE
Cook Inlet
0.50
Low
High
430
380
380
EN,
NACE
North Sea
> 62N 4
0.26-0.33
0-12
High
Mod.
220
100
130
NACE
Gulf of Mexico
Deep water
0.29
4-12
Low
Varies
194
75
86
EN,
NACE
North Sea
55 62N 4
0.26-0.33
0-12
High
Mod.
180
90
120
NACE
Brazil
0.20
15-20
Mod.
High
180
65
86
EN
North Sea
< 55N 4
0.26-0.33
0-12
High
Mod.
150
80
100
NACE
U.S. West
Coast
0.24
15
Mod.
Mod.
150
86
100
GL
Baltic Sea
< 60N
0.85-1.15 5
0-12
Low
Low
150
65
90
NACE
Arabian Gulf
0.15
30
Mod.
Low
130
65
86
NACE
Australia
Southeast
0.23-0.30
12-18
High
Mod.
130
86
86
NACE
West Africa
0.20-0.30
5-21
Low
Low
130
65
86
EN
India
130
70
90
Code
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NACE
Australia
Northwest
NACE
Gulf of
Mexico
0.20
22
Mod.
NACE
Indonesia
0,19
24
NACE
South China
Sea
0,18
30
EN
Mediterran.
Sea, Adriatic
Sea
120
65
65
Mod.
110
54
75
Mod.
Mod.
110
54
75
Low
Low
100
32
32
110
60
80
Notes
1 NACE SP0176, EN 12495, EN 13173 and GL (Germanischer Lloyd)
2 Surface water temperature (sea level)
3 Turbulence Factor
4 Conditions in the North Sea can vary greatly from the northern to the southern area, from winter to summer, from the coast
near to the coast far, and during storm periods.
5 Salinity 7 to 10 ppt
D.3
Cathodic protection systems
Cathodic protection can be achieved using:

the galvanic (or sacrificial) anodes system
the impressed current system
a combination of both cathodic protection systems (Hybrid Systems)
For permanently installed offshore structures, galvanic anodes are usually preferred.
However, due to weight and drag forces caused by galvanic anodes, impressed current cathodic protection systems are sometimes chosen for permanently installed floating structures.
When using hybrid systems the galvanic anodes should provide cathodic protection during float out, initial
installation and subsequently during the impressed current systems shutdowns.
Galvanic anodes should also be installed in areas where it may be difficult to achieve adequate level of
polarization by the impressed current system due to shielding effects.
As the electrical current demand is not constant with time, the cathodic protection system shall be able to
deliver the re- polarization current density required for short periods throughout the life of the structure.
D.4
Galvanic anodes system
D.4.1
Design considerations
The three design electrical current densities as defined in D.2 shall be considered:
The initial electrical current density shall be used to verify that the output current capacity of new anodes, i.e. their initial dimensions, is adequate to obtain a complete initial polarization of the structure
within a few weeks.
The mean (or maintenance or average) electrical current density shall be used to determine the
weight of the anodes. This current density is required to maintain an adequate polarization level of
the structure during its design life.
The final (or re-polarization) electrical current density shall be used to verify that the output current
capacity of the anodes when they are consumed to an extent commensurate with their utilization factor, i.e. their final usable dimensions, is adequate to re-polarize the structure after severe storms or
after marine growth cleaning operations.
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Table 5.9
Typical design current density values for special cases
Case
No.
Code 4
EN
NACE
Design Current Density [mA/m2]
Description
Initial
Mean
Final
Bare metal in extended tidal zone
1.2
Table 5.8
1.2
Table 5.8
1.2
Table 5.8
Deep-water structures depth > 100 m
Table 5.10 Table 5.10 Table 5.10
EN
25
20
20
NACE
Freely flooded compartments
Table 5.8
Table 5.8
Table 5.8
NACE
Closed compartments with free access to air
Table 5.8
Table 5.8
Table 5.8
NACE
Closed and sealed flooded compartments
20
20
20
Table 5.8
Table 5.8
Table 5.8
5000
5000
5000
NORSOK
Bare metal in marine sediment
Current Drain by mud mats, skirt and piles
NORSOK
EN
Open pile ends

Current Drain per platform wells
10
NORSOK
Current Drain per subsea wells
8000
8000
8000
Table 5.8
and 5.9 3
Table 5.8
and 5.9 3
Table 5.8
and 5.9 3
11
NORSOK
Current Drain to anchor chain
12
NORSOK
For components heated by an internal fluid

for each C exceed 25 C, additional to base
values
13
NORSOK
For embedded steel in concrete structures

exposed on one side in immersed zone
14
NORSOK

exposed on both sides in immersed zone
15
NORSOK

exposed on one side in extended tidal zone
16
NORSOK

exposed on both sides in extended tidal zone
1.5
1.5
1.5
17
NORSOK
For Al- and Zn- components or coated with Al

or Zn
10
10
10
18
NORSOK
For Al- and Zn- components or coated with Al

or Zn and heated by an internal fluid for each
C exceed 25 C, additional to case 17
0.2
0.2
0.2
Notes
1
based on the outer (sediment exposed) external surface area
The top internal surface shall be included for a distance of 5 times the internal diameter
For anchor systems with mooring topside only, 30 m of each chain shall be accounted for in the CP design. For anchor
system with mooring point below sea level, the seawater exposed chain section from sea level to mooring point and 30 m
from the mooring point shall be accounted for in the CP design for each chain.
NACE SP0176, EN 12495, EN 13173 and NORSOK M-503
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Table 5.10 Typical design current density values of bare metal surface in immersed zone > 100 m
water depth (NACE SP0176) 1
Design Current Density [mA/m2]
Temperature C
Initial
Mean
Final
4 C
350
140
300
5 C
300
85
250
6 C
250
75
200
7 C
210
65
160
8 C
170
60
120
9 C
140
55
90
10 C
120
52
70
11 C
115
48
65
12 C to 17 C
110
45 to 40
60
18 C to 23 C
100
40 to 35
50
24 C to 30 C
100 to 90
35 to 30
50 to 40
Note
1 For deep-water structures different design current density values should be used for different temperature zones. To optimize the design the structure should be split up into separate zones over which the temperature does not vary by more than
1 C at temperatures 11 C and 5 C at temperatures > 11 C. The depth average temperature of each interval should be
used to assess the required current densities.
A large variety of shapes and sizes can be used to deliver protective electrical current to the structure in
order to optimize the electrical current distribution (see D.4.3).
The performance of galvanic anodes in sea water depends critically upon the alloy composition, particularly when aluminum or zinc alloys are used (see EN 12496, NACE SP0387 and NACE SP0492)
The electrochemical properties of the anodic material shall be documented or determined by appropriate
tests.
The information required includes:
the driving voltage to polarized steel, i.e. the difference between closed circuit anode potential and
the positive limit of the protection potential criterion
the practical electrical current capacity (Ampere hour per kilogram = Ah/kg) or consumption rate
(kilogram per Ampere per year = kg/Ay)
the susceptibility to passivation
the susceptibility to intergranular corrosion
D.4.2
Galvanic anode materials
D.4.2.1
Chemical composition and physical quality requirements
The requirements specified in EN 12496 shall be applied. Further information for inspection of anodes is
given in NACE SP0387 and NACE SP0492. For the Aluminum and Zinc anodes the chemical compositions of Table 5.11 are required.
D.4.2.2
Electrochemical properties
For design purposes, the data given in Table 5.12 shall be used unless otherwise documented. The use
of practical current capacity greater than the values of Table 5.12 shall be justified by long term free running test of minimum 12 month in accordance to DNV RP-B401, Annex C. Electro chemical quality control
testing shall be in compliance with the requirements in DNV RP-B401. The test procedure shall be in accordance to DNV RP-B401, Annex B (short time test of 96 h).
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Table 5.11 Chemical composition for Al- and Zn anodes gives as mass fraction in %
Al alloy A2 1,3,4
Elements
Al alloy A3 2,3,4
Zn alloy Z1 5
Aluminum (Al)
Remainder
Remainder
0.1 0.5
Zinc (Zn)
3.0 5.5
4.75 5.75
99.314 min.
Indium (In)
0.016 0.040
0.016 0.020
Iron (Fe)
0.09 max.
0.06 max.
0.005 max.
Silicon (Si)
0.10 max.
0.08 0.12
Copper (Cu)
0.005 max.
0.003 max.
0.005 max.
Cadmium (Cd)
0.002 max.
0.002 max.
0.025 0.07
Lead (Pb)
0.006 max.
Other Impurities (each)
0.02 max.
0.02 max.
Other Impurities (total)
0.1 max.
0.05 max.
0.10 max.
Notes
1
Al alloy A2 is normally used for offshore applications.
Al alloy A3 is normally used for deepwater and cold water applications.
Al alloy A2 and A3 have proved to be applicable in marine sediments, i.e. covered with mud
Al alloys A2 and A3 are only applicable for environments with salinity of greater than 5 ppt, i.e. typically in seawater /
brackish water environments with resistivity of less than 2 ohm-m. Higher resistivity may occur at the mouths of major rivers in the Baltic Sea (see Table 5.8)
Zn alloy Z1 should not be used at temperatures above 50 C in sediments
Table 5.12 Design values for galvanic anodes

Seawater
Anode type
Sediments
Closed circuit
potential
Ag/AgCl/seawater
(mV) Ea
Current
capacity
(Ah/kg)
Closed circuit
potential
Ag/AgCl/seawater
(mV) Ea
Current
capacity
(Ah/kg)
-1050
2000
-1000
1500
Max. 30
-1030
780
-980
750
580
Max. 30
30 to 50
Al alloy
A2,A3 1,3
Zn alloy Z1 2
Temperature
Limits C
Notes
1 Al-Density 2725 kg/m3
2 Zn-Density 7130 kg/m3
3 Anode capacity for all Al-based alloys will be significantly lower at higher operating temperature. For example anode capacity for
alloy A2 will drop essentially linearly from 2500 Ah/kg at 25 C (short time test) to 500 Ah/kg at 80 C. In saline mud, at elevated
temperatures, the capacity values will be lower than those indicated for seawater.
D.4.3
Anode shapes and utilization factors
D.4.3.1
Stand-off anodes
Stand-off anodes shall be used as far as possible with a minimum distance to the steel surface of 300 mm
(see Fig. 5.2). The insert should be preferably cylindrical in order to avoid gas entrapment during the alloy
casting. The physical tolerances, anode weight, anode dimensions and straightness, steel inserts and
metallurgical requirements shall be in accordance to EN 12496 or NACE SP0387.
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The dimensions of the insert and the support are to be designed taking into account the weight of the
anodicalloy and with the various environmental loading conditions as detailed in EN 12495 Chapter 5.5.4
Structural considerations.
D.4.3.2
Flush-mounted anodes
Flush-mounted anodes are designed to limit hydrodynamic effects when fitted to the structure (see Fig.
5.2). The physical tolerances, anode weight, anode dimensions and straightness, steel inserts and metallurgical requirements shall be in accordance to EN 12496 or NACE SP0387.
Zn anodes located underneath mud mats shall be flush-mounted.
Flush-mounted anodes may be recommended for the protection of mobile floating units.
D.4.3.3
Bracelet anodes
Bracelet anodes are designed to reduce the wave loads on steel jackets. Bracelet anodes are shaped as
half-rings to be positioned on tubular items. Two half-ring anodes will have to fit together to become a
bracelet anode (see Fig. 5.2). The physical tolerances, anode weight, anode dimensions and straightness, steel inserts and metallurgical requirements shall be in accordance to EN 12496 or NACE SP0492.
Stand-off anodes
L
C
Flush-mounted anodes
L
B
S=
L+B
2
Bracelet anodes
Ro
A 2 p Ro L
Fig. 5.2 Typical anode shapes
D.4.3.4
Utilization factor
The utilization factor is determined by the proportion of anodic material that may be consumed before the
anode ceases to provide the required current output. The shape of the anode will affect the utilization
factor.
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Table 5.13 Recommended anode utilization factors

Anode type
Anode utilization factors u
Long slender stand-off, if L 4 r
0.90
Short slender stand-off, if L < 4 r
0.85
Long flush-mounted, if
L 4 width
0.85
L 4 thickness
Short flush-mounted, bracelet
D.4.4
0.8
Calculation of anode resistance
The anode resistance, Ra shall be in accordance with the following formulas:

Stand-off anodes, if L 4 r:
Ra =
4L
1
ln
2 L
r
(4)
Stand-off anodes, if L < 4 r:
ln 2 L 1 + 1 + r
r
2 L
Ra =
2L
2
+ r 1+ r
2 L
2L
(5)
Flush-mounted anodes:
Ra =
2 S
(6)
Bracelet anodes:
Ra =
0,315
(7)
Ra
: anode resistance [Ohm]
: sea water/sediment resistivity [ohm m] (see Table 5.14)
: length of the anode [m]
: radius of the anode [m] (for other shapes than cylindrical, r = C/2 , where C [m] = cross
section periphery)
: arithmetic mean of anode length and width [m]
: exposed surface area of anode [m2]
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Table 5.14 Sea water resistivity as a function of temperature, salinity and density
Temperature [C]
Salinity
[ppt]
Density
[kg/m3]
Resistivity [ohm m]
-5
30
1024
0.47
-5
35
1028
0.40
-5
40
1032
0.34
30
1024
0.41
35
1028
0.35
40
1032
0.29
30
1024
0.35
35
1028
0.30
40
1032
0.24
10
30
1023
0.30
10
35
1027
0.26
10
40
1031
0.21
15
30
1022
0.27
15
35
1026
0.23
15
40
1030
0.18
20
30
1021
0.24
20
35
1025
0.21
20
40
1029
0.17
25
30
1020
0.22
25
35
1023
0.19
25
40
1027
0.16
30
30
1018
0.20
30
35
1022
0.18
30
40
1026
0.15
D.4.5
Sea water resistivity and temperature
D.4.5.1
Temperature has a significant influence on sea water resistivity, dissolved oxygen and calcareous deposit formation.
As the temperature along with salinity of sea water has a significant effect on the resistivity of sea water
and as this is directly related to the effective resistance of galvanic anodes, it should be taken into account in the design of cathodic protection systems.
In the open sea the salinity does not vary significantly and temperature is the main factor. The relation
between resistivity and temperature at a salinity of 30 to 40 ppt (parts per thousand) is given in Table
5.14. Fig. B.1 of ISO 12495 shall be used for sea water densities between 1000 kg/m3 and the values of
Table 5.14.
D.4.5.2
Compared to sea water, the resistivity of marine sediments is higher by a factor ranging from
about 2 for very soft clays to 5 for sand. Unless sediment data for the location are available, the highest
factor shall be assumed for calculation of the resistance of any buried anodes.
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Cathodic protection calculation and design procedure
The purpose of this paragraph is primarily the clarification of the Cathodic Protection (CP) Calculation
Procedure. The procedure will be demonstrated by using two different examples:
Example 1: Tripod
A tripod with mudmats, built from carbon steel, located in West Africa, designed for a life time of 30 years
Example 2: PLET (Pipeline end termination unit)
Carbon steel subsea structure (PLET =Pipeline end termination unit) connected to carbon steel flow line
and jumper with Super-Duplex 25Cr flow meter, located in the East Mediterranean Sea in 500 m water
depth, sea bed temperature 13 C, internal fluid temperature 50C, designed for a life time of 25 years
D.4.6.1
Subdivision of the object in sections
The object has to be subdivided into sections using the zone definitions of Fig. 5.1.
Example 1: Tripod
The four following zones shall be separately considered:
atmospheric zone
extended tidal zone
immersed zone
buried zone
The following text, Figures and Tables shall be considered:
Fig. 5.1:
Zones and profile of the thickness loss of an unprotected steel structure in sea water
B.1 and B.2: Methods of corrosion protection in the four zones

C.1 and C.2: Coating selection for the four zones (Table 5.5, 5.6, and 5.7)
D.1 and D.2: The subdivision shall consider all sections which influence the cathodic protection current
demand and the different design current densities (Table 5.8, 5.9, and 5.10).
Possible solution:
Atmospheric Zone will not drain current from the CP system. This zone shall not include in the CP system
and shall be protected minimum with a coating system of Table 5.5.
Extended Tidal Zone may be protected with 90-10 Cu-Ni on rubber-base insulator and will not drain current from the CP system.
Section 1: Immersed Zone may be protected with coating systems of coating category IV of Table 5.6.
Section 2: Mudmat underside may be none coated
Example 2: PLET
The following zones shall be considered:
immersed zone
The following text, Figures and Tables shall be considered:
B.1 and B.2: Material Selection for deep water applications (Table 5.1, 5.2, 5.3, 5.4)
C.1 andC.2: Coating Selection for deep water structures and piping components (Table 5.6, 5.7)
D.1 and D.2: The Subdivision shall consider all sections which influence the cathodic protection current
demand and the different design current densities (Table 5.8, 5.9, 5.10).
Possible solution:
Section 1: Subsea structure (PLET) may be protected with a coating system of coating category IV
Section 2: Flow line may be protected with a coating system of coating category V
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Section 3: Jumper with Super-Duplex 25Cr flow meter may be protected with a coating system of coating
category IV, because the CPT and CCT of Super-Duplex 25Cr are equal or lower than the fluid temperature, so this material shall cathodic protected.It shall be considered that Super-Duplex 25Cr is potential
susceptible to HISC due to over polarization. Within the potential range of cathodic protection by Alanodes (i.e. -0.80 to -1.10V Ag/AgCl/seawater) the production of hydrogen increases exponentially towards the negative potential limit. Forgings, casts, like flow meters and welds are more prone to HISC
than wrought materials due to the course microstructure allowing HISC to propagate preferentially in the
ferrit phase. I.e. the anodes shall be located as far as possible away from the Super-Duplex 25Cr component.
For Example 2 only the cathodic protection of Section 1 will be shown. In case of Section 2 the requirements of ISO 15589-2 shall be considered.
D.4.6.2
Surface area of sections
For each section, with or without coating the surface areas shall be calculated separately.
Example 1: Tripod
Solution:
2
Section 1: Ac1 = 659 m

Example 2: PLET
Solution:

D.4.6.3
Calculation of current demand
For each section the following required current demands shall be calculated:
Ici1
= Ac1 ici1 fci1
(8)
Icm1
= Ac1 icm1 fcm1
(9)
Icf1
= Ac1 icf1 fcf1
Ici1
: required initial current demand of section 1 [mA]
Icm1
: required mean current demand of section 1 [mA]
Icf1
: required final current demand of section 1 [mA]
Ac1
: surface area of section 1 [m2]
ici1
: required initial design current density of section 1 [mA/m2]
icm1
: required mean design current density of section 1 [mA/m2]
icf1
: required final design current density of section 1 [mA/m2]
fci1
: initial coating breakdown factor, if section 1 is coated; fci1 = 1, if bare metal surface
fcm1
: mean coating breakdown factor, if section 1 is coated; fci1 = 1, if bare metal surface or
fcm1 >1.
fcf1
: final coating breakdown factor, if section 1 is coated; fci1 = 1, if bare metal surface or fcf1 >1
(10)
Example 1: Tripod
The following clauses, figures and tables shall be considered:
C.2:
Calculation of coating breakdown factors (Table 5.7)
D.1 and D.2: Required design current densities of geographic areas and in specific areas of the structure
(Table 5.8, and 5.9)
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Solution:
Section 1: Coating category IV
Selection of k1 and k2 (Table 5.7: Immersed zone):
k1 = 0.015, k2 = 0.005
Selection of design current densities (Table 5.8: West Africa):
ici1 = 130 mA/m2, icm1= 65 mA/m2, icf1= 86 mA/m2
fci1
= k1 = 0.015
fcm1
= k1 + k2 t/2 = 0.015 + 0.005 30/2 = 0.09
fcf1
= k1 + k2 t = 0.015 + 0.005 30 = 0.165
Calculation of required current demands: Ici1, Icm1 and Icf1 for Ac1 = 659 m2
Ici1
= Ac1 ici1 fci1 = 1285 mA
Icm1
= Ac1 icm1 fcm1= 3855 mA
Icf1
= Ac1 icf1 fcf1= 9351 mA
Section 2: Mudmat underside with bare metal surface

Selection of design current densities (Table 5.9: Case No. 3: Bare metal in marine sediment):
ici2 = 25 mA/m2, icm2 = 20 mA/m2, icf2 = 20 mA/m2
2
Calculation of required current demands Ici2, Icm2 and Icf2 for Ac2 = 238 m :
Ici2
= Ac2 ici2
= 5950 mA
Icm2
= Ac2 icm2 = 4760 mA
Icm3
= Ac2 icf2
= 4760 mA
Example 2: PLET
C.2: Calculation of coating breakdown factors (Table 5.7)
D.1 and D.2: Required design current densities in deep water (Table 5.10).
Solution:
Section 1: Coating category IV.
k1 = 0.015, k2 = 0.005
Selection of design current densities (Table 5.10):
ici1 = 110 mA/m2, icm1 = 44 mA/m2, icf1 = 60 mA/m2
fci1
= k1 = 0.015
fcm1
= k1 + k2 t/2 = 0.015 + 0.005 25/2 = 0.078
fcf1
= k1 + k2 t = 0.015 +0.005 25 = 0.14
Calculation of required current demands: Ici1, Icm1 and Icf1 for Ac1 = 288 m2
Ici1
= Ac1 ici1 fci1 = 475 mA
Icm1
= Ac1 icm1 fcm1 = 988 mA
Icf1
= Ac1 icf1 fcf1 = 2419 mA
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D.4.6.4
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Selection of anode materials and shapes
D.4.1, D.4.2, und D.4.3 shall be considered.

Example 1: Tripod
Solution:
Stand-off aluminum alloy anodes for immersed zone (see Fig. 5.2)
Flash-mounted zinc alloy anodes on mud mats facing downwards (see Fig. 5.2).
Example 2: PLET
Solution:
Stand-off aluminum alloy anodes placed on subsea structure
D.4.6.5
Calculation of anode mass
Calculation of the required net anode mass (Ma) for the required mean current demand Icm (see D.4.6.3)
for each section.
The Table 5.8 (Geographic area, Water temperature), D.4.1, D.4.2 (Table 5.12), und D.4.3 (Table 5.13)
shall be considered.
Ma = Icm t 8760 / 1000 u1 1
(11)
Ma
: net anode mass [kg]
Icm
: required mean current demand [mA] (D.4.6.3)
: design life (years)
8760
: refers to hours per year
: anode utilization factor (Table 5.13)
: anode current capacity [Ah/kg] (Table 5.12)
Example 1: Tripod
Solution:
Section 1:
Selection of Anode current capacity 1 (1 = section 1) in seawater, considering anode material (Table
5.12: Alloy A2) and sea water temperature (Table 5.8: West Africa water temperature 5 -21): 1 = 2000
[Ah/kg]
Selection of utilization factor u1 (1 = section 1) considering Anode Type Stand-off with L 4 r (Table
5.13): u1 = 0.9
Calculation of net anode mass Ma1 of section 1:
Ma1 = Icm1 t 8760 / 1000 u1 1 = 3855 30 8760/ 1000 0.9 2000 = 562 kg
where: Icm1 = 3855 mA, t = 30 years
Section 2:
Selection of Anode current capacity 2 (2 = section 2) in sediment, considering anode material (Table
5.12: Alloy Z1) and sea water temperature (Table 5.8: West Africa water temperature 5-21): 2 = 750
(Ah/kg)
Selection of utilization factor u2 (2 = section 2) considering Anode Type Flush-mounted (Table 5.13):
u2 = 0.85
Ma2 = Icm2 t 8760 / 1000 u2 2 = 4760 30 8760 / 1000 0.85 750 = 1962 kg
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Example 2: PLET
Solution:
Section 1:
Selection of Anode current capacity 1 (1 = section 1) in seawater, considering anode material (Table
5.12: Alloy A3) and subsea water temperature of 13 C: 1 = 2000 (Ah/kg)
Selection of utilization factor u1 (1 = section 1) considering Anode Type Stand-off with L 4 r (Table
5.13): u1 = 0.9
Ma1 = Icm1 t 8760 / 1000 u1 1 = 988 25 8760 / 1000 0.9 2000 = 120 kg
D.4.6.6
Calculation of anode number
D.4.6.6.1 Acceptance criteria

The calculation shall be iterative, starting with a commercially available product sizing, e.g. example Tripod, section 1 with Ma1 = 562 kg, N = 4 (stand-off anode with anode net weight of ma = 150 kg). The result
of the iteration shall be:
.1
The number of initial (new) anodes (Ni) of one section multiplied with the initial anode current output (Iaio) of one anode shall be equal or larger than the required initial current demand (Ici) of the section.
Ici Ni Iaio
(12)
.2
The Number of final (consumed) anodes (Nf) of one section multiplied with the final anode current
output (Iafo) of one anode shall be equal or larger than the required final current demand (Icf) of the section.
Icf Nf Iafo
(13)
.3
The Number of anodes (N) based on mean current output of one section multiplied with the mean
current capacity (Cao) of one anode shall be equal or larger than the required mean current output of the
section.
Ca = N Cao Icm t 8760 / 1000
(14)
The following clauses, Figures and Tables shall be considered:

B.3, Table 5.4: Protective Potentials for various metals in sea water
D.4.2, Table 5.12: Closed circuit anode potential Ea
D.4.4, D.4.5, and Table 5.14: Calculation of Anode Resistance
In the case of stand-off anodes the dimensions of the insert and the support are to be designed taking
into account the weight of the anodic alloy and with the various environmental loading conditions as detailed in ISO 12495 Chapter 5.5.4 Structural considerations, see D.4.3.
The design protective potential Ec for all metals of Table 5.4 in seawater and anaerobic environment
(sediment, mud) shall be 800 mV.
Iteration with N
Iaio
Iaio =
(Ec Ea)
Rai
(15)
Iaf o =
(Ec Ea)
Raf
(16)
Ca o = mam u
(17)
: initial current output of one anode [mA]
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Iafo
: final current output of one anode [mA]
Ea
: closed circuit anode potential [mV] (see Table 5.12)
Ec
: Design protective potential [800 mV]
Rai
: initial anode resistance of the new anode [ohm] (D.4.4)
Raf
: final anode resistance consumed to its utilization factor u [Ohm]
Cao
: Anode mean current capacity of one anode [Ah]
mam
: mean anode net mass of one anode [kg]
: Anode utilization factor (Table 5.13)
: Anode current capacity [Ah/kg] (Table 5.12)
D.4.6.6.2 Calculation of initial and final anode resistance

The final net anode mass maf and final volume Vaf is given by:
maf = mai (1 u)
Vaf =
(18)
maf
(19)
mai
: initial anode net mass of the new anode [kg]
maf
: final anode net mass consumed to its utilization factor u [kg]
: Density of the anode material [kg/m3] (Table 5.12)
Vaf
: final volume of the final anode [m3]
The final dimensions and final anode resistance Raf of the different anode shapes can be calculated as
follows:
Stand-off anodes:
Vaf =
maf (daf 2 dac 2 )

=
Laf
(20)
daf
: final diameter of the anode (daf = 2 raf) [m]
dac
: core diameter [m]
raf
: final radius of the anode [m]
Laf
: final length of the anode shall be: Laf = Lai 0.9 [m]
Lai
: initial length of the anode [m]
maf dac2 Lai 0.9

4
daf =
+

Lai 0.9
4
(21)
Raf calculation with the equations (4) and (5) of D.4.4:

Stand-off anodes, if L 4 r:
Raf =
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4 Laf
ln raf 1
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Stand-off anodes, if L < 4 r:

ln 2 Laf
raf

Raf =
2 Laf
+ raf
2 Laf
1 + 1 + raf
2 Laf
2
raf
1+
2 Laf
(23)
Raf
: final anode resistance [ohm]
: sea water resistivity [ohm m] (see D.4.5, Table 5.8 and Table 5.14)
Laf
: Lai 0.9 = final length of the anode [m]
raf
: daf/2 = final radius of the anode (for other shapes than cylindrical, assuming that the final
anode shape is cylindrical) [m]
Flush-mounted anodes:
The shape of flush-mounted anodes are almost similar to the non cylindrical stand-off anodes (see Fig.
5.2). The final shape shall be assumed to be semi-cylindrical and the final length (Laf), final radius (raf)
shall be calculated with the equations (20) and (21).
Vaf =
maf (daf 2 dac 2 )

=
Laf
(20)
daf
dac
: core diameter (for other shapes than cylindrical, dac = C/, where C [m] = cross section periphery) [m]
raf
Laf
Lai
maf dac2 Lai 0.9

4
daf =
+

Lai 0.9
4
(21)
Raf calculation with the equation (6) of D.4.4:

Raf =
2 Saf
Raf
: final anode resistance [Ohm]
: sea water resistivity [Ohm m] (see D.4.5, Table 5.8 and Table 5.14)
Laf
: Lai 0.9 = final length of the anode [m]
daf
: final diameter of the anode (for other shapes than cylindrical, assuming that the final anode
shape is cylindrical) [m]
Saf
: (Laf + daf) / 2 = arithmetic final of anode length and diameter [m]
Bracelet anodes:
For bracelet anodes the final exposed area (Aaf) shall be assumed to be equivalent to the initial exposed
area (Aai).
Raf calculation with the equation (7) of D.4.4:
Raf =
Raf
0,315
Aaf
: final anode resistance [Ohm]
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Section 5
: sea water resistivity [Ohm m] (see D.4.5, Table 5.8 and Table 5.14)
Aaf
: exposed final surface area of anode [m2]
D.4.6.6.3 Calculation of initial and final current output and mean current capacity of the anodes
Example 1: Tripod
Solution:
Section 1:
Selection of stand-off anode size (see Fig.5.2, not cylindrical), closed circuit anode potential Ea =-1050 mV
(Table 5.12), design protective potential Ec = -800 mV, anode current capacity =2000 Ah/kg (Table 5.12)
and Anode utilization factor u = 0.9 (Table 5.13).
The following parameters may be selected, if Ma1= 562 kg:
N
: 4 (Number of anodes)
mai
: 150 (initial anode weight) [kg]
: 2725 (density of the anode material Table 5.12) [kg/m3]
Lai
: 1.77 (initial anode length) [m]
: 0.184 (initial anode width) [m]
: 0.184 (initial anode depth) [m]
dac
: 0.06 (core diameter) [m]
: 0.9
: 0.24 (average water temperature of West Africa acc. to Table 5.8: 13 C); salinity may be 35
ppt; resistivity 0.24 [Ohmm] acc. to Table 5.14) [Ohm m]
Calculation of Rai according to formula (4):
rai =
C
= 0.117 [m]
2
Rai =
2 Lai
C = 2 W + 2 D = 0.736 [m]
4 Lai
ln rai 1 = 0.067 [Ohm]
Calculation of Raf according to formular (22):

maf = mai (1 u) = 15 [kg]
Vaf =
maf
(see (18))
(see (19))
= 0.0055 [m3]
maf
: final anode net mass consumed to its utilization factor u [kg]
Vaf
: final volume of the final anode [m3]
maf dac 2 Lai 0.9

4
daf =
+
= 0.089 [m]
Lai 0.9
daf
raf
Laf
Lai
Raf =
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4 Laf
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ln
2 Laf
raf
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(see (21))
(see (22))
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D.4.6.6.4 Examination of fulfillment of acceptance criteria:

Example 1: Tripod
Solution:
Section 1:
Ec
: 800 mV
Ea
: 1050 mV
Iaio
: initial current output of one anode [mA]
Iafo
: final current output of one anode [mA]
Raf
: final anode resistance consumed to its utilization factor u [Ohm]
Cao
: Anode mean current capacity of one anode [Ah]
mam
: mean anode net mass of one anode [kg]
: 2000 Ah/kg (anode current capacity)
Iaio =
Iaf o =
( Ec Ea )
Rai
( Ec Ea )
Raf
= 3730 mA
(see (15))
= 2632 mA
(see (16))
Cao = mam u = 270 000 Ah
(see (17))
Acceptance Criteria:
.1
Ici1 N Iaio = 4 3730 = 14920 mA; Ici1 = 1285 mA;
(see (12))
.2
Icf1 N Iafo = 4 2632 = 10528 mA; Icf1 = 9351 mA;
(see (13))
.3
Ca = N Cao Icm1 t 8760/1000 = 1013094 Ah; Ca = 1080000 Ah;
(see (14))
If the equations 13, 14 and 15 cannot be fulfilled for the initially selected dimensions and/or numbers,
another anode size and/or numbers shall be selected and the calculation repeated until the criteria are
fulfilled.
D.4.7
Location of anodes
Based on the calculated number of anodes required for different zones of the structure, for the distribution
of anodes EN 12495 and EN 13173 and the following aspects shall be considered:
anodes shall be uniformly distributed
anodes for the splash zone shall be located on the upper level of immersed zone
anodes shall be located nearer complex and critical points such as node areas, but not closer than
600 mm to nodes
anodes protecting conductor pipes shall be uniformly distributed at the different levels in their immediate proximity on the conductor guide frames
anodes corresponding to the current drain of wells shall be uniformly distributed over all the immersed part of the structure
on legs, the anodes shall face the centre of the structure
on diagonals, the anodes shall be alternately placed on the upper and lower surface if more than
one anode is required
on horizontal bracings at different levels, the anodes shall be installed alternately facing up and
down with the exception of the uppermost level where they shall be mounted facing downwards
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The adequacy of the current distribution can be improved using a greater number of anodes, which
have a lower individual electrical current output.
The location of all individual anodes shall be shown on drawings. With the exception of stand-off anodes,
coating with minimum a coating category II (Table 5.6) shall be applied to the anode surface towards the
protection object.
D.4.8
Anodes' inserts and attachments design
The method of attachment of the anodes to the structure shall be in accordance with EN 12495 and EN
13173.
D.4.9
Documentation of Cathodic Protection Design Report
The Cathodic Protection Design Report shall contain the following parts:
design criteria including the design life, the environment characteristics (see Table 5.8 and 5.14), the
protection criteria, the electrical current density requirements (see Table 5.8, 5.9, and 5.10), the assumed values of the anode current output at these various periods, and the anode theoretical current capacity and closed circuit anode potential (see Table 5.12) incl. all relevant project specifications, codes, standards, literatures;
subdivision of the object in sections incl. to all design data (see D.4.6.1)
surface area calculation of all sections (see D.4.6.2)
current demand calculation (see D.4.6.3)
calculation of minimum required net anode mass (see D.4.6.5)
calculation of minimum anode number (see D.4.6.6)
calculation of initial and final anode resistance (see D.4.6.6.2)
calculation of initial and final current output and mean current capacity of the anodes (see D.4.6.6.3)
examination on fulfillment of acceptance criteria (see D.4.6.6.4)
the number of galvanic anodes, their dimensions (see Fig. 5.2), weight, specification, chemical composition (see Table 5.11), practical consumption rate or current capacity (as measured during laboratory tests, see D.4.2.2), utilization factor (see Table 5.13), as well as the manufacturer/suppliers
references and documentation
anode location drawings (see D.4.7)
anode attachment drawings (see D.4.8)
D.4.10
Design of monitoring system
Permanently installed monitoring systems may be used with galvanic anodes system.
The monitoring system of a cathodic protection system measures and may be used to control the operating parameters and the effectiveness of the cathodic protection system. EN 12495 and EN 13173 shall be
used as a guideline.
D.4.11
Commissioning and surveying
The objectives of the commissioning and the survey of the cathodic protection system are:
to ensure that the cathodic protection system functions in accordance with the intentions of the design at structure installation
to establish if the cathodic protection system is continuing to perform in accordance with the design
and that the structure remains satisfactorily protected from corrosion
a cathodic protection survey of the entire structure shall be performed within three month for bare
steel structure or one year on coated structures from the installation of the structure
the survey should include the measurement of the potential at selected locations
the actual location and status of the anodes should be verified and recorded
The documentation of commissioning and surveying shall include:
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the location of each and every anodes as checked during construction or after positioning, all discrepancies with the design location being highlighted in the as-built drawings, the method of attachment, the date of installation; these data should be updated during the life of the structure
the description, specification and position of any electrical current or potential control or monitoring
device, including type of reference electrode, measuring equipment, and connecting cables
the commissioning results including the potential survey data
D.4.12
Safety and cathodic protection
The cathodic protection system shall comply with all safety standards and regulations related to electrical
equipment that may apply to fixed steel offshore installations.
Herewith the safety hazards due to cathodic protection systems and related to diving personnel during
their underwater operations are defined. The galvanic anodes system will be considered, in association
with physical obstruction and evolution of dangerous gases.
The major risk from anodes is the entanglement of the divers umbilical or life line around the anodes or
the anode supports, and the mechanical damage to the equipment due to chafing. Thus the following
galvanic anode and anode assembly characteristics are recommended (see Fig. 5.2):
stand-off anodes with J-shaped cylindrical stand off supports, protruding from anode extremities
flush- mounted anodes
bracelet anodes
Similarly, anode cable conduits, junction boxes, etc. shall be designed to exclude any sharp edges or
corners or protruding extremities.
Polarization of the structure to potential more negative than 800 mV can result in the evolution of hydrogen gas at the steel surface. If the gas is allowed to collect in confined air spaces, such as cofferdams
which are only part full of sea water, it may present a risk of explosion. All designs shall include an adequate venting to prevent the build up of hydrogen.
D.5
Impressed current system
D.5.1
The impressed current system for fixed steel offshore structures and floating structures usually includes a
variable transformer rectifier and one or several anodes and normally a number of reference electrodes.
Manually adjustable rectifiers are generally selected because the current demand does not vary significantly with time.
Rectifiers with automatic potential control may be used in particular cases where the environment condition and the structure configuration induce large and frequent variations of the current demand.
Specific areas presenting particular situations may even require the consideration of a multi-zone control
system in order to adapt and optimize the current distribution to the protection demands, the control of the
protection of each zone being performed by a separate specific impressed current system.
The number and location of the anodes shall be determined in order to achieve, as far as is practical an
adequate protective potential level.
Individual impressed current anodes usually deliver higher electrical currents than galvanic anodes, therefore with impressed current anodes either dielectric shields or larger anode to structure separation should
be used to prevent localized over-polarization and improve the electrical current distribution to the cathode.
D.5.2
Direct current power source
The transformer rectifier or controllable DC generator shall be able to deliver the total current demand to
the zone it is intended to protect.
The output voltage shall take into account the resistance of the electric circuit (cables, anodes) and the
back e.m.f. (back electromotive force) between the anode and the cathode. The back e.m.f. is the naturally occurring open circuit potential difference between the anode and the cathode in sea water.
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The transformer rectifier shall be able to deliver sufficient

steel / sea water / reference electrode potential within the design range.
current
to
maintain
the
DC power source with automatic potential control shall deliver an electrical current when one of the reference electrodes used for the control of the DC power source leads to a potential reading less negative
than the set minimum negative potential or more negative than the set maximum negative potential (see
Table 5.4).
There shall be devices to limit the output current to each anode to a pre-set value.
A DC power source without current limitation circuits should have an effective shutdown in the event of an
external short circuit.
D.5.3
Anode materials
Anodes used for impressed current systems can be of two main types: semi-consumable or inert anodes.
Platinum coated titanium and niobium anodes were claimed to be the most commonly used electrodes for
cathodic protection of large offshore structures. Lead alloy anodes were listed as being popularly used to
protect semi-submersible drilling rigs.
Impressed current anodes, unlike galvanic anodes, can be driven over a wide range of anode current
densities, depending on the designers preferences and the demands of a particular application. Because
anode current loadings have a definite bearing on consumption rates, any meaningful listing of consumption rates for various anode materials shall necessarily include the approximate anode current density at
which such rates have been established.
Table 5.15 lists consumption rates, associated anode current densities of various impressed current anode materials used for CP systems on offshore structures.
Platinum is the ideal permanent impressed current anode material. It is one of the most noble metals and
in practically all environments forms a thin invisible film which is electrically very conductive. In addition,
the exchange current densities of most anodic reactions on the Pt surface are greater than on other anode materials. Due to its high cost, platinum is applied as a thin coating (15 m) on metallic substrates
such as titanium, niobium and tantalum.
To avoid the dissolution of titanium at unplatinized locations on the surface, the operating voltage of the
anode is limited by anodic breakdown potential of titanium which is in the range of 9 to 9.5 V in the presence of chlorides. Hence the maximum recommended operating voltage of platinized titanium anodes is
8 V. The corresponding maximum current density output is approximately 1 kA/m2.
For cathodic protection systems where operating voltages are relatively high, niobium and tantalum based
anodes are generally selected. This is because these two substrates have anodic breakdown potentials
greater than 100 V in chloride containing electrolytes.
Table 5.15 Typical electrochemical characteristics for impressed current anodes
Consumption rate
[g/A y]
Max. current density

[A/m2]
Max. Voltage [V]
Platinized Titanium
0.0012 to 0.004
500 to 3000
Platinized Niob
0.0012 to 0.004
500 to 3000
50
Platinized Tantalum
0.0012 to 0.004
500 to 3000
100
Mixed
Metal Oxide
0.0006 to 0.006
400 to 1000
Lead Silver
25 to 100
250 to 300
24
Chromium silicon iron
250 to 500
10 to 30
50
Anode materials
Note
EN 12945 and EN 13173
The rate of platinum consumption has been found to accelerate in the presence of AC current ripple. Most
consumption was observed to occur with AC frequencies of less than 50 Hz. Ripples frequencies less
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than 100 Hz should be avoided. The repeated oxidation/ reduction processes result in the formation of a
brownish layer of platinum oxide. To avoid the occurrence of this phenomenon, a single or a three phase
full-wave rectification is recommended. The consumption rate of platinized anodes is also adversely affected by the presence of organic impurities such as sugar and diesel fuel.
D.5.4
Anode shapes and installation
Impressed current systems are more critical with respect to mechanical damage because relatively few
anodes, each discharging a substantial amount of protective current, are involved. The loss of an anode
can seriously reduce system performance.
The electrical connection between the anode lead cable and the anode body shall be watertight and mechanically sound.
Cable and connection insulating materials should be resistant to chlorine, hydrocarbons, and other deleterious chemicals.
Care shall be taken to provide suitable mechanical protection for both the anode and its connecting cable.
On suspended systems, the individual anodes or anode strings may be equipped with winches or other
retrieval means as a damage- preventing measure during severe storms or for routine inspection and
maintenance. The loss of protection during these periods should be considered.
Acceptable methods of installing fixed-type impressed current anodes include, but are not limited to, the
following:
D.5.4.1
Tubular, rod and wire anodes
Tubular, rod, and wire anodes can be installed at the lower ends of protective vertical steel pipe casings
or conduits. Casings should be attached to above-water structure members and supported at repeating
members below water. The anodes should be lowered through the casings (which protect the anode lead
wires) and should be allowed to extend below a termination fitting at the bottom of each casing. This
method provides a means of anode retrieval or replacement using the anode cable, without diver assistance. Marine growth or corrosion scale may make anode retrieval difficult.
D.5.4.2
Flush mounted anodes
Flush- mounted anodes, insulating-type holders can be attached directly to submerged structure members or to auxiliary structural members, such as vertical pipes, which can be removed for anode replacement. Properly designed systems of the latter type permit anode retrieval without diver assistance.
D.5.4.3
Stand-off anodes
Stand-off anodes can be installed on submerged structure members. Diver assistance is required for this
type of anode replacement.
D.5.4.4
Bottom-installed anodes
Bottom-installed anodes are typically mounted on specially designed concrete sleds for stability; this
minimizes the possibility of their becoming covered with mud or silt.
D.5.4.5
Location of anodes
All precautions shall be taken to avoid any leakage of water through the hull penetration. It is usually a
requirement to fit a cofferdam. Typical anode mountings with cofferdam arrangement are given in EN
13173 annex D.
Impressed current anodes should be located as far as practical from any structure member (usually a
minimum distance of 1.5 m, but proportional to current magnitude (see Table 5.15). If a spacing of 1.5 m
is not feasible a dielectric shield should be used to minimize wastage of protective current by localized
overprotection.
Anode holder should be designed to avoid such wastage and to minimize the possibility of a short circuit
between the anode and the structure.
There may be a delay of several months to a year or more between the time a structure is set until permanent electrical power becomes available. Plans should be made for either temporary power and early
energizing of impressed current systems or a short-term galvanic anode system (see also D.3). Other-
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wise, serious corrosion of structure members, as well of as the underwater components of the impressed
current system, can occur.
D.5.5
Dielectric shields
The objective of dielectric shields, and coatings used as dielectric shields, is to prevent extremely high
current densities and current wastage in the vicinity of the anodes. This serves to promote more uniform
protective current distribution.
Materials selected shall be suitable for the intended service.
Liquid applied coatings, fiberglass reinforced plastic, prefabricated plastic or elastomeric sheets can be
used on the structure adjacent to the anodes, or incorporated into the anode assembly.
The electrochemical reactions occurring at the anode and cathode surfaces produce corrosive products
and gases which may deteriorate the dielectric shield or include its disbanding.
The design of the dielectric shield should take into account the possible deterioration and aging characteristics of the materials.
Liquid applied coatings, prefabricated plastic or elastomeric sheets can be used on the structure adjacent
to the anodes, or incorporated into the anode assembly.
D.5.6
Reference electrodes
Reference electrodes are used to measure the steel to electrolyte potential and may be used to control
the output current of the cathodic protection system. They are either zinc or silver/silver chloride/sea water electrodes (see ISO 12473). Zinc electrodes are more robust whereas silver/silver chloride/sea water
electrodes are more accurate.
When reference electrodes are used to control the impressed current system, they should be installed at
locations determined by calculations or experience to ensure the potential of the structure is maintained
within the design set limits (see Table 5.4).
Precautions should be taken in order to avoid any direct electrical contact between the electrodes and the
steel structure.
D.5.7
Cathodic protection calculation and design procedure
The required current demand for each section of the object shall be calculated as described in D.4.6.1 to
D.4.6.3.
For current demand determination of floating structures, the underwater surface area should always include the boot topping, but never the atmospheric zone.
To compensate for a less efficient current distribution (small number of anodes), the impressed current
coating protection system shall be designed to be able to provide 1.25 to 1.5 times the calculated total
current demand, which is the total design current demand.
Example 1: Tripod
C.2:
Calculation of coating breakdown factors (Table 5.7)
D.1 and D.2:Required design current densities of geographic areas and in specific areas of the structure
(Table 5.8, and 5.9).
Solution:
Section 1: Coating category IV.
k1
= 0.015, k2=0.005
Selection of design current densities (Table 5.8: West Africa):

ici1= 130 mA/m2, icm1= 65 mA/m2, icf1= 86 mA/m2
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fci1
= k1 = 0.015
fcm1
= k1 + k2 t/2 = 0.015 + 0.005 30/2 = 0.09
fcf1
= k1 + k2 t
= 0.015 +0.005 30 = 0.165
Calculation of required current demands: Ici1, Icm1 and Icf1 for Ac1=659m2
Ici1
= Ac1 ici1 fci1
= 1285 mA
Icm1
= Ac1 icm1 fcm1
= 3855 mA
Icf1
= Ac1 icf1 fcf1
= 9351 mA
Multiplied with a factor of 1.5 the minimum required total current demand shall be:
Icf1tot = 1.5 Icf1 = 14027 mA
For any cathodic protection system, the size of the anodes shall be determined using Ohm's law. In the
case of inert anodes, like platinized or mixed metal oxide anodes the anode resistance Ra will be stable
during the life time, because no change of the dimensions will occur. In case of semi- consumable anodes, like lead silver and chromium silicon iron the initial and final anode resistance shall be considered
(see D.4.6.6).
Ia =
( Ec Ea )
(see 15)
Ra
Ia
: current output of anodes [mA]
Ea
: Closed circuit potential (see Table 5.15) [mV]
Ec
: Design protective potential (see Table 5.4) [mV]
Ra
: anode resistance (D.4.4)
The anodic resistance is a function of the resistivity of the anodic environment and of the geometry (form
and size) of the anode. The equations (4) and (5) for Stand-off anodes, (6) for Flush-mounted anodes and
(7) for Bracelet anodes shall be used.
The acceptance criteria:
The maximum value of Ici, Icm, and Icf multiplied with a factor of 1.5 shall be smaller than the current
output of the anodes.
D.5.8
Design of monitoring system
Permanently installed monitoring system shall be used with impressed current systems.
The monitoring system of a cathodic protection system measures and may be used to control the operating parameters and the effectiveness of the cathodic protection system.
The cathodic protection is an active system, i.e. it is effective only when the impressed current systems
are operating and provide adequate polarization of the steel to achieve the protection criteria stated.
Therefore, the steel potential should be measured during the life of the structure in order to verify the
adequacy of the protection.
The monitoring system may include the following:
Permanent reference electrodes. The reference electrode should be installed and secured on each
immersed level of the structure, close to the steel surface, and at locations as mentioned in D.5.4.
These reference electrodes shall be electrically insulated from the structure and connected to the
data transmission system.
Conduit systems, cables, junction boxes, data transmission systems shall be in accordance to EN
12495
D.5.9
Potential measurements
The potential measurements shall be conducted in accordance to EN 12495 and EN 13173.
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D.5.10
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Commissioning and surveying
For the commissioning of the impressed current cathodic protection system the following operations shall
be carried out:
check wiring to ensure correct polarity (negative terminal to structure)
switching-on the transformer-rectifier(s) to supply direct current to the structure
monitoring of the structures potentials with the monitoring system until the required potential values
are reached
A cathodic protection potential survey of the structure should be performed within one month of the commissioning of the cathodic protection system.
This survey should include the recording of the structure potential at selected locations. The actual location and status of anodes, cables, conduits, monitoring system should be verified and recorded.
D.5.11
Documentation
The following data should be kept for reference and permanently updated, if applicable:
design criteria including the design life, the environment characteristics (see Table 5.8 and 5.14), the
protection criteria, the electrical current density requirements (see Table 5.8, 5.9, and 5.10) the assumed values of the anode current output (Table 5.15) incl. all relevant project specifications, codes,
standards, literatures
subdivision of the object in sections incl. to all design data (see D.4.6.1)
surface area calculation of all sections (see D.4.6.2);
current demand calculation (see D.4.6.3)
calculation of anode resistance (seeD.4.4)
calculation of the required current output of the anodes (see D.5.7)
examination on fulfillment of acceptance criteria (see D.5.7)
the number of anodes, their dimensions, specification (see D.5.7 and Table 5.15), description of anodic equipment and connection, effective output current densities, associated consumption rates and
allowable voltage (see Table 5.15), as well as the manufacturer/suppliers references and documentation
the description and means of attachment of anodes, the composition and location of any dielectric
shield, as well as the specification, characteristics and attachment method and through wall or
through hull arrangements of the connecting cables (see D.5.4 and D.5.5)
the location of each and every anodes as checked during construction or after positioning, all discrepancies with the design location being highlighted in the as-built drawings, the method of attachment, the date of installation; these data should be updated during the life of the structure (see
D.5.4)
the location, detailed specification, drawings, and output characteristics of each DC power source
with their factory test reports (seeD.5.2)
the location, description and specification of any protection, potential control or monitoring device,
including reference electrode, measuring equipment and connecting cables (see D.5.6, D.5.8, and
D.5.9)
the commissioning results including the potential survey data; current and voltage output values of
each DC power source and any adjustment made for non-automatic devices (see D.5.10)
the results of data recorded during periodic maintenance inspection including protection potential
values, DC output values, maintenance data on DC power sources and downtime periods in order to
follow the changes of the protection potential level status of the structure.
D.5.12
Safety and cathodic protection
The cathodic protection system shall comply with all safety standards and regulations related to electrical
equipment that may apply to fixed or floating steel offshore installations.
This clause deals with safety hazards due to cathodic protection systems and related to diving personnel
during their underwater operations. The galvanic anodes system will be considered, in association with
physical obstruction, electric shock and evolution of dangerous gases.
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The major risk from anodes is the entanglement of the divers umbilical or life line around the anodes or
the anode supports, and the mechanical damage to the equipment due to chafing.
Similarly, anode cable conduits, junction boxes, etc. should be designed to exclude any sharp edges or
corners or protruding extremities.
In the event that the impressed current cathodic protection system equipment is defective, or the diver
inadvertently makes direct contact with the active anode element, he may suffer an electric shock.
During diving operations not directly related to cathodic protection system, and any diving inspection carried out close to impressed current anodes, the DC supply of the anodes shall be switched off. However,
diving cathodic protection inspection may be performed, with the impressed current system in operation,
providing all relevant safety regulations and precautions are applied (see EN 12495 annex D).
Polarization of the structure to potential more negative than 800 mV can result in the evolution of hydrogen gas at the steel surface. If the gas is allowed to collect in confined air spaces, such as cofferdams
which are only part full of sea water, it may present a risk of explosion.
To avoid this hazard, the following measures should be taken:
all designs to include an adequate venting to prevent the build up of hydrogen
the structure to electrolyte potential to be kept at values less negative than the threshold value at
which hydrogen evolution is not significant. This can be achieved by ensuring that a minimum distance should be kept between the structure and impressed current anodes.
Electrochemical reactions at the surface of impressed current anodes in sea water invariably result in the
evolution of chlorine gas which is highly toxic and corrosive. If this is allowed to collect in confined air
spaces above the water line, it may present a hazard to personnel and materials.
To avoid this hazard, all design shall prevent the build up of gas.
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Foundations
Section 6
A
B
C
D
E
Foundations
General ....................................................................................................................... 6-1

Geotechnical Investigations ........................................................................................ 6-1
General Design Considerations .................................................................................. 6-2
Steel Pile Foundations ................................................................................................ 6-4
Shallow Foundations................................................................................................... 6-8
General
A.1
Scope
This Section applies to the foundations of fixed offshore structures and covers piled as well as gravity
type designs. Requirements regarding self-elevating platforms (mobile units) see GL Rules for Mobile
Offshore Units (IV-6-2), Section 2.
A.2
Foundation design
The foundation design of fixed offshore structures shall consider all types of loads which may occur during installation and operation of the structure. The design can be carried out according to the following
standards:
API Recommended Practice 2A-WSD (RP 2A-WSD) for pile and shallow foundations
or
ISO 19902:2007 (same as DIN EN ISO 19902:2008-07) for pile foundations
ISO 19901-04:2003 (same as DIN EN ISO 19901-4:2005-07) for general requirements and shallow foundations
A.3
Soil
The soil behaviour and its interaction with the foundation shall be investigated with special regard to
static, dynamic and transient loading.
A.4
Evolution of foundations
The design practise for foundations has proved to be very innovative and this evolution is expected to
continue. Therefore circumstances may arise when the procedures described herein are insufficient on
their own to ensure that a safe and economical foundation design is achieved. In such a case new requirements have to be discussed and agreed by GL.
Geotechnical Investigations
B.1
Field investigation
The field investigation shall be carried out at the actual site, defined as the area within which the structure
may be installed, including accepted tolerance limits from theoretical centre. The field investigation programme shall comprise but not necessarily be limited to the following:
site geology survey in order to establish geological conditions in general
geophysical explorations for the purpose of extending the localized information from the borings and
in situ testing
bottom topography including registration of rocks or hard objects on the bottom
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soil sampling to ensure a sufficient number of good quality samples, that will allow the properties of
all important layers to be determined
in situ cone penetration tests (or other equivalent in situ test) performed, if possible, to a depth that
will cover the critical shear zone
The actual extent of a geotechnical field investigation has to be set up individually for each site.
B.2
Boring vessel
B.2.1
Positioning system
The boring vessels shall be equipped with a positioning system which ensures an adequate accuracy of
borehole positioning.
B.2.2
Laboratory and personnel
The boring vessel shall contain a high quality soil laboratory for classification and testing of soil specimens. The opening of samples on board, the visual inspection and the classification of the soil shall be
performed by qualified geotechnical personnel.
B.3
Samples
The handling, storage and transport of soil samples shall be such as to retain a satisfactory sample quality.
General Design Considerations
C.1
Influences to be considered
The design of foundations shall take account of all effects which may be of influence on deformations,
bearing capacity and installation of the foundation system.
C.2
Characteristics of soil layers
For each soil layer the physical properties shall be thoroughly evaluated with the help of in-situ and laboratory testing.
The main parameters for the foundation design are:
For sand:
effective friction angle '
[degrees]
submerged unit weight '
[kN/m3]
Youngs modulus E
[Mpa]
initial soil modulus K
[MN/m3]
For clay:
undrained shear strength cu
[kN/m2]
submerged unit weight '
[kN/m3]
Youngs modulus E
[Mpa]
Strain at 50 % of failure e50
[-]
C.3
Cyclic loads
C.3.1
The effect of cyclic loading, which may cause a reduction of shear strength and bearing capacity of the soil, shall be investigated.
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C.3.2
Especially for structures installed in seismically active areas the proneness of the soil to partial
liquefaction and possibly resulting reduction in soil strength and stiffness have to be evaluated with great
care.
C.4
Scour
C.4.1
The possibility of scour or undermining around the foundation shall always be investigated.
Normally cohesive soils are not prone to scour but for a cohesionless soil condition global and local scour
may occur.
In case that scouring is possible,
the foundation has to be protected by suitable means
alternatively, the foundation has to be considered to be partly unsupported
C.4.2
If no other data are available for the specific site conditions, the scour depth at pile foundations may be estimated as 1.5 d (d = pile diameter) for design purposes including an overburden reduction depths of 6 d, please refer to API or ISO.
Experience shows that 1.5 d is not conservative for the German sector of the North Sea. We recommend applying 2.5 d for these locations
C.4.3
The design criteria shall be verified by regular surveys, see GL Rules for Certification and
Surveys (IV-7-1), Section 4. Countermeasures shall be taken in case of exceeding the limits established
in the design.
C.5
Hydraulic stability
The hydraulic stability shall be investigated for those types of foundations which may exhibit significant
hydraulic gradients within the supporting soils.
C.6
Soil stability
C.6.1
If necessary, due to existing slope or due to installation effects, the risk of slope failure or the
possibility of a deep slip shall be investigated.
C.6.2
Total or effective stress analysis shall be used for soil stability investigations.
C.6.3
Especially for soft, normally consolidated clays or loose sand deposits consideration of seafloor instability is required.
C.6.4
Seabed movements due to action of waves, earthquake or operational effects, e.g. drilling,
dredging, may cause reduced resistance or increased loading and shall be investigated.
C.7
Settlements and displacements
Long term settlements and displacements of the structure as well as the surrounding soil shall be monitored.
C.8
Load deformation behaviour
The load deformation behaviour of a piled foundation is to be analysed with special regard to possible
structural interaction.
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Steel Pile Foundations
D.1
General
D.1.1
shore:
Among several existing types of pile foundations the following are most frequently used off-
open ended and driven piles

driven and underreamed piles
drilled and grouted piles
Many other designs are used to suit the needs of the individual soil conditions.
D.1.2
For each type of pile foundation the soil-pile interaction and pile capacity have to be evaluated
with due regard to site specific soil conditions.
D.1.3
The following paragraphs are not intended for monopole foundations.
D.2
Pile design, design methods
D.2.1
The design of piled foundations has to fulfil requirements for axial and lateral bearing capacity,
load-deflection behaviour (non-linear springs) and displacements.
D.2.2
Among others the following factors will affect the design: diameter and wall thickness, penetration, mudline restraint, material, pile footing, pile group spacing (if applicable) and installation method.
D.2.3
The design method has to incorporate the pile geometry, properties and arrangement. It
should be capable of simulating the non-linear properties of the soil and be compatible with the load displacement behaviour of the structure and pile foundation system.
D.2.4
Displacements and rotations shall be checked for individual piles and pile groups.
The design shall consider bending moments as well as axial and lateral loads.
D.2.5
In D.3 axially loaded piles are treated according to API ASD method whereas D.4 describes
the method according to ISO LRFD. D.5 and following subparagraphs treat the other pile related requirements which are identical in both standards (API and ISO).
D.2.6
In D.11 additional requirements of the German authority BSH (Bundesamt fr Seeschiffahrt
und Hydrographie) are summarized.
D.3
Axially loaded piles acc. to ASD-Method
The allowable stress design (ASD) method has to be carried out according to API RP 2A-WSD latest
revision.
D.3.1
Design loads
The design loads are defined in Section 3, C.2 The resulting axial load (from the design load combinations) in the pile is FA.
D.3.2
Design format for axial capacity
The required design axial pile capacity may be expressed as follows:
FA
Qd
Vg
FA
: Axial pile load from design load combination
Qd
: Ultimate bearing capacity
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: Global safety factor for pile capacity, factors in Table 6.1 are valid for main-text- method of
API
gg
Qd has to be calculated according to API RP 2A-WSD. There are 2 principal methods how to calculate Qd.
One is described in the main text and the other methods (CPT-based) are explained in detail in the commentary part of the API.
If one of the CPT-based methods from the commentary part of the API is applied the global safety factors
have to be agreed upon with GL. The applied additional safety factor has to be justified by rational analysis and soil expert statement.
Safety factors g for different loading conditions
Table 6.1
Loading conditions
No.
Safety factor g
Designation
Operating loads
2.0
Extreme environmental loads with specified max. vertical loads
1.5
Extreme environmental loads with minimum weights (for pullout)
1.5
D.3.3
Pile stresses
Pile stresses have to be checked according to corresponding interaction formulas (refer to chapter 3 of
API) for the design loading conditions. The pile is mostly loaded by axial loads and bending moments.
The calculation of stresses should consider the horizontal and vertical support by the soil as well as the
deformed shape of the pile by the design loads.
D.4
Axially loaded piles acc. to LRFD-Method
The load resistance factor design (LRFD) method has to be carried out according to ISO 19902 latest
revision.
D.4.1
Design loads
The design loads are defined in Section 3, C.3. The resulting axial load (from the design load combinations) in the pile is Pd.
D.4.2
Design format for axial capacity
The required design axial pile capacity may be expressed as follows:
Pd Qd =
Qr
VR
Pd
: Design axial load on the pile
Qd
: Design axial pile capacity
Qr
: Representative value of axial pile capacity
gR
: Partial resistance factor for pile capacity, factors in Table 6.2 are valid for main-text-method
of ISO
Qr has to be calculated according to ISO 19902. There are 2 principal methods how to calculate Qr. One
is described in the main text and the other methods (CPT-based) are explained in detail in the Annex A.
If one of the CPT-based methods from the Annex A of the ISO is applied the partial resistance factors
have to be agreed upon with GL. The applied additional factor on the resistance has to be justified by
rational analysis and soil expert statement.
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Partial resistance factors R for pile capacity and different loading conditions
Table 6.2
Partial Resistance Factor r
Loading conditions
Operating loading condition or loading condition with permanent and variable actions
1.25
Extreme environmental loading conditions
D.4.3
1.5
Pile stresses
Pile stresses have to be checked according to corresponding interaction formulas (refer to chapter 13 of
ISO) for the design loading conditions. The pile is mostly loaded by axial loads and bending moments.
The calculation of stresses should consider the horizontal and vertical support by the soil as well as the
deformed shape of the pile by the design loads.
D.5
Axial pile performance
D.5.1
The axial pile performance has to fulfil specified service requirements by the owner.
D.5.2
Pile axial static deflections should be within acceptable serviceability limits and shall be compatible with internal forces and moments.
D.5.2.1
Cyclic effects on axial performance have to be considered. Repetitive actions can cause temporary or permanent decrease in pile resistance and/or accumulation of deformation. Rapidly applied
actions can cause an increase in resistance and/or pile stiffness. The design pile penetration shall be
sufficient to develop the required design pile capacity.
As an approach cyclic effects shall be considered if the cyclic load amplitude is greater than 10 % or the
cyclic load range is greater than 20 % of the ultimate static pile resistance to be considered for the extreme loading condition.
D.6
Soil reactions for piles under axial loads
D.6.1
The axial resistance of the soil for pile axial loads is provided by a combination of soil-pile
adhesion and associated shear transfer along the skin of the pile. For axial compression loads on the pile
the end bearing resistance at the pile tip is activated.
D.6.2
The axial shear transfer is based on t-z curves. The end bearing for compression loads is defined by a Q-z curve. Both curves are provided in API and ISO for clay and sand soil types.
D.7
Soil reactions for piles under lateral loads
D.7.1
The pile foundation shall be designed to resist static and dynamic lateral loads. The lateral
resistance of the soil near the surface has a significant influence on the pile design. In this respect scour
has to be considered.
D.7.2
The non-linear lateral support of the soil is represented by the so called p-y curves. The p-y
curves from API or ISO can be used for different soil types (soft and stiff clay as well as sand).
D.8
Pile group behaviour
D.8.1
For pile groups with pile spacing of less than eight times pile diameter, pile group effects have
to be evaluated.
D.8.2
For axial pile loads the group capacity in clay may be less than the sum of the single pile capacities, whereas the group capacity in sand may be higher than the sum of the individual pile capacities.
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D.8.3
For lateral loads the pile group will normally undergo larger deflection than a single pile under
corresponding average loading.
D.8.4
The analysis of a pile group may be carried out according to acknowledged methods 1 as
agreed with GL.
D.8.5
All piles of a pile group should end in the same soil layer.
D.9
Pile structure design
D.9.1
General
The pile structure design shall consider all types of loads which may occur during installation and operation phases.
D.9.2
Stresses in piles during installation
D.9.2.1
During pile installation the max. combined stresses shall not exceed the yield stress of the pile
material. In general, it can be assumed that buckling of the pile during hammering will not occur as a result of dynamic portion of the driving stresses.
D.9.2.2
Consideration shall be given to axial loads and bending moments due to pile weight and full
hammer weight. Bending moments due to pile batter eccentricities are to be accounted for. For vertical
piles 2 % of pile and hammer weight shall be assumed as if acting laterally to account for possible impacts and eccentricities during hammer placement.
D.9.2.3
Dynamic stresses shall be calculated based on wave propagation theory. Dynamic stresses
shall not exceed 80 to 90 % of yield stress depending on specific circumstances, see API or ISO.
D.9.2.4
Pile wall thickness
D.9.2.4.1 The ratio of pile diameter and wall thickness shall be small enough so that local buckling during installation is avoided. General guidelines are given in API RP 2A and ISO 19902.
D.9.2.4.2 The pile wall thickness may vary along its length according to the stress level in the different
sections. Thickened portions should be reasonably extended in order to allow for underdrive or overdrive.
D.9.2.4.3 For piles to be driven in hard soils a driving shoe should be provided.
D.9.3
Stresses in piles during platform operation
D.9.3.1
All loads resulting from the design load conditions of the platform are to be considered for the
pile structure design.
Normally these loads will control the pile design in the mudline area.
D.9.3.2
The axial load transfer may be calculated according to the "axial soil resistance - pile deflection" characteristics or alternatively according to the skin friction capacity of the pile, see D.6.
D.9.3.3
The lateral soil stiffness, see D.7, has to be accounted for when calculating the bending moment distribution. Due regard shall be given to the effect of scour and lack of soil adhesion due to large
pile deflections.
D.9.3.4
The pile strength shall be designed according to D.3 or D.4.
For piles having large horizontal deflections a stress increase due to second order effects shall be considered.
D.9.3.5
For pile sections embedded in the soil normally column buckling needs not to be investigated.
See e.g. Focht and Koch, OTC 1896, 1973. This procedure combines the subgrade reaction (p-y) analyses and elastic half
space procedures. It results in modified p-y curves for an isolated pile to represent the single pile behaviour in a pile group.
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D.9.4
Pile Fatigue
D.9.4.1
In principal pile fatigue has to be considered due to pile driving and in-service loads.
D.10
Grouted pile to structure connection
D.10.1
Platform loads may be transferred to leg and sleeve piles by grouting the annulus.
The application of shear keys is recommended in order to improve the capacity of the steel grout bond.
D.10.2
Grouted pile to structure connections may be designed according to API or ISO. The design
loads have to be taken from the design loading conditions according to the applied standard, refer to either D.3 or D.4. The design checks have to be carried out according to the chosen standard.
D.10.3
plied.
For fatigue check of the grout connection NORSOK N-004, Rev. 3, Appendix K can be ap-
D.10.4
For geometries not covered by the existing formulae the strength of the grouted connection
has to be proven by suitable calculation methods or by test.
D.10.5
Grout quality
D.10.5.1 Prior to the installation, the suitability of the grout mix has to be proven. The compressive
strength has to be confirmed by laboratory tests on grout samples which were mixed and cured under
field conditions.
D.10.5.2 The design grout strength has to be verified by a representative number of specimens taken
during grouting operations. It has to be ensured that the specimens will be cured simulating in-situ conditions.
D.11
Additional BSH requirements for steel pile foundations
For projects in the German exclusive economic zone BSH (Bundesamt fr Seeschiffahrt und Hydrographie) is the approving authority. In this case the following additional requirements for pile foundations
generally apply. These requirements however are subject to project specific confirmation by BSH.
In principal API RP 2A-WSD and ISO 19902 can be applied for design purposes of steel pile foundations in the German sector.
The main text method of both standards has to be applied in general. Any exemption needs to be
explicitly agreed with BSH.
In case that ISO standard is applied the partial resistance factor for extreme condition is 1.40 for
compression and 1.50 for tension (according to the DIN 1054: 2010-12) instead of 1.25.
The max. value of unit skin friction is limited to 115 kN/m2.
While capacities of the piles and soil have to be calculated with characteristic soil parameters, lower
and upper bound values may have to be used for stiffness related analysis as well as for pile drivability analysis.
The cyclic behaviour of piles has to be considered and designed e.g. according to the methods dend
scribed in reference EA Pfhle, 2 edition, 2012.
A concept of a dynamic axial load test (dynamische Pfahlprobebelastung) after installation of the
piles has to be presented prior to installation, please refer to EC 7-1:2009-09 and DIN1054:2010-12
nd
in correspondence with to EA-Pfhle, 2 edition 2012.
Shallow Foundations
E.1.1
Scope of Application
E.1.2
The shallow foundations considered herein are typically used for temporary support of unpiled
structures, especially mudmats during installation phase.
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Characterization
Shallow type foundations are characterized as foundations with relatively small penetration into the soil,
compared to the width of the foundation bases, and relying predominantly on compressive contact with
the supporting soil.
E.1.4
Scope of design
The design of the foundation shall include the following considerations:

On-bottom stability including failure due to overturning, bearing, sliding or combinations thereof.
static deformations
dynamic behaviour, i.e. performance of the foundation under cyclic loads
hydraulic instability, such as scour or underwashing due to wave pressures
flat-bottom components or structures shall be designed with due consideration given to non-uniform
soil reactions which can cause hard points acting on the structure
E.1.5
Design loads
The design loads have to be taken from the design loading conditions according to the applied standard,
refer to either D.3 or D.4.
E.1.6
Code Checks
The code checks have to be carried out according to API RP 2A-WSD or ISO 19901-4 for shallow foundations according to the required scope defined in E.1.3.
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Section 7
A
Cranes......................................................................................................................... 7-1
Cranes
A.1
General
A.1.1
Scope
This Section provides requirements for Certification of lifting appliances, especially cranes, on offshore
installations/units for different purposes, e.g. lifting duties like loading and discharging to and from the
platform, assistance for platform works, personnel transfers, etc.
A.1.2
Standards and Guidelines
Within the scope of Certification the following standards are accepted for GL:
GL Rules for Loading Gear on Seagoing Ships and Offshore Installations (VI-2-2)
GL Guideline for Personnel Transfers by Means of Lifting Appliances (IV-6-9)
EN 13001 1 Cranes - General design - Part 1: General Principles and requirements
EN 13001 2 Cranes General design Part 2: Load actions
EN 13001 3 1 Cranes - General design
Part 3 1:Limit states and proof competence of steel structures
EN 13001 3 2 Cranes - General design
Part 3 2:Limit states and proof competence of wire ropes in reeving systems
EN 13852 1 Cranes Offshore cranes Part 1: General-purpose offshore cranes
EC Guideline no. 2006/42/EC: Mechanical engineering Directive on Machinery
ILO C152 Occupational Safety and Health (Dock Work) Convention
A.1.3
Other Regulations
Certification may be requested by the manufacturer or Owner including specified items. In case of other
regulations, which are not covered by the standard Certification system, this has to be clarified, which
Rules and/or combinations shall apply. The covering of additional requirements may be limited. If the
additional requirements not comply with the general Certification work, this shall be reported to the Owner
in writing.
A.1.4
Extension and reduction of work
Upon request of the Owner, the scope of work may be extended or reduced beyond the subjects and
aspects covered by the Certification. Both extent and reduction have to be agreed in writing.
In case of lowering of the safety standards due to leading hazards or other discrepancies this will not
agreed by the Certifier.
A.1.5
Cranes and lay-down areas
Offshore substations shall be fitted with a lifting device for handling of cargo and personnel transfer, if
requested. The location of crane, working area and lay-down area shall be free from hazard sources. In
case of unavoidable positioning adequate impact protection to be installed. Lay-down areas are not to be
placed in the vicinity of helicopter decks and not on the same level.
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A.1.6
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Structural Design

Repairs and maintenance
When important repairs or renewals are required to be made to each lifting device, the repairs are to be
carried out under the attendance and to the satisfaction of the GL Surveyor. Tests and examinations of
the particular lifting devices, as may be deemed necessary, are to be carried out in accordance to the
existing Rules.
Maintenance to be performed according to manufacturer's crane manual and a programme shall be provided for all lifting equipment and shall include all important maintenance tasks highlighted.
A.2
Coverage of Certification Procedure
A.2.1
Activities
Following activities are covered by the Certification:

design examination
survey during fabrication and installations
witness of testing and marking
A.2.1.1
Design examination
The design approval is subject with respect to strength and suitability for its purpose and covers all loadcarrying and other important components of the lifting appliance including the relevant substructures.
Environmental conditions to be applied.
If the stiffeners and crane loads may have a significant effect on the load distribution and local stressing,
crane pedestals shall be included in the analytic model of the primary structure of the installation/unit.
The design approval may also be obtained either on a case-by-case basis or as a general approval like a
Type Approval. In this case certain conditions to be observed and period of validity will be limited.
A.2.1.2
Survey during fabrication and installation
Generally a survey during manufacturing of each separate lifting appliance shall be performed by the GL
Surveyor, in order to ascertain compliance with the approved drawings and other requirements of the
Certification standard as well as good workmanship.
After completion of fabrication and testing (FAT) at manufacturer's site a provisional Certification to be
issued. Attached shall also the manufacturer's documentation, e.g. material Certificates, details of welding, NDT reports, etc.
After installation of the lifting appliance in the final location, and before testing, a final survey shall be performed by the Surveyor.
A.2.1.3
Testing and Marking
The testing shall be carried out according to an approved test programme.

After successful testing of both load requirements and function, components and the lifting appliance shall
be marked.
A.2.2
Parts, components and systems
Following parts, components and systems to be covered by the Certification procedure:

all load-carrying structural members and components of the lifting appliance
all loose gear, e.g. cargo hooks, chains, rings, blocks, sheaves, shackles, lifting beams, swivels and
ropes
rope drums
slewing bearing including fasteners
power systems for hoisting, luffing, slewing, and travelling
brakes and brake systems
seating and fastening for prime movers, winches and for bearing of power transmitting components
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electrical installation
control and monitoring systems
safety equipment
protection against fire
A.3
Crane manufacturing and construction
A.3.1
Major related items
The manufacturer shall cover all aspects of a quality control system with defined responsibilities and competent personnel.
Following items to be observed, but not limited to:
approved drawings and specifications
material designation and handling including surface requirements
dimensional tolerances
calculations for fatigue, buckling, accelerations, etc.
check of design and strength of components, e.g. buckling stability of jibs
personnel transfer applicability
approved welding procedure specifications
weld preparations according to recognized standards
weld performance including preheating
approved repair welding procedure specification
qualified welders
approved welding consumables
specification for forming materials
heat treatment, if required
production welds
performance of works
inspection and testing of welds
weld acceptance criteria
NDT methods, including approved specifications and qualified personnel
minimum NDT requirements to be mentioned
defects and deficiencies to be documented and corrected before painting or coating
material protection against corrosion
machinery components, e.g. winches, drums, gear transmissions, ropes, with fittings and anchorage, sheaves, ventilation, etc.
slewing bearing of jib crane
lifting gear including loose gear
electrical equipment and power systems, e.g. prime movers
hydraulic, pneumatic, instrumentation, automation, communication
control and monitoring system
operator's cabin including equipment and arrangement
safety and safety equipment
platform, access possibilities, parking area
specific requirements cranes with safety functions with reducing the risk connected to crane operations
monitoring of safety functions
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list of hazards including detailed descriptions

risk analysis, if required
protection and precaution against fire
performance procedure of load tests, e.g. by weights or dynamometer, depending on SWL
specification and examination after testing including sling and lifting tackles
check of electrical installation, insulation resistance
marking and signs
verification procedure including final shut down
etc.
A.3.2
Documentation on board
Crane manual for each crane with following information:

design standard, operation, erection, dismantling and transportation
all limitations during normal and emergency operations with respect to SWL, safe working moment,
maximum wind, design temperature and braking systems
all safety devices
diagrams for electrical, hydraulic and pneumatic systems and equipment
materials used in construction, welding procedures and extent of non-destructive testing
guidance on maintenance and periodic inspections
Certification of components, e.g. hydraulic cylinders
Certification of additional equipment, e.g. baskets, skids, pad eyes, etc.
Certification of wire ropes
A.4
Certification and Classification
A.4.1
Certification
Certification of offshore cranes includes the issuance of a GL Register Book by GL Surveyor as described
in the GL Rules for Loading Gear on Seagoing Ships and Offshore Installations (VI-2-2). In addition the
GL Surveyor will add the test Certificate(s) for crane(s) and other test Certificate(s), whatever is in use.
A.4.2
Classification
In case of offshore crane Classification in addition to the crane Certification, the acting GL Surveyor will
make a relevant note in the Register Book and the Operator will get a crane Class Certificate from the GL
Head Office.
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Section 8
A
B
General ....................................................................................................................... 8-1

Structure of the Helicopter Deck ................................................................................. 8-2
General
A.1
Scope
A.1.1
This Section summarizes main design considerations relating to helicopter landing facilities.
Aspects which are mostly aeronautically determined, like size and marking of the helicopter deck, clearances around the platform, sectors for approach and take-off have to be treated according to the relevant
international and national regulations or codes, compare the GL Rules for General Safety (IV-7-3), Section 5, D.
A.1.2
In this Section it is assumed that the structure of the helicopter deck is made of steel. If a
structure made of aluminium alloys shall be provided, the design should follow the GL Rules for Hull
Structures (I-1-1) or recognized standards, like standards of the American Petroleum Institute (API).
A.1.3
For electrical installations on helicopter facilities, see GL Rules for General Safety (IV-7-3),
Section 5, D.
A.2
Standards and regulations
Depending on the location of the offshore installation or the flag state of the offshore unit relevant national
and international standards and regulations have to be fulfilled besides of these GL Rules. The following
examples can be defined:
ISO/CD 19901-3 Standard: Petroleum and Gas Industries Specific Requirements for Offshore
Structures Topside Structure, 8.5
IMO: Code for the Construction and Equipment of Mobile Offshore Drilling Units (MODU Code),
Chapters 9 and 13
IMO Res. A.855(20): Standards for on board Helicopter Facilities
ICS (International Chamber of Shipping): Guide to Helicopter/Ship Operations
CAP 437: Offshore Helicopter Landing Areas - Guidance on Standards, Civil Aviation Authority,
Gatwick Airport South, West Sussex, RH6 0YR, UK
A.3
Helicopter data
For providing relevant helicopter facilities the Owner/Operator has to deliver the following information:
types of helicopters to be operated
geometrical main dimensions, especially length of fuselage, number and diameters of rotors, etc.
total overall length of the helicopter when the rotors are turning (D-value)
weight, weight distribution and wheel or skid configuration
highest vertical rate of descent on the helicopter deck, e.g. because of a single engine failure, etc.
data for winching operations, if applicable
lashing systems to be provided
possibility of an unserviceable helicopter stowed on the side of the deck while a relief helicopter is
required to land, if applicable
fuel used and type and capacity of refuelling equipment to be provided
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starting equipment, if applicable

A.4
Documentation to be submitted
A.4.1
Plans showing the arrangement, scantlings and details of the helicopter deck are to be submitted. The arrangement plan is to show the overall size of the helicopter deck and the designated landing
area. If the arrangement provides for the securing of a helicopter or helicopters to the deck, the predetermined position(s) selected to accommodate the secured helicopter, in addition to location of deck fittings
for securing the helicopter is to be shown.
A.4.2
The helicopter for which the deck is designed is to be specified and calculations for the relevant loading conditions are to be submitted.
Structure of the Helicopter Deck
B.1
General
B.1.1
deck.
The helicopter deck shall be dimensioned for the largest helicopter type expected to use the
B.1.2
For scantling purposes, other loads (cargo, snow/ice, etc.) are to be considered simultaneously or separately, depending on the conditions of operation to be expected. Where these loads are not
known, the data contained in 2. may be used as a basis.
B.1.3
The following provisions shall in principle apply to landing areas on special, pillar-supported
landing decks or on the upper deck, superstructure deck or deckhouse of a fixed or mobile installation/unit.
B.2
Design loads
The following design load cases (LC) which are described in B.2.1 B.2.4 are to be considered:
B.2.1
Load case LC 1
Helicopter lashed on deck of mobile units, where helicopter deck is used in floating condition, with the
following vertical forces acting simultaneously:
B.2.1.1
Wheel and/or skid force P acting vertically at the points resulting from the lashing position and
distribution of the wheels and/or supports according to helicopter construction, see Fig. 8.1.
P = 0.5 G (1 + av) [kN]
P
Fig. 8.1
Skid/wheel loads of a helicopter
: maximum permissible take-off weight [kN]
: evenly distributed force over the contact area f = 30 30 cm for single wheel or according to
data supplied by helicopter manufacturers; for dual wheels or skids to be determined individually in accordance with given dimensions
: wheel or skid distance according to helicopter types to be expected
av
: acceleration addition to be defined primarily by a motion analysis
av
: acceleration addition for non self-propelled units where the towing speed v L0.5 [kn] to be
estimated as follows:
av
: 0.11 m
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: 1.61 3.05 x / L
x / L 0.2
: 1.0
0.2 < x / L 0.7
: 1 + 8.7 (x / L 0.7) 0.7 < x / L 1.0

: length of the unit [m] as defined in GL Rules for Mobile Offshore Units (IV-6-2), Section 1,
B.4
B.2.1.2
Evenly distributed vertical load over the entire helicopter deck, taking into account snow, cargo, personnel, etc.
p = 2.0 kN/m2
B.2.1.3
Vertical force on supports of the deck due to weight of helicopter deck Me:
Me (1 + av) [kN]
B.2.2
Load case LC 2
Helicopter lashed on deck with the following vertical and horizontal forces acting simultaneously:
B.2.2.1
Wheel and/or skid force P acting vertically at the points resulting from the lashing position and
distribution of the wheels and/or supports according to helicopter construction, see Fig. 8.1.
P = 0.5 G [kN]
B.2.2.2
Vertical force on supports of the deck due to weight of helicopter deck:
Me [kN]
B.2.2.3
Evenly distributed vertical load over the entire helicopter deck, taking into account snow, cargo, personnel, etc.
: 2.0 kN/m2 for fixed installations and units
: 0.0 kN/m2 for floating units

B.2.2.4
Horizontal forces on the lashing points of the helicopter:
H = ah G + WHe [kN]
: acceleration on the helicopter in horizontal direction
ah
: to be defined primarily by a motion analysis if no details are known, the following values may
be used:
: 0
for fixed installations and units
: 0.6
for floating units
WHe
: wind load on the helicopter at the lashing points
B.2.2.5
Horizontal force on supports of the deck due to weight and structure of helicopter deck:
H = ah Me + WSt [kN]
WSt
: wind load on the structure of the helicopter deck, compare B.2.3.4
B.2.3
Load case LC 3
Normal landing impact on fixed offshore installations and floating offshore units, with the following
forces acting simultaneously:
B.2.3.1
Wheel and/or skid load P at two points simultaneously, at an arbitrary (most unfavourable)
point of the helicopter deck (landing zone + safety zone), see Fig. 8.1.
P = 0.75 G [kN]
P to be increased by 15 % if the helicopter deck is part of a deckhouse with accommodations below.
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Section 8
B.2.3.2
Evenly distributed load over the entire helicopter deck, taking into account snow or other environmental loads:
p = 0.5 kN/m2
B.2.3.3
Vertical force on supports of the deck due to deadweight of helicopter deck:
Me [kN]
B.2.3.4
Horizontal force on supports of the deck due to structure of helicopter deck:
H = WSt [kN]
WSt
: wind load on the structure of the helicopter deck for the wind velocity admitted for helicopter
operation vW'
vW'
: wind velocity, to be taken according to local weather conditions

: 25 m/s if no other relevant data available
B.2.4
Load case LC 4
Emergency/crash landing impact on fixed and floating offshore installations/units, with the following
vertical force:
B.2.4.1
Wheel and/or skid load P at two points simultaneously, at an arbitrary (most unfavourable)
point of the helicopter deck (landing zone + safety zone), see Fig. 8.1.
P = 1.25 G [kN]
B.2.4.2
Forces according to B.2.3.2 to B.2.3.4
B.3
Scantlings of structural members
B.3.1
Structural analysis
Structural analysis of the supporting structure shall be effected in accordance with Section 3 by direct
calculations. Regarding construction and materials employed, see Section 4.
Proof of sufficient buckling strength is to be carried out in accordance with Section 3, H for structures
subjected to compressive stresses.
B.3.2
Permissible stresses
Permissible stresses for stiffeners, girders and substructure:

zul = 235 / (k ) [N/mm2]
: material factor
: 295 / (ReH + 60)
: safety factor according to Table 8.1
Table 8.1
Safety factors for different load cases of helicopter decks
Structural element
LC1 + LC2
B.3.2.1.1 LC3
B.3.2.1.2 LC4
Stiffeners (deck beams)
1.25
1.10
1.00
Main girders (deck girders)
1.45
1.45
1.10
1.7
2.0
1.20
Load bearing substructure

(pillar system)
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B.3.3
Industrial Services
Structural Design

Plating
The thickness of the plating is not to be less than the greater of the two following values::
t = n c P k + t k [mm]
or
t = 1.1 a p k + t k [mm]
: 1 in general
: 0.9 for crash landing of helicopters (LC 4)

: total load in [kN] of one wheel or group of wheels with print area f on a plate panel F = a b,
see Fig. 8.2
: values for different load cases LC 1 - 4 according to B.2

a
: width of smaller side of plate panel (in general beam spacing)
: width of larger side of plate panel
F need not be taken greater than 2.5 a2
f
Fig. 8.2
Area of plate panel influenced by a wheel print
In case of narrowly spaced wheels these may be grouped together to one wheel print area.
tK
: corrosion allowance depending on material, protection, service and maintenance conditions,

if any [mm]
: factor to be determined as follows:

for the aspect ratio b/a = 1 and for the range 0 < f / F 0.3:
c = 0.95 1.87 (f/F) (3.4 4.4 f / F)
for the aspect ratio b/a = 1 and for the range 0.3 < f / F 1.0:
c = 0.95 (1.20 0.40 f / F)

for the aspect ratio b/a 2.5 and for the range 0 < f / F 0,3:
c = 0.95 2.0 (f/F) (5.2 7.2 f / F)
for the aspect ratio b/a 2.5 and for the range 0.3 < f / F 1.0:
c = 0.95 (1.20 0.517 f / F)

For intermediate values of b/a the factor c is to be obtained by direct interpolation.
: evenly distributed pressure load [kN/m2]

: values for different load cases LC 1 - 4 according to B.2
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Marine Operations
Section 9
A
B
C
Marine Operations
General ....................................................................................................................... 9-1

Standards and Guidelines........................................................................................... 9-1
Lifting Operations........................................................................................................ 9-2
General
A.1
Marine operations, i.e. operations associated with moving or transporting an offshore structure
or parts thereof during the construction, installation or abandonment process, may have decisive influence on the overall design and on the dimensioning of scantlings, see also GL Rules for Certification and
Surveys (IV-7-1). Marine operations concerning structural integrity are therefore normally included in the
design review by GL.
A.2
Where such operations, i.e. loadout, transportation, lifting/launching, upending, levelling, piling,
float-over/lifting, mating and lowering /embedding, impose important loads or critical conditions on the
structure, they have to be taken account of in the design.
The review and survey by GL will cover, as far as applicable:
Location Survey and environmental conditions
Loadout Analyses
Transportation Analyses including motion response
Lifting/Launching/Upending Analyses including on-bottom stability
Lifting/float-over, Lowering and Touchdown Analyses including dynamic influences
Additional to above investigations Marine Warranty Survey (MWS) document review and on-site surveillance will cover as far as applicable:
Condition Survey of vessels and equipment involved
Loadout Procedure including quay condition, mooring and retrieval system
Transportation Arrangement including seafastening, stability, towing
Lifting/Launching/Upending Procedure (rigging, mooring, clearances)
Installation Procedures including anchor handling, positioning, piling, grouting, mating
A.3
A complete Certification of the design and construction of an offshore installation will be based
on surveys and attendance to all important transport and installation operations. The necessary extent of
such attendance will be agreed upon in each individual case, and certified accordingly. However, the
operations shall be conducted by the responsible personnel of the service company in charge, which is
assumed to be competent and experienced for the respective tasks.
A.4
Construction phases of a (e.g. concrete) platform in a floating, moored condition are not understood to be within the scope of this Section.
Standards and Guidelines
For procedures in connection with marine operations not specifically covered by these Rules GL Noble
Denton Guidelines may be applied where appropriate and agreed upon:
0001/ND General Guidelines for Marine Projects
0009/ND Self elevating platforms, guidelines for elevated operations
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0013/ND Guidelines for Loadouts

0015/ND Concrete offshore gravity structures, guidelines for approval of construction, towage and
installation
0016/ND Seabed and sub-seabed data required for approvals of mobile offshore units (MOU)
0021/ND Guidelines for the approval o towing vessels
0027/ND Guidelines for marine lifting operations
0028/ND Guidelines for the transportation and installation of steel jackets
0030/ND Guidelines for marine transportations
0031/ND Guidelines for float-over installations
0032/ND Guidelines for moorings
Within the scope of Certification and Marine Warranty Survey the further the following standards are accepted by GL:
NORSOK STANDARD: Applicable Chapters regarding Marine Operations
ISO 19901-6 Marine Operations
GL Rules VI Additional Rules and Guidelines, Part 11 Other Operations, Chapter 1 Guidelines
for Ocean Towage
Lifting Operations
C.1
General
C.1.1
Overall dimensions, weight and centre of gravity of a module to be lifted, number of lifting points, arrangement and characteristics of lifting equipment, etc. should be considered at an early design stage in
view of the means which will be available, and of the static and dynamic loads associated with the anticipated procedure.
C.1.2
Calculations
C.1.2.1
Parameters
The analysis of the lifting and lowering procedures shall take into account, where adequate, the elastic
properties of both, the structure itself and the lifting equipment, the dimensional tolerances of the lifting
slings, dimensional and weight tolerances of the lifted object, and the dynamic conditions which depend
on the environment and the type of lifting gear employed. The weight of the rigging/lifting equipment (e.g.
spreaders) shall be accounted for where relevant.
C.1.2.2
Additional external influences
Additional external influences and loads such as hydrodynamic and hydrostatic forces acting on submerged structures, wind, tug forces and foreseeable impact forces shall be considered where they are
deemed to be important.
C.2
Load assumptions
C.2.1
Weight contingency factors
For lifted objects a weight contingency factor fCONT [-] shall be considered as follows:
fCONT
: 1.03
for weighed weights
: 1.10
for calculated weights
For rigging equipment a rigging weight contingency factor fRIG shall be considered as follows:
fRIG
: 1.03
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C.2.2
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Structural Design
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Dynamic amplification fDAF
C.2.2.1
A dynamic amplification factor fDAF [-] depending on the mass M [t] of the lifted object according to Table 9.1 has to be considered for any controlled lifting operation using one hook.
C.2.2.2
In any case the dynamic amplification factor can be evaluated in a detailed motion analysis.
C.2.2.3
For lifting and lowering procedures involving floating objects and/or two or more crane barges,
a special investigation of the motion characteristics of the coupled system will usually be necessary,
unless it can be shown that the maximum forces likely to occur are sufficiently smaller than the lifting capacity provided.
Table 9.1
Dynamic amplification factor fDAF
Mass
Unprotected areas offshore 1
Sheltered areas
(inshore)1 and onshore
M 1000 t
f DAF = 1.15 + 0.15 1
1000
f DAF = 1.05 + 0.10 1
1000
M > 1000 t
1.15
1.05
1 it is assumed that operations are carried out under defined, controlled weather conditions
C.2.3
Lifting weight WL
The lifting weight is defined as follows:

WL = M g fCONT fDAF [kN]
M
: mass [t], for the lifted object
: gravity acceleration (9,81 m/s2)
fCONT
: weight contingency factor according to 2.1
fDAF
: dynamic amplification factor according to 2.2
C.2.4
Rigging weight WR
The rigging weight is defined as follows:

WR = MR g fRIG fDAF * [kN]
MR
: mass of all rigging equipment (slings, shackles, etc.)
: gravity acceleration (9,81 m/s2)
fRIG
: rigging weight contingency factor acc. to 2.1
fDAF
: dynamic amplification factor according to 2.2
* same fDAF as for WL to be applied

C.2.5
Hook load H
The hook load H may be determined as follows:

H = WL + WR [kN]
C.2.6
Inaccuracy of centre of gravity fCOG
Depending on the type of structure and possible accuracy of calculation (design stage), a tolerance factor
fCOG [-] shall be chosen to take into account errors regarding the position of centre of gravity (COG).
Standard procedure should be the consideration of the worst position of the COG inside an envelope of
1 m 1 m.
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Possible tilting effects have to be considered.

Where this procedure can not be applied a minimum factor of
: 1.10
fCOG
has to be considered.
C.2.7
Skew load factor fSKL
The skew load factor fSKL [-] is applied to account for dimensional tolerances of the slings and the influence of elasticity of slings length or properties.
For indeterminate (4-sling) lifts a skew load factor of:
: 1.25
fSKL
shall be applied to each diagonally opposite pair of lift points in turn.

For determinate (2- and 3-point) lifts the skew load factor is:
fSKL
: 1.00
C.2.8
Lift point resolved lift weight PRLW
The lift point resolved lift weight PRLW [kN] is the vertical load on each lift point (padeye / trunnion) taking
into account the lift weight WL and the geometric arrangement of the lifting points in relation to the COG
only.
C.2.9
Resolved lift point load (sling load) PS
The sling load PS [kN] is the total load acting on the padeye in direction of the sling:
PS =
PRLW f COG f SKL

sin ( )
: angle between the sling and the horizontal plane.
C.2.10
Additional influences
Additional influences e.g. from horizontal forces, see C.1.2.2, shall be especially considered. At the points
of load application (padeyes), a force of at least 5 % of PS is to be accounted for, acting perpendicular to
the padeye plane.
C.2.11
Spreader frames
When using spreader frames, the sling forces may be calculated according to C.2.9 and C.2.10, being
the angle between sling and (horizontal) spreader plane.
C.3
Safety factors
C.3.1
Safety factors for lift points and lifted objects
C.3.1.1
Consequence factors fcons
The following consequence factors fcons [-] shall be applied to the lift points and supporting structure.
fcons
: 1.35
for lift points, attachments and supporting members, including those on spreaderframes
fcons
: 1.00
for other structural members
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Global safety factor g
C.3.1.2
The global safety factor g is:

g
: 1.45
for axial and bending stresses
: 2.16
for shear stresses
: 1.25
for equivalent stresses
C.3.2
Safety factors for lifting equipment
For the safety factor of lifting equipment see C.5

C.4
Design of lifted object and lift points
C.4.1
General
The structure to be lifted, including the elements introducing the loads into the structure shall be designed
according to the principles laid down in Section 3 and Section 4.
C.4.2
Shock loading
Elements which may be subjected to shock loading during the lifting and lowering procedure shall be
especially considered and duly strengthened. Protection by guides and in special cases fendering may be
necessary.
C.4.3
Arrangement of padeyes
Padeyes shall be so arranged that the sling direction lies in the plane of the padeye main plate. A bending
force according to C.2.10 in the direction of the eye axis is to be considered. The padeye main plate shall
be introduced into the structure, avoiding sling forces to be transmitted across girder or deck plates.
Where through thickness loading of plates cannot be avoided, the material used shall be documented to
be free of laminations, with a recognized through-thickness designation.
Pinholes should be bored/reamed, and shall be designed to suit the shackle proposed. Adequate spacer
plates shall be provided to centralise shackles.
C.4.4
Design of standard padeyes
Padeyes of usual configuration shall comply with the following indications, Fig. 9.1.
The following formulae are valid for a relation between the pin diameter of the proposed shackle (dp) and
the diameter of the pinhole (d) of:
dp
d
C.4.4.1
0.95
Section A-A:
Shear stress:
= f cons
Ps 1000 R eH
[MPa]
2 AS1
g
AS1
: shear area of Section A-A, related to force Ps ( for D / 2R 0.8, AS1 = A1) [mm2]
A1
: area of Section 1-1 [mm2]
ReH
: minimum nominal upper yield strength [MPa]
: global safety factor for shear stresses according to C.3.1

: 2.16
fcons
: consequence factor for lift points according to C.3.1

: 1.35
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Ps
t1
t1
Fz
y e
1
Fx
Fy
d D
C
e2
Section A - A (similar B - B)
l
y
Section C - C
y
Fig. 9.1
Standard padeye
: base length [mm]

h
: pin hole height above base [mm]
: main plate radius [mm]
: pin hole diameter [mm]
: Cheek plate diameter [mm]
e1
: neutral axis of Section B-B related to pin hole edge [mm]
e2
: pin hole eccentricity related to the neutral axis y-y of Section C-C [mm]
: main plate thickness [mm]
t1
: cheek plate thickness [mm]
: throat thickness of cheek plate weld [mm]
: sling angle against x-axis
Ps
: resolved padeye load (according to C.2.9) [kN]
Fx
: PS 1000 cos () [N]
Fy
: minimal 0.05 PS 1000 (see C.2.10) [N]
Fz
: PS 1000 sin () [N]
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Section 9
C.4.4.2
Marine Operations
Section B-B:
Equivalent stress:
2
eq
1
F
d + 2 e1
= fcons Fz
+
+ 3 x
2 A2 15 Z2y
2 AS2
R eH
[MPa]
g
A2
: area of Section B-B (similar A-A) [mm2]
AS2
: shear area of Section B-B, related to force Fx ( for D / 2R 0.8, AS2 = A2) [mm2]
Z2y
: section modulus of Section B-B related to axis y-y [mm3]
ReH
: global safety factor for equivalent stresses according to C.3.1

: 1.25
fcons
: 1.35
C.4.4.3
Section C-C:
Combined axial and bending stress:
F
F e F h Fy h R eH
a / b = f cons z z 2 x
[MPa]
A3
Z3y
Z3x g
Location with highest stresses is relevant

A3
: area of Section C-C [mm2]
Z3x(y)
: section modulus of Section C-C for location under consideration related to axis x-x or y-y,
respectively [mm3]
: safety factor for axial and bending stresses according to C.3.1

: 1.45
fcons

: 1.35
Shear stress:
(x) = f cons
(y) = f cons
A3
Fx
AS3(x)
Fy
AS3(y)
R eH
[MPa]
g
R eH
[MPa]
g
: area of Section C-C [mm]

: shear area of Section C-C, related to force Fx or Fy [mm2], respectively (for rectangular cross
section t , without stiffening brackets, A3 = AS3(x) = AS3(y) = t )
ReH
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: 2.16
fcons
: 1.35
Equivalent stress:
eq = a2 / b + 3 ( x ) + ( y )
R eH
[MPa]
g
ReH
: global safety factor for equivalent stresses according to C.3.1

: 1.25
fcons
: 1.35
C.4.4.4
Weld connection between cheek plate and main plate:
Shear stress:
f cons
Ps 1000
t1
R
eH [MPa]
D a t + 2 t1
g
ReH

: 2.16
fcons

: 1.35
Minimum weld thickness:
a min = 1,5
t + t1
[mm]
3
but not less than 3 mm

C.4.5
Arrangement of trunnions
The diameter of the trunnion has to be chosen with respect to the minimum allowable bending radius of
the proposed lifting sling, see Fig. 9.2. In general the diameter of the trunnion shall not be less than:
Dt
: 9 Ds
Ds
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Fz
Ps
Fz
Ps
Fx
Fy
b
c
Dt
Fig. 9.2
Typical trunnion arrangement
Dt
: trunnion diameter [mm]
: clearance for sling between keeper plates [mm]
: stub length of trunnion [mm]
: sling angle against x-axis
: sling angle against y-axis
Ps
: resolved trunnion load (according to C.2.9) [kN]
Where practical aspects do not allow keeping this minimum diameter, a reduction of the allowable sling
load has to be considered.
Adequate clearance shall be included between trunnion keeper plates, to allow for ovalisation of the sling
section under load. In general, the width available for the sling shall be not less than:
b = 1.25 Ds + 25 [mm]
However, the practical aspects of the rigging and de-rigging operations may demand a greater clearance
than this.
Through-thickness loading of the trunnions and their attachments to the structure shall be avoided if possible. If such loading cannot be avoided, the material used shall be documented to be free of laminations,
with a recognized through-thickness designation.
C.4.6
Design of trunnions
Trunnions are subject to a strength investigation based on the following loads.

Safety factors are to be chosen according to C.3.1
Fx
: PS 1000 cos() [N]
Fy
: PS 1000 cos(), but not less than 0.05 1000 PS [N] (see C.2.10)
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Fz
Industrial Services
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Marine Operations
:
( PS 1000 )2 Fx2 Fy2 [N]
where z is the vertical direction:

Fz
: PRLW 1000 fCOG fSKL
PRLW
: Lift point resolved lift weight (according to C.2.8) [kN]
C.4.6.1
Loadings on trunnion
The following loadings have to be considered for the design of the trunnion and the weld connection.
The loads are acting simultaneously.
Bending moment:
M = Fx2 + Fz2 c [Nmm]

2
Axial load:
FA
: Fy [N]
Shear force:
FS
Fx2 + Fz2 [N]
For abbreviations see Fig. 9.2.

C.4.6.2
Weld connection of trunnion stub to shell
The trunnion stub shall generally be welded to the shell by means of a full penetration weld.
C.4.6.3
Shell and substructure
The shell and the substructure are also subject to strength investigation with the local loads as defined in
C.4.6.1, especially when the shell is unstiffened.
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Section 10
Industrial Services
Structural Design
Containers
Section 10 Containers
A
B
C
D
E
F
G
H
I
Scope ........................................................................................................................ 10-1

Certification for Offshore Service Containers ........................................................... 10-2
Structural Parts ......................................................................................................... 10-6
Materials and Production .......................................................................................... 10-7
Electrical Requirements ............................................................................................ 10-8
Heating, Ventilation and Air Conditioning ............................................................... 10-10
Public Address and Main Alarm Systems............................................................... 10-10
Portable Offshore Unit ............................................................................................ 10-11
Certification Procedure ........................................................................................... 10-12
Scope
A.1
General
These Rules shall cover the different types of offshore containers with respect to design, manufacturing,
testing, certification, marking and periodic inspection.
Additional other requirements shall cover the container structure and any permanent equipment for handling, filling, emptying, refrigeration, heating and safety purposes.
Regarding handling and operation of offshore containers several items have to be observed for the intended use.
Following types shall be covered by this Certification:
Offshore service containers
Offshore portable units
A.2
Offshore service containers
The Offshore Service container is designed and equipped on board of a fixed installation or floating unit
and equipped for a special service task, e.g. workshop, stores, power plants, control units, etc. Location
and installation are subject to the applying regulations.
A.3
Offshore portable units
These portable units are not containers as defined in A.2. The specific purpose for these units must be
considered when assessing the fitness for each design type and where necessary for each transport
event.
Operational restrictions have to be issued in the Certificate.
A.4
Codes and Standards
Following codes and standards shall apply:

EN 12079 Offshore containers and associated lifting sets:
Part 1: Offshore container Design, manufacture and marking
Part 2:Lifting sets Design, manufacture and marking
Part 3: Periodic inspection, examination and testing
IMO MSC/Circ. 860 Guideline on Certification of Offshore Containers
IMO FTP Code - International Code for Application of Fire Test Procedures
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Structural Design
Containers
IMO FSS Code - International Code for Fire Safety Systems

CSC Convention International Convention for Safe Containers, 1972
GL Guidelines for the Construction, Repair and Testing of Freight Containers (VI-1-1)
Statutory Rules and regulations, if applicable
Certification for Offshore Service Containers
B.1
General
For the certification of offshore containers the following steps apply:

design assessment
prototype test, if applicable
production inspections
production testing
inspection of completed installation
function testing
issuance of Certificates
plating and marking
B.2
Design assessment
The documentation package shall contain all relevant information for performing the design assessment
to verify that the design complies with the requirements.
An individual design approval will be performed on case-by-case.
If series production of containers is intended, Type Approval of the design is to be carried out.
B.3
Required documentation
Following documents are to be submitted for evaluation:

strength of structure, lifting set and other permanent equipment
material specifications
welding and other joining methods
system's evaluation for the Certification
arrangement of systems
suitability of components including cables, materials, etc.
Ex-Certification and type of materials and components, if required
fire protection
plating and marking
testing
B.3.1
Types of documentation
B.3.1.1
General information
General information is required for:

instructions for hook-up/installation on the offshore installation/unit
operating instructions where relevant for equipment of importance to safety
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B.3.1.2
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Structural Design
Containers
Structural matters
Following details are required:

general arrangement plan with dimensions, scantlings of strength members, pad eyes and other design with specified details of material to be used
particulars of joining methods, e.g. welding, bolting and/or other types of connections
details of corrosion protection and painting, e.g. type application, colour, dry film thickness, etc.
design calculation
any information about details in case of special purposes and/or special equipment
etc.
B.3.2
Electrical matters
Following electrical documents are required:

Arrangement drawings of the container showing the location of electrical equipment and cable
routes.
Explanation how equipment is fixed and protected to resist shocks at transportation.
One line diagrams for power distribution circuits.
Logic wiring diagrams for power distribution and controls.
Electrical material lists giving main data for components. The material lists shall have identification
keys enabling the components to be traced to the single line diagrams, wiring diagrams or the arrangement/assembly drawings.
Manufacturers' data sheets for components of safety importance or for other components with influence on the certification are to be added, where necessary to show their rating and identification and
to give the precise data for the components needed for evaluation of their suitability.
Cable lists showing main data for cables. Alternatively the same information and identification keys
for cables may be given in the single line diagrams and wiring diagrams.
Construction data and test references for cables including certificates for, if available.
Wiring diagrams for intrinsically safe circuits.
Listing of all Ex-certified components. The list shall include identification systems for each component towards the drawings, and shall show type of Ex protection, Certificate no. and indicate,
whether the Certificate contain special conditions to be taken into account.
For intrinsically safe circuits the list shall show that all relevant data for compatibility between the
barrier and the field components have been complied with i.e. max. voltages, current, capacitance,
inductance, etc.
Ex-Certificates arranged in an indexing system.
Drawings showing the hook-up of electrical, control and signal system, in particular the hook-up to
the installation/vessel control room.
When programmable controllers are used for safety functions, e.g. over pressure monitoring, fire detection, etc., than these types shall be suitable for the environmental conditions on site, e.g. offshore
installations/units. Documentation shall be required.
B.3.2.1
Public addresses and alarm systems
Following items are required:

relevant types of documentation listed under electrical installation
operational description of the systems
B.3.2.2
Fire protection
Following documents are required:

operational description for fire protection systems
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general arrangement of the fire alarm system, together with type and location of detectors with details of how the signals are transmitted
description of wall constructions and materials used for passive fire protection
Certificates of non-combustibility and fire resistance of materials used
Certificates/information on doors, windows, bulkheads, ceilings and fire dampers used in the construction
details of penetrations, location of fire dampers and general arrangement of the ventilation system
type and number of portable extinguishers with certificates
description of any fixed fire extinguishing system
GL Certificates or Certificates from other recognized bodies for important components in the fire
alarm and extinguishing system
B.3.2.3
HVAC
Following documents are required:

arrangement drawings for the ventilation system
operational description of over-pressure ventilation system, if relevant
calculation of over-pressure ventilation system purge time
calculation of ventilation, heating and cooling capacity
B.3.2.4
Other systems
In case of other requirements additional documentation to be approved, e.g. gas detection system, etc.
B.4
Type approval
Type approval has to be related to an on-going production. Testing may be performed with an agreed test
programme and is a verification of the ability to meet specific requirements, e.g. type testing.
The renewal of Type Approval is due after 4 years.
B.5
Inspection and testing
Surveys for inspection and testing are to be agreed between GL and the client as a part of the certification agreement.
The steel structure is to be built and tested under supervision of an Inspector according to GL. The requirements for manufacturing and survey of the structural parts, i.e. pad eyes, framework, panels (excluding fire protection), etc., details see also GL Guidelines for the Construction, Repair and Testing of Freight
Containers (VI-1-1).
The structure should be inspected and structural tests carried out before insulation and/or equipment is
installed.
Manufacturing and surveys for structural parts are to be according to the agreed referenced standard for
these structures.
Surveys of electrical systems should normally include:
Checking that all documentation represents the as-built status of the unit, and that all equipment is
sufficiently documented. Any deviations are to be dealt with as deemed appropriate by the attending
Inspector.
Final approval of electrical components including checking of marking and main data. Checking of
Ex Certificates.
Installation details such as earthing, cables and other items as deemed appropriate by the attending
Inspector.
Function tests of electrical-, alarm-, HVAC systems etc.
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When all surveys have been completed and documentation is approved, the Offshore Service Container
Certificate will be issued. Certification marking should be according to GL Guidelines for the Construction,
Repair and Testing of Freight Containers (VI-1-1).Copies of reports and of the certificate should be submitted to GL Head Office.
B.6
Design requirements
For containers with special features, additional design requirements may be applicable.
Container shall be designed as structural frames, with non-load bearing cladding where necessary. All
connections between frame members and between pad eyes and frame members shall be designed to
give good continuity.
Protruding parts on the outside of the container frame that may catch or damage other containers or
structures shall be avoided. Doors, handles, hatch cleats, etc. shall be so placed or protected that they do
not catch the lifting set. Pad eyes may protrude above the top level of the container frame.
The design temperature TD shall not be taken higher than the statistically lowest daily mean temperature.
The required strength of a container is found by calculations and verified by prototype tests. Minimum
material thickness shall apply according to the calculations, but for primary structure t 4 mm, corner
parts and bottom rails t 6 mm and secondary structure t = 2 mm.
In case of fire resistance, the FTP code shall apply, i.e. minimum thickness for A 0 class standard is
t = 4 mm.
B.7
Design details
B.7.1
Pad eyes
In order to prevent lateral bending moments on pad eyes they should be aligned with the sling to the centre of lift, with a maximum manufacturing tolerance of 2.5.
If the lifting force is transferred through the thickness of a plate, i.e. the z-direction, plates with specified
through thickness properties must be used, see also Section 4, A.4.4.3.
B.7.2
Doors and hatches
Doors and hatches including hinges and locking devices shall be designed for at least the same horizontal forces as the primary structure.
If weather tightness is required the doors shall be equipped with gaskets.
B.7.3
Equipment
Equipment installed in offshore containers shall be designed and installed to withstand the dynamic loading and other environmental forces to which it may be exposed.
B.7.4
Coating and corrosion protection
Offshore containers shall be suitable for the offshore environment by means of construction, use of suitable material and/or corrosion protection and coating.
All offshore container roofs, including those constructed from checker plate, shall be coated with a permanent non-slip medium.
B.7.5
Both tank and bulk containers
Offshore containers for liquid or solid bulk cargoes are subject to international regulations or standards
according to this subsection and may also be subject to other codes and requirements.
In addition to the design requirements the frame shall be designed to also protect the tank and the fittings.
On tank containers for dangerous goods, all parts of the tank and fittings shall be suitably protected from
impact damage.
International and/or national Rules shall apply in case of storage of hazardous and/or dangerous goods.
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B.7.6
Industrial Services
Structural Design
Containers
Prototype testing
For all offshore container types prototype tests are required and shall be considered as a design requirement. The testing has to be witnessed by GL.
The prototype testing may be a partial substitute for strength calculations, but may not replace the design
review.
A test programme to be approved by GL. The testing to be performed with verified equipment and calibrated gauges.
Vertical impact test shall not be performed with containers permanently located on the installation/unit.
Structural Parts
C.1
Requirements related to offshore transport and handling
The general structure of offshore containers including their attached lifting set is part of primary and secondary structures.
Note
Supports for tanks or heavy machinery are primary structures and internal walls are secondary structures.
Fittings and sub-frames, e.g. for insulation panels are not part of a container structure.
Structural loads on containers occurring during use on offshore installations are not covered. Only requirements related to lifting operation to and from the supply vessel in open sea as well as handling by
fork lift trucks.
In the particular specification for such a service container, it is advised, that the rating is chosen higher
than the estimated fitted out load, e.g. to specify a certain pay-load even, if the container is not intended
to carry cargo.
In case of permanent installed containers the offshore location has to be prepared including the approved
substructures on the installation/unit.
C.2
Additional requirements
If additional pad eyes or other lifting fittings for moving and/or other offshore handlings are required, this
has to be mentioned in the Certificate. Generally these addition lifting fittings are not intended for use of
loading and/or discharging of the whole unit.
C.3
Additional loads
Additional loads, statically or dynamically, to be subject in case of external environmental loads and/or
internal loads, e.g. machinery or winches, etc.. The matters shall be considered on the basis of client's
specification as well as national requirements in the container structure.
C.4
Structural components
C.4.1
Primary structure
Following parts are required:

main load carrying and supporting frame
load carrying panels, e.g.floor
fork lift pockets
pad eyes
substructure for tanks
substructure for heavy equipment
corner brackets/corner posts
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C.4.2
Industrial Services
Structural Design
Containers
Secondary structure
Following items are included:

doors, walls, roof panels
panel stiffeners and corrugations
structural elements for protection purposes
internal securing points
C.4.3
Type of lifting set
Following items are relevant:

single or multi leg system
master links, shackles, chains, etc.
Materials and Production
D.1
Steel
D.1.1
General
Material selection to be mentioned in the material specification.. Chemical composition, mechanical properties, heat treatment and weldability shall be suitable for the purpose. Steels shall comply with material
requirements of the recognized standard. High strength steels, with specified yield strength above 500
MPa, shall not been used.
Steel forgings shall be carbon or carbon-manganese steels. Such forgings shall be made from killed and
fine-grain treated non-ageing steel.
Alloy steel shall be delivered in quenched and tempered condition.
ISO-corner fittings made from cast steel shall fulfil the requirements of ISO 3755.
Bolt assembly considered as an essential for structural and operational safety shall conform to ISO 898 or
other recognized standard.
Non-ferrous materials shall be suitable for the purpose.
D.1.2
Certificates
Materials for construction of offshore containers shall be according to following types:

type 3.2 (EN 10204) for ISO-corner fittings, pad eyes
type 3.1 (EN 10204) for primary structural members
type 2.2 (EN 10204) for secondary structural members
D.2
Welding
All main welds between the primary frame structure and pad eyes shall always be full penetration welds.
If additional supporting welds are required on pad eyes and/or supporting structures fillet welds may be
acceptable after special consideration.
Essential and non-redundant primary structural members shall be welded with full penetration welds.
Fork lift pockets shall be connected to the bottom rails with full penetration welds. In case of other primary
members fillet welds may be permitted after special agreement with the Certifying Body.
For secondary structural members fillet welds or intermittent fillet welds are acceptable. Corrosion protection requirements have to be observed.
Welds between primary and secondary structural members are considered to be fillet welds.
Welding consumables shall be according to recognized standards.
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Welding procedures shall be approved, depending on the type of material and a certified welding procedure qualification record (WPQR), for primary steel. Material test requirements are to be selected according to Section 4, A.4 for an exposure level L3.
Approved welders according to recognized standards are required.
D.3
Production
D.3.1
General
Production shall be performed according to approved drawings, specifications and procedures.

The manufacturer shall present a quality plan for acceptance before production starts. Relevant production documents shall be presented for acceptance before start of production, details see also (IV-7-4).
D.3.2
Inspection and NDE
The inspections shall be performed during manufacturing, witnessed testing and review of the production
documentation, details see Section 4.
Non-destructive testing shall be carried out according to both approved specifications and qualified operators, details see Section 4.
D.3.3
Marking and plating
Safety markings due to the type of container and manufacturing details are subject of the general marking.
The plate has to be marked according to EN 12079-1
D.4
Lifting sets
The lifting set shall be specially designed for use on offshore containers.
Lifting sets shall be approved and certified by Certifying Body. Testing of the lifting set with its components shall be performed to recognized standard. Traceabel material certificates to be used, type of Certificates shall be 3.1 according to EN 10204.
Periodic examination shall be performed at intervals not exceeding 12 months.
Electrical Requirements
E.1
Safety requirements
Following safety requirements shall apply:

installation shall be performed by qualified personnel
risk is to minimize for injury of personnel, damage of the environment in case of short circuits, earth
fault, fires, explosions and electrical shocks
protected devices to prevent overload, excessive heating and other damages
fail to safety principles due to missing electrical components
E.2
Components and equipment
All items shall be constructed according to an IEC or other recognized standard. Components and cables
to be rated based on IEC publications or other recognized standards.
Electrical equipment and systems are to be suitable for the environmental conditions as well as to withstand of a certain vibration level range. Protection against corrosion is required.
Insulation materials are to be flame retardant.
If the location of electrical components are outside of the container, the ingress protection classification
shall be at least IP56 and inside of the container at least IP20. For fire extinguishing systems are proEdition 2013
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vided, electrical equipment shall be at least IP56 for the safety functions. The environmental requirements
to be observed for an installation of electrical equipment, e.g. range of temperatures, humidity and sun
radiation, etc.
The indoor spaces shall be acceptable for performing maintenance and repair works in a safe way.
E.3
Arrangements
Following requirements of arrangements to be observed:

before final location outside equipment to be sheltered and/or protected against transportation damages
the heating shall be performed permanently for both onshore and offshore
portable equipment is to be securely fixed
E.4
Earthing system
The container earthing arrangement shall be selected to suit the requirements of the installation/unit on
which the container may be located.
All insulated electrical and control systems within the container are to have continuous insulation monitoring. Earth leakage circuit breakers are to be provided in the final sub circuits or at a suitable location upstream.
E.5
Requirements for electrical equipment exposed to hazardous atmospheres.
Following mandatory requirements shall apply:

Certification of a recognized institution for the equipment used in this area
type of relevant category for the intended area
temperature classification to be mentioned
E.6
Inspections of installation, repair and maintenance of Ex-equipment
Both the methods of installation and condition of Certification shall be verified.

Following items shall be prepared:
check lists for parts used and installed
functional testing of single components under normal and under service conditions as well as in
case of emergency requirements
intrinsically safe circuits shall be installed
no repairs shall be performed on Ex-equipment
E.7
Earthing of structure
Following earthing of the container structure required:

earth lug plate to be welded to the main steel structure on the outside of the container in the lower
part
AC systems above 30 V and DC systems above 50 V and all electrical power systems for containers
for hazardous areas
earthing system to be described
national requirements, if applicable, to be observed
E.8
Cables
Cables shall be securely fastened and terminated in a durable manner. Special attention shall be paid to
the gland arrangements and bending of cables near the entries and the bulkhead penetrations.
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E.9
Industrial Services
Structural Design
Containers
Electrical Systems
Following systems shall apply:

lighting
gas detection arrangement, if required
emergency shut down
systems required in emergencies, e.g. fire protection circuits, emergency lighting, public address
and general alarm circuits
etc.
All these systems are part of the whole electrical equipment and outfitting system and shall comply with
the relevant regulations according to IEC and/or other mandatory Rules, codes and standards.
Heating, Ventilation and Air Conditioning
F.1
General
General requirements for these systems on offshore containers are:

adequate ventilation and comfortable working temperature
ventilation may be used to keep the atmosphere free from explosive gases and vapours
internal over-pressure with respect to the external environment in case of a hazard source outside
calculations shall be performed and be based on a worst case flammable substance release scenario
offshore service containers shall be designed to meet the requirements
F.2
Ventilation arrangement
Mechanical ventilation or fan powered inlet ventilation should be applied for containers as working place.
Natural ventilation may be applied for storage purposes. Requirements for heating and/or cooling are
subject for special containers as a working space or equipment.
F.3
Over-pressure ventilation system
In case of such a system all other systems, e.g. electrical equipment, fire protection system, emergency
lighting, communication systems, etc. are subject to suitability. Also doors and other openings should be
arranged for this purpose and an air lock can support practically the flow out.
Public Address and Main Alarm Systems
G.1
General
According to the Rules such systems are required. Safety alarms, e.g. fire alarm, gas alarm and muster
alarms, have to cover all areas.
The final decision to what equipment is necessary will be up to the discretion of the persons responsible
on the installation/unit, when the final location of the container is decided.
G.2
Fire protection
The actual requirements for fire protection depend on both the fire risk inside the container and on the
actual location on the installation/unit.
The fire protection philosophy for offshore containers is subject of 4 main points:
passive fire protection
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active fire protection
means of escape
G.2.1
Passive fire protection
The purpose of passive fire protection may be both preventing a fire from spreading from the inside of the
container to the outside, and protecting equipment and personnel inside the container from flames or heat
radiation from the outside.
Ratings of passive fire protection are defined in IMO Res. A.754 (18) or equivalent standards. Materials
shall be tested to IMO FTP Code.
G.2.2
Fire detection and alarm system
Location and installation as well as type shall be according to the actual fire risk. All fire alarm components shall be type approved by GL or other recognised Certifying Bodies.
For containers permanently located on the platform the systems shall be part of an integral fire alarm
system.
If non-permanent location for offshore containers is required, the installation and all requirements have to
be fulfilled. Under such circumstances the fire detection system has been activated, e.g. stop of ventilation, activating of the extinguishing system, etc.
G.2.3
Active fire protection
Portable fire extinguishers have to be placed near each exit depending on the fire load and the type.
Fixed fire extinguishing system will be subject to evaluation in each separate case based on the fire risk
of the equipment mounted inside the container. Release facilities should be located outside of the container at an easily accessible position and shall be of manual type. In case of emergency the relevant
alarms and required shut-offs to be activated.
G.2.4
Escape routes
Generally two separate escape routes from each compartment are required, where personnel normally
are employed. On both sides these exits to be marked in both English and local language.
G.3
Application
Generally for an installation/unit the statutory regulations shall apply. Results from risk analysis and
evaluation of dimensional accidental events should be included in the consideration of the required protection and equipment.
G.4
Noise and vibration
Any noise and vibration sources situated in the container shall be addressed.
Portable Offshore Unit
H.1
General
The portable offshore unit is a package or unit intended for repeated or single offshore transportation and
installation/lifting. Here we have equipment or any other kind of installation intended for a service function
offshore.
H.2
Type of Structures
H.2.1
Primary structure
The primary structure includes:

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all main structural components

pad eyes
Other elements are lashing points, fork lift pockets, load distribution floor, deck beams, panels supporting,
substructures for tanks and/or for heavy equipment.
H.2.2
Secondary structure
Following structural parts are non-load carrying:

doors, walls and roof panels
panel stiffeners and corrugations
structural components used for protection only
H.3
Required design documentation
Following documents shall be submitted:

general arrangement, dimensions, any protruding parts
maximum gross weight and payload
design drawings of main structure including joints
design drawings of pad eyes
relevant design calculations with details of weight and centre of gravity (CoG)
design loads for main structures and design details
sling set details with maximum and minimum sling angles
material selection including material specification
joining methods
kind of operation, e.g. single event or multiple transport, handling procedures, etc.
corrosion protection, if required
list of applicable codes and standards
Certification Procedure
Following main steps of this procedure shall apply:

application
design verification including all details
production follow-up including manufacturing, inspection and testing
documentation
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IV

Rules for the Certification and Construction

The following Rules come into force on 1 October 2013.

Principles for Structural Design

Helicopter Deck Structures

Crane and Crane Support Structures

Basic Considerations ....................................................................................................

Normal environmental design conditions

Extreme environmental design conditions

Superposition of different environmental design parameters is to be based on physical relations or on

: horizontal coordinate axis in the direction of the wave propagation [m]

: vertical coordinate axis above still water level [m]

: water depth [m]

: wave height, crest to trough [m]

: wave period [s]

: wave length [m]

still water line

Mean wind speed

: mean wind speed at a reference height of 10 m [m/s]

: wind speed averaging time factor

: averaging time [minutes]

: reference averaging time

Wind speed averaging time factors Ct related to reference time tr = 10min

Minimum wind speed for stability calculations of mobile offshore units

Gust wind speed

Design wind speeds

: vertical coordinate axis above mean still water level [m]

still water line

Sea currents are characterized as:

near-surface currents, i.e., wind/wave generated currents, see C.2

Near-surface currents are typically wind induced.

: near surface current velocity [m/s]

: factor depending linearly on the vertical coordinate z

: to be obtained by linear interpolation for 0 > z > 15 m

: vertical coordinate axis above mean sea level [m]

: sustained wind speed used for design [m/s]

: sub-surface current velocity [m/s]

: water depth [m]

: vertical coordinate axis [m]

: current velocity at sea level [m/s]

Linear superposition of uSS(z) and uw(z) is applicable.

: near-shore current velocity [m/s]

: breaking wave height [m]

: 1.6 / [1 + exp(19 s)]

: water depth at the location of the breaking wave [m]

: period of the breaking wave [s]

For very small beach slopes, HB may be estimated from

Combined wave and current kinematics

Current blockage factors

Stretching of current profile and linear wave kinematics

Two-dimensional wave kinematics of regular waves

Equivalent design wave

Design wave period and design wave height

: design wave period [s]

: significant wave height [m]

: design wave height [m]

The design wave period TD shall not exceed 25 s.

: water depth [m]

0.002 < d / g T 2 < 0.06

Stokes 5th order

Intermediate Depth Waves

Dimensionless wave steepness

Regions of applicability of wave theories