SIST EN ISO 13535:2001
(Main)Petroleum and natural gas industries - Drilling and production equipment - Hoisting equipment (ISO 13535:2000)
Petroleum and natural gas industries - Drilling and production equipment - Hoisting equipment (ISO 13535:2000)
La présente Norme internationale définit les exigences pour la conception, la fabrication et les essais des équipements de levage utilisables pour les opérations de forage et de production. La présente Norme internationale couvre les équipements de levage utilisés pour le forage et la production suivants : a) poulies de levage b) moufles mobiles et fixes c) adaptateurs entre moufles et crochets d) pièces de connexion et d'adaptation pour bras élévateurs e) crochets de forage ; f) crochets pour tubes de production et barres de pompage g) bras élévateurs ; h) élévateurs pour tubes de cuvelage, de production, tiges et masse-tiges de forage i) élévateurs pour barres de pompage ; j) adaptateurs d'oeillets de têtes d'injection k) têtes d'injection (rotary swivels) ; l) têtes d'injection motorisées (powerswivels) m) raccords motorisés (powersubs) ; n) cales à coins lorsqu'elles peuvent être utilisées comme élévateurs o) réas ; p) compensateurs de pilonnement en ligne q) équipements de vissage de tiges carrées lorsqu'ils peuvent être utilisés comme équipement de levage r) réservoirs sous pression et tuyauterie installés sur des équipements de levage s) colliers de sûreté lorsqu'ils peuvent être utilisés comme équipement de levage t) chariots rétractables (doilies) (annexe B). La présente Norme internationale établit des exigences correspondant à deux niveaux de spécification de produits (PSL). Ces deux appellations PSL définissent différents niveaux d'exigences techniques. Toutes les exigences des chapitres 4 à 11 sont applicables à PSL 1, à moins d'être expressément identifié comme PSL 2. PSL 2 comprend toutes les exigences de PSL 1 plus des pratiques complémentaires prescrites dans le présent document. Des exigences supplémentaires ne s'appliquent que lorsqu'elles sont spécifiées. L'annexe A donne un nombre d'exigences supplémentaires normalisées.
Erdöl- und Erdgasindustrien - Bohr- und Fördereinrichtungen - Hebegerät (ISO 13535:2000)
Diese Internationale Norm enthält Normen für die Konstruktion, Fertigung und Prüfung von Hebegerät, das sich für den Einsatz bei Bohr- und Förderarbeiten eignet.
Diese Norm behandelt das nachstehende Hebegerät für Bohr- und Fördereinrichtungen:
a) Seilscheiben;
b) Flaschenzugblöcke und Hakenblöcke;
c) Block/Haken-Passstücke;
d) Verbindungsstücke und Bügelpassstücke;
e) Bohrhaken;
f) Steigrohr- und Pumpgestängehaken;
g) Elevatorbügel;
h) Futterrohr-, Steigrohr-, Bohrgestänge- und Schwerstangenelevatoren;
i) Pumpgestängeelevatoren;
j) Spülkopfbügel-Passstücke;
k) Spülköpfe;
l) Kraftspülköpfe;
m) Kellyverschraubvorrichtungen;
n) Keiltöpfe, wenn zum Einsatz als Elevatoren geeignet;
o) Totseilanker;
p) Bohrstrang-Bewegungsausgleichsvorrichtungen;
q) Kellyverschraubvorrichtungen, wenn zum Einsatz als Hebegerät geeignet;
r) Druckbehälter und am Hebegerät befestigte Rohrleitungen;
s) Sicherheitsklemmen, wenn zum Einsatz als Hebegerät geeignet;
t) Führungswagen (Anhang B).
Diese Internationale Norm enthält Anforderungen für zwei Produktspezifikationsstufen (PSL). Die beiden Bezeichnungen der Produktspezifikationsstufen legen unterschiedliche Stufen technischer Anforderungen fest. Alle Anforderungen der Abschnitte 4 bis 11 gelten für Produktspezifikationsstufe 1, sofern sie nicht besonders für die
Produktspezifikationsstufe 2 ausgewiesen sind. Produktspezifikationsstufe 2 schließt alle Anforderungen von
Produktspezifikationsstufe 1 sowie zusätzliche in der vorliegenden Norm aufgeführte Verfahren ein.
Zusätzliche Anforderungen gelten nur, wenn dies besonders angegeben ist. Anhang A enthält eine Anzahl
standardisierter zusätzlicher Anforderungen.
Industries du pétrole et du gaz naturel - Equipements de forage et de production - Equipement de levage (ISO 13535:2000)
La présente Norme internationale définit les exigences pour la conception, la fabrication et les essais des équipements de levage utilisables pour les opérations de forage et de production. La présente Norme internationale couvre les équipements de levage utilisés pour le forage et la production suivants : a) poulies de levage b) moufles mobiles et fixes c) adaptateurs entre moufles et crochets d) pièces de connexion et d'adaptation pour bras élévateurs e) crochets de forage ; f) crochets pour tubes de production et barres de pompage g) bras élévateurs ; h) élévateurs pour tubes de cuvelage, de production, tiges et masse-tiges de forage i) élévateurs pour barres de pompage ; j) adaptateurs d'oeillets de têtes d'injection k) têtes d'injection (rotary swivels) ; l) têtes d'injection motorisées (powerswivels) m) raccords motorisés (powersubs) ; n) cales à coins lorsqu'elles peuvent être utilisées comme élévateurs o) réas ; p) compensateurs de pilonnement en ligne q) équipements de vissage de tiges carrées lorsqu'ils peuvent être utilisés comme équipement de levage r) réservoirs sous pression et tuyauterie installés sur des équipements de levage s) colliers de sûreté lorsqu'ils peuvent être utilisés comme équipement de levage t) chariots rétractables (doilies) (annexe B). La présente Norme internationale établit des exigences correspondant à deux niveaux de spécification de produits (PSL). Ces deux appellations PSL définissent différents niveaux d'exigences techniques. Toutes les exigences des chapitres 4 à 11 sont applicables à PSL 1, à moins d'être expressément identifié comme PSL 2. PSL 2 comprend toutes les exigences de PSL 1 plus des pratiques complémentaires prescrites dans le présent document. Des exigences supplémentaires ne s'appliquent que lorsqu'elles sont spécifiées. L'annexe A donne un nombre d'exigences supplémentaires normalisées.
Petroleum and natural gas industries - Drilling and production equipment - Hoisting equipment (ISO 13535:2000)
General Information
Relations
Related Packages
Standards Content (Sample)
SLOVENSKI STANDARD
01-junij-2001
Petroleum and natural gas industries - Drilling and production equipment -
Hoisting equipment (ISO 13535:2000)
Petroleum and natural gas industries - Drilling and production equipment - Hoisting
equipment (ISO 13535:2000)
Erdöl- und Erdgasindustrien - Bohr- und Fördereinrichtungen - Hebegerät (ISO
13535:2000)
Industries du pétrole et du gaz naturel - Equipements de forage et de production -
Equipement de levage (ISO 13535:2000)
Ta slovenski standard je istoveten z: EN ISO 13535:2000
ICS:
75.180.10 Oprema za raziskovanje in Exploratory and extraction
odkopavanje equipment
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.
INTERNATIONAL ISO
STANDARD 13535
First edition
2000-12-15
Petroleum and natural gas industries —
Drilling and production equipment —
Hoisting equipment
Industries du pétrole et du gaz naturel — Équipements de forage et de
production — Équipement de levage
Reference number
ISO 13535:2000(E)
©
ISO 2000
ISO 13535:2000(E)
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ii © ISO 2000 – All rights reserved
ISO 13535:2000(E)
Contents Page
Foreword.v
Introduction.vi
1 Scope .1
2 Normative references .2
3 Terms, definitions and abbreviated terms .3
3.1 Terms and definitions .3
3.2 Abbreviated terms .5
4 Design .5
4.1 General.5
4.2 Design conditions.5
4.3 Strength analysis.5
4.4 Size class.7
4.5 Contact surface radii .7
4.6 Rating.7
4.7 Design safety factor .7
4.8 Shear strength.8
4.9 Specific equipment.8
4.10 Design documentation .8
5 Design verification test .8
5.1 General.8
5.2 Sampling of test units .8
5.3 Test procedures.8
5.4 Determination of load rating.9
5.5 Alternative design verification test procedure and rating.9
5.6 Design verification test apparatus.10
5.7 Design changes .10
5.8 Records.10
6 Materials requirements .10
6.1 General.10
6.2 Written specifications .10
6.3 Mechanical properties.11
6.4 Material qualification .11
6.5 Manufacture.12
6.6 Chemical composition .12
7 Welding requirements .15
7.1 General.15
7.2 Welding qualifications.15
7.3 Written documentation.15
7.4 Control of consumables.15
7.5 Weld properties.15
7.6 Post-weld heat-treatment.16
7.7 Fabrication welds.16
7.8 Repair welds.16
8 Quality control.17
8.1 General.17
8.2 Quality control personnel qualifications.17
8.3 Measuring and test equipment.17
8.4 Quality control for specific equipment and components.17
ISO 13535:2000(E)
8.5 Dimensional verification .22
8.6 Proof load test.22
8.7 Hydrostatic testing.23
8.8 Functional testing .23
9 Equipment.24
9.1 General.24
9.2 Hoisting sheaves.24
9.3 Travelling blocks.25
9.4 Block-to-hook adapters.26
9.5 Connectors, link-adapters and drill-pipe elevator-adapters.26
9.6 Drilling hooks .26
9.7 Elevator links.26
9.8 Elevators .26
9.9 Rotary swivels.29
9.10 Power swivels.36
9.11 Power subs.36
9.12 Wireline anchors .37
9.13 Drill-string motion compensators .37
9.14 Pressure vessels and piping .37
9.15 Anti-friction bearings.37
9.16 Safety clamps when capable of being used as hoisting equipment .37
10 Marking .38
10.1 Product marking.38
10.2 Rating marking.38
10.3 Composite equipment marking .38
10.4 Component traceability .38
10.5 Serialization.38
10.6 Marking method .38
11 Documentation.38
11.1 General.38
11.2 Documentation to be kept by the manufacturer.39
11.3 Documentation to be delivered with the equipment .39
Annex A (normative) Supplementary requirements .41
A.1 General.41
A.2 SR 1 Proof load test.41
A.3 SR 2 Low temperature test.41
A.4 SR 3 Data book.41
A.5 SR 4 Additional volumetric examination of castings.42
A.6 SR 5 Volumetric examination of wrought material.42
Annex B (normative) Guide dollies.43
B.1 General.43
B.2 Principal loading conditions and corresponding safety factors .43
B.3 Loads and load combinations .43
B.4 Fatigue considerations.44
B.5 Special safety precautions.44
Annex C (informative) Guidance for qualification of heat-treatment equipment.45
C.1 Temperature tolerance .45
C.2 Furnace calibration.45
C.3 Instruments.46
Bibliography .47
iv © ISO 2000 – All rights reserved
ISO 13535:2000(E)
Foreword
ISO (the International Organization for Standardization) is a worldwide federation of national standards bodies (ISO
member bodies). The work of preparing International Standards is normally carried out through ISO technical
committees. Each member body interested in a subject for which a technical committee has been established has
the right to be represented on that committee. International organizations, governmental and non-governmental, in
liaison with ISO, also take part in the work. ISO collaborates closely with the International Electrotechnical
Commission (IEC) on all matters of electrotechnical standardization.
International Standards are drafted in accordance with the rules given in the ISO/IEC Directives, Part 3.
Draft International Standards adopted by the technical committees are circulated to the member bodies for voting.
Publication as an International Standard requires approval by at least 75 % of the member bodies casting a vote.
Attention is drawn to the possibility that some of the elements of this International Standard may be the subject of
patent rights. ISO shall not be held responsible for identifying any or all such patent rights.
International Standard ISO 13535 was prepared by Technical Committee ISO/TC 67, Materials, equipment and
offshore structures for petroleum and natural gas industries, Subcommittee SC 4, Drilling and production
equipment.
Annexes A and B form a normative part of this International Standard. Annex C is for information only.
ISO 13535:2000(E)
Introduction
rd
This International Standard is based upon API Spec 8C [2], 3 edition, December 1997.
Users of this International Standard should be aware that further or differing requirements may be needed for
individual applications. This International Standard is not intended to inhibit a vendor from offering, or the purchaser
from accepting, alternative equipment or engineering solutions for the individual application. This may be
particularly applicable where there is innovative or developing technology. Where an alternative is offered, the
vendor should identify any variations from this International Standard and provide details.
vi © ISO 2000 – All rights reserved
INTERNATIONAL STANDARD ISO 13535:2000(E)
Petroleum and natural gas industries — Drilling and production
equipment — Hoisting equipment
1 Scope
This International Standard provides requirements for the design, manufacture and testing of hoisting equipment
suitable for use in drilling and production operations.
This International Standard is applicable to the following drilling and production hoisting equipment:
a) hoisting sheaves;
b) travelling blocks and hook blocks;
c) block-to-hook adapters;
d) connectors and link adapters;
e) drilling hooks;
f) tubing hooks and sucker-rod hooks;
g) elevator links;
h) casing elevators, tubing elevators, drill-pipe elevators and drill-collar elevators;
i) sucker-rod elevators;
j) rotary swivel-bail adapters;
k) rotary swivels;
l) power swivels;
m) power subs;
n) spiders, if capable of being used as elevators;
o) wire-line anchors;
p) drill-string motion compensators;
q) kelly spinners, if capable of being used as hoisting equipment;
r) pressure vessels and piping mounted onto hoisting equipment;
s) safety clamps, if capable of being used as hoisting equipment;
t) guide dollies (annex B).
ISO 13535:2000(E)
This International Standard establishes requirements for two product specification levels (PSLs). These two PSL
designations define different levels of technical requirements. All the requirements of clause 4 through clause 11
are applicable to PSL 1 unless specifically identified as PSL 2. PSL 2 includes all the requirements of PSL 1 plus
the additional practices as stated herein.
Supplementary requirements apply only when specified. Annex A gives a number of standardized supplementary
requirements.
2 Normative references
The following normative documents contain provisions which, through reference in this text, constitute provisions of
this International Standard. For dated references, subsequent amendments to, or revisions of, any of these
publications do not apply. However, parties to agreements based on this International Standard are encouraged to
investigate the possibility of applying the most recent editions of the normative documents indicated below.
Members of ISO and IEC maintain registers of currently valid International Standards.
ISO 10422, Petroleum and natural gas industries – Threading, gauging and thread inspection of casing ,tubing and
line pipe threads – Specifications.
ISO 11960, Petroleum and natural gas industries – Steel pipes for use as casing or tubing for wells.
1)
API RP 9B, Application, Care, and Use of Wire Rope for Oil Field Service.
API Spec 7, Rotary Drill Stem Elements.
2)
ASME B31.3, Chemical Plant and Petroleum Refinery Piping.
ASME V BPVC Section 5, 1998, Non-destructive Examination.
ASME VIII, DIV 1, Rules for Construction of Pressure Vessels.
ASME IX, Welding and Brazing specification.
3)
ASTM A370, Standard Test Methods and Definitions for Mechanical Testing of Steel Products.
ASTM A 388, Standard Practice for Ultrasonic Examination of Heavy Steel Forgings.
ASTM A 488, Standard Practice for Steel Castings, Welding, Qualifications of Procedures and Personnel.
ASTM A 770, Standard Specification for Through-Thickness Tension Testing of Steel Plates for Special
Applications.
ASTM E 4, Load Verification of Testing Machines.
ASTM E 125, Standard Reference Photographs for Magnetic Particle Indications on Ferrous Castings.
ASTM E 165, Standard Test Method for Liquid Penetrant Examination.
ASTM E 186, Standard Reference Radiographs for Heavy-Walled (2 to 4 1/2-in. (51 to 114-mm)) Steel Castings.
ASTM E 280, Standard Reference Radiographs for Heavy-Walled (4 1/2 to 12-in. (114 to 305-mm)) Steel Castings.
1) American Petroleum Institute; 1220 L St N.W.; Washington DC, 20005; USA.
th
2) American Society of Mechanical Engineers; 345 East 47 Street; New York, NY 10017; USA.
3) American Society for Testing and Materials; 100 Barr Harbor Drive; West Conshohocken, PA 19428; USA.
2 © ISO 2000 – All rights reserved
ISO 13535:2000(E)
ASTM E 428, Standard Practice for Fabrication and Control of Steel Reference Blocks Used in Ultrasonic
Inspection.
ASTM E 446, Standard Reference Radiographs for Steel Castings Up to 2 in. (51 mm) in Thickness.
ASTM E 709, Standard Guide for Magnetic Particle Examination.
4)
ASNT-TC-IA , Recommended practice for personnel qualification and certification in non-destructive testing.
AWS D1.1, Structural welding code.
AWS QC1, Standard for AWS Certification of Welding Inspectors.
EN 287 (all parts), Approval testing of welders – Fusion welding.
EN 288 (all parts), Specification and qualification of welding procedures for metallic materials.
5)
MSS SP-55, Quality standard for steel castings for valves, flanges and fittings and other piping components –
Visual method for evaluation of surface irregularities.
3 Terms, definitions and abbreviated terms
For the purposes of this International Standard, the following terms, definitions and abbreviated terms apply.
3.1 Terms and definitions
3.1.1
bearing-load rating
calculated maximum load for bearings subjected to the primary load
3.1.2
design load
sum of static and dynamic loads that would induce the maximum allowable stress in an item
3.1.3
design safety factor
factor to account for a certain safety margin between the maximum allowable stress and the specified minimum
yield strength of a material
3.1.4
design verification test
test performed to validate the integrity of the design calculations used
3.1.5
dynamic load
load applied to the equipment due to acceleration effects
3.1.6
equivalent-round
standard for comparing various shaped sections to round bars, used for determining the response to hardening
characteristics when heat-treating low-alloy and martensitic corrosion-resistant steels
4) American Society for Nondestructive Testing; 4153 Arlingate Plaza; Box 28518; Columbus, OH 43228; USA.
5) Manufacturers' Standardization Society of the Valve and Fittings Industry; 127 Park Street NE; Vienna, VA 22180; USA.
ISO 13535:2000(E)
3.1.7
linear indication
indication revealed by NDE, having a length of at least three times the width
3.1.8
load rating
maximum operating load, both static and dynamic, to be applied to the equipment
NOTE The load rating is numerically equivalent to the design load.
3.1.9
maximum allowable stress
specified minimum yield strength divided by the design safety factor
3.1.10
primary load
axial load which equipment is subjected to in operations
3.1.11
primary-load-carrying component
component of the equipment through which the primary load is carried
3.1.12
product specification level
degree of controls applied on materials and processes for the primary-load-carrying components of the equipment
NOTE The two product specification levels are identified by the code PSL 1 or PSL 2.
3.1.13
proof load test
production load test performed to validate the load rating of a unit
3.1.14
repair
removal of defects from, and refurbishment of, a component or assembly by welding, during the manufacture of
new equipment
NOTE The term "repair", as referred to in this International Standard, applies only to the repair of defects in materials
during the manufacture of new equipment.
3.1.15
rounded indication
indication revealed by NDE, with a circular shape or with an elliptical shape having a length of less than three times
the width
3.1.16
safe working load
the design load minus the dynamic load
3.1.17
size class
designation by which dimensionally-interchangeable equipment of the same maximum load rating is identified
3.1.18
special process
operation which may change or affect the mechanical properties, including toughness, of the materials used in the
equipment
4 © ISO 2000 – All rights reserved
ISO 13535:2000(E)
3.1.19
test unit
prototype unit upon which a design verification test is conducted
3.2 Abbreviated terms
ER equivalent-round
HAZ heat-affected zone
PSL product specification level
NDE non-destructive examination
PLC principal loading condition
PWHT post-weld heat-treatment
4 Design
4.1 General
Hoisting equipment shall be designed, manufactured and tested so that it is in every respect fit for its intended
purpose. The equipment shall safely transfer the load for which it is intended. The equipment shall be designed for
simple and safe operation. Guide dollies shall be designed in accordance with annex B.
4.2 Design conditions
The following design conditions shall apply:
a) the operator of the equipment shall be responsible for determination of the safe working load for any hoisting
operation;
b) the minimum design and operating temperature shall be – 20 °C, unless supplementary requirement SR 2 has
been applied (see A.3).
CAUTION — The equipment should not be used at the full load rating at temperatures below –20 °C unless appropriate
materials with the required toughness properties at lower design temperatures have been used (see A.3).
4.3 Strength analysis
4.3.1 General
The equipment design analysis shall address excessive yielding, fatigue and buckling as possible modes of failure.
The strength analysis shall be generally based on the elastic theory. An ultimate strength (plastic) analysis may,
however, be used where appropriate. Finite-element mesh analysis, in conjunction with analytical methods, may be
used.
All forces that may govern the design shall be taken into account. For each cross-section to be considered, the
most unfavourable combination, position and direction of forces shall be used.
ISO 13535:2000(E)
4.3.2 Simplified assumptions
Simplified assumptions regarding stress distribution and stress concentration may be used, provided that the
assumptions are made in accordance with generally accepted practice or based on sufficiently comprehensive
experience or tests.
4.3.3 Empirical relationships
Empirical relationships may be used in lieu of analysis, provided such relationships are supported by documented
strain gauge test results that verify the stresses within the component. Equipment or components which, by their
design, do not permit the attachment of strain gauges to verify the design shall be qualified by testing in
accordance with 5.5.
4.3.4 Equivalent stress
The strength analysis shall be based on elastic theory. The nominal equivalent stress, according to the
Von Mises-Hencky theory, caused by the design load shall not exceed the maximum allowable stress AS as
max
calculated by equation (1).
YS
min
AS � (1)
max
SF
D
where
YS is the specified minimum yield strength;
min
SF is the design safety factor.
D
4.3.5 Ultimate strength (plastic) analysis
An ultimate strength (plastic) analysis may be performed under any one of the following conditions:
a) for contact areas;
b) for areas of highly localized stress concentrations caused by part geometry, and other areas of high stress
gradients where the average stress in the section is less than or equal to the maximum allowable stress as
defined in 4.3.4.
In such areas, the elastic analysis shall govern for all values of stress below the average stress.
In the case of plastic analysis, the equivalent stress as defined in 4.3.4 shall not exceed the maximum allowable
stress AS as calculated by equation (2).
max
TS
min
AS � (2)
max
SF
D
where
TS is the specified minimum ultimate tensile strength;
min
SF is the design safety factor.
D
4.3.6 Stability analysis
The stability analysis shall be carried out according to generally accepted theories of buckling.
6 © ISO 2000 – All rights reserved
ISO 13535:2000(E)
4.3.7 Fatigue analysis
The fatigue analysis shall be based on a period of time of not less than 20 years, unless otherwise agreed.
The fatigue analysis shall be carried out according to generally accepted theories. A method that may be used is
defined in reference [3].
4.4 Size class
The size class shall represent the dimensional interchangeability and the load rating of equipment.
4.5 Contact surface radii
Figure 7, Figure 8, Figure 9 and Table 6 show radii of hoisting-tool contact surfaces. These contact radii are
applicable to hoisting tools used in drilling (including tubing hooks), but all other work-over tools are excluded.
4.6 Rating
All hoisting equipment furnished under this International Standard shall be rated as specified herein.
Such ratings shall consist of a load rating for all equipment and a bearing-load rating for all equipment containing
bearings within the primary load path.
The bearing-load rating is intended primarily to achieve consistency of ratings, but is also intended to provide a
reasonable service life for bearings when used at loads within the equipment-load rating.
The load rating shall be based on the design safety factor as specified in 4.7, the specified minimum yield strength
of the material used in the primary-load-carrying components and the stress distribution as determined by design
calculations and/or data developed in a design verification load test as specified in 5.5.
The load rating shall be marked on the equipment (refer to clause 10).
4.7 Design safety factor
The design safety factor shall be established from Table 1 as follows.
Table 1 — Design safety factor
Load rating
Design safety factor
R
SF
D
kN (ton)
1 334 kN (150 short tons) and less 3,00
a
1 334 kN (150 short tons) to 4 448 kN (500 short tons) inclusive
3,00 – [0,75 � (R – 1 334)/3 114]
Over 4 448 kN (500 short tons) 2,25
a
In this formula, the value of R shall be in kilonewtons.
The design safety factor is intended as a design criterion and shall not under any circumstances be construed as
allowing loads on the equipment in excess of the load rating.
ISO 13535:2000(E)
4.8 Shear strength
For purposes of design calculations involving shear, the ratio of yield strength in shear to yield strength in tension
shall be 0,58.
4.9 Specific equipment
Refer to clause 9 for all additional equipment-specific design requirements.
4.10 Design documentation
Documentation of the design shall include methods, assumptions, calculations and design requirements. Design
requirements shall include, but not be limited to, those criteria for size, test and operating pressures, material,
environmental and specification requirements, and pertinent requirements upon which the design is to be based.
The requirements shall also apply to design change documentation.
5 Design verification test
5.1 General
To assure the integrity of equipment design, design verification testing shall be performed as specified below.
Design verification testing of equipment shall be carried out and/or certified by a department or organization
independent of the design function.
Equipment which, by virtue of its simple geometric form, permits accurate stress analysis through calculation only
shall be exempted from design verification testing.
5.2 Sampling of test units
To qualify design calculations applied to a family of units with an identical design concept but of varying sizes and
ratings, the following sampling options apply:
� a minimum of three units of the design shall be subjected to design verification testing. The test units shall be
selected from the lower end, middle and upper end of the size/rating range;
� alternatively, the required number of test units shall be established on the basis that each test unit also
qualifies one size or rating above and below that of the selected test unit.
NOTE The second option generally applies to limited product size/rating ranges.
5.3 Test procedures
5.3.1 Functional test
Load the test unit to the design load. After this load has been released, check the unit to verify that the functions of
the equipment and its components have not been impaired by this loading.
5.3.2 Design verification test
Apply strain gauges to the test unit at all places where high stresses are anticipated, provided that the configuration
of the units permits such techniques. Tools such as finite-element analysis, models, brittle lacquer, etc. should be
used to confirm the proper location of the strain gauges. Three element strain gauges should be applied in critical
8 © ISO 2000 – All rights reserved
ISO 13535:2000(E)
areas to permit determination of the shear stresses and to eliminate the need for exact orientation of the strain
gauges.
The design verification test load to be applied to the test unit shall be determined as follows:
Design verification test load = 0,8� R � SF , but not less than 2R (3)
D
where
R is the loadratinginkilonewtons;
SF is the design safety factor as defined in 3.1.3 and 4.7.
D
Load the unit to the design verification test load. This test load should be applied carefully, reading the strain gauge
values and observing the yield. The test unit should be loaded as many times as necessary to obtain adequate
data.
The stress values computed from the strain gauge readings shall not exceed the values obtained from design
calculations (based on the design verification test load) by more than the uncertainty of the testing apparatus
specified in 5.6. Failure to meet this requirement or premature failure of any test unit shall be cause for a complete
reassessment of the design followed by additional testing of an identical number of test units as originally required,
including a test unit of the same size and rating as the one that failed.
Upon completion of the design verification test, disassemble the unit and check the dimensions of each part for
evidence of yielding.
Individual parts of a unit may be tested separately if the holding fixtures simulate the load conditions applicable to
thepartintheassembledunit.
5.4 Determination of load rating
Determine the load rating from the results of the design verification test and/or the design and stress-distribution
calculations required by clause 4. The stresses at that rating shall not exceed the values allowed in 4.3. Localized
yielding is permitted at areas of contact. In a test unit that has been design-verification tested, the critical
permanent deformation determined by strain gauges or other suitable means shall not exceed 0,2 %, except in
contact areas. If the stresses exceed the allowable values, redesign the affected part or parts to obtain the desired
rating. Stress-distribution calculations may be used to establish the load rating of equipment only if the results of
the analysis are shown to be within acceptable engineering allowances as verified by the design verification test
prescribed by clause 5.
5.5 Alternative design verification test procedure and rating
Destructive testing of the test unit may be used, provided an accurate yield and tensile strength of the material
used in the equipment has been determined. This may be accomplished by using tensile-test specimens of the
actual material in the part destructively tested and determining the yield-to-ultimate strength ratio. The ratio is then
used to rate the equipment by the following equation:
YS
m
RL�� (4)
b
TS � SF
aD
where
SF is the design safety factor (see 4.7);
D
YS is the minimum specified yield strength;
m
TS is the actual ultimate tensile strength;
a
ISO 13535:2000(E)
L is the breaking load;
b
R is the load rating.
Since this method of design qualification is not derived from stress calculations, qualification shall be limited to the
specific model, size and rating tested.
5.6 Design verification test apparatus
Calibrate the loading apparatus used to simulate the working load on the test unit in accordance with ASTM E 4 so
as to ensure that the prescribed test load is obtained. For loads exceeding 3 558 kN (400 short tons), verify the
load-testing apparatus with calibration devices traceable to a Class A calibration device and having an uncertainty
of less than 2,5 %.
Test fixtures shall load the test unit (or part) in essentially the same manner as in actual service and with essentially
the same areas of contact on the load-bearing surface. All equipment used to load the test unit (or part) shall be
verified as to its capability to perform the test.
5.7 Design changes
When any change in design or manufacturing method changes the load rating, a supportive design verification test
in conformance with clause 5 shall be carried out. The manufacturer shall evaluate all changes in design or
manufacturing methods to determine whether the load rating is affected. This evaluation shall be documented.
5.8 Records
All design verification records and supporting data shall be subject to the same controls as specified for design
documentation in 11.2.
6 Materials requirements
6.1 General
All materials shall be suitable for the intended service.
The remainder of clause 6 describes the various material qualification, property and processing requirements for
primary-load-carrying components and pressure-containing components unless otherwise specified.
6.2 Written specifications
Materials shall be produced to a written material specification which shall, as a minimum, define the following
parameters and limitations:
� mechanical property requirements;
� material qualification;
� processing requirements, including permitted melting, working and heat treatment;
� chemical composition and tolerances;
� repair-welding requirements.
The description of the working practice shall include the forging reduction-ratio.
10 © ISO 2000 – All rights reserved
ISO 13535:2000(E)
6.3 Mechanical properties
Materials shall meet the property requirements specified in the manufacturer's material specification.
The impact toughness shall be determined from the average of three tests, using full-size test pieces if the size of
the component permits. If it is necessary for sub-size impact test pieces to be used, the acceptance criteria for
impact values shall be those stated below but multiplied by the appropriate adjustment factor listed in Table 3. Sub-
size test pieces of width less than 5 mm shall not be used.
For materials of a specified minimum yield strength of at least 310 MPa (45 ksi), the average impact toughness
shall be at least 42 J (31 ft-lb) at –20 °C, with no individual value less than 32 J (24 ft-lb).
For materials with a minimum specified minimum yield strength of less than 310 MPa (45 ksi), the average impact
toughness shall be 27 J (20 ft-lb) at –20 °C with no individual value less than 20 J (15 ft-lb).
For design temperatures below – 20 °C (e.g. arctic service), supplementary impact toughness requirements shall
apply, see annex A, SR2.
Where the design requires through-thickness properties, materials shall be tested for reduction of area in the
through-thickness direction in accordance with ASTM A 770. The minimum reduction shall be 25 %.
PSL 2 components shall be fabricated from materials meeting the applicable requirements for ductility specified in
Table 2.
Table 2 — Elongation requirements (PSL-2)
Yield strength Elongation, minimum
%
a a
MPa (ksi)
L =4d L =5d
o o
Less than 310 (45) 23 20
310 to 517 (45 to 7
...
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