DEP SPECIFICATION

MANUFACTURE, TESTING, AND INSPECTION OF

PERMANENT MOORING SYSTEM CHAIN AND
ACCESSORIES FOR FLOATING STRUCTURES
(BASED ON DNV-OS-E302)

DEP 37.81.21.30-Gen.

February 2012
ECCN EAR99

DESIGN AND ENGINEERING PRACTICE

© 2012 Shell Group of companies

All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, published or transmitted, in any form or by any means, without the prior
written permission of the copyright owner or Shell Global Solutions International BV.

This document contains information that is classified as EAR99 and, as a consequence, can neither be exported nor re-exported to any country which is under an
embargo of the U.S. government pursuant to Part 746 of the Export Administration Regulations (15 C.F.R. Parts 746) nor can be made available to any national of such
country. In addition, the information in this document cannot be exported nor re-exported to an end-user or for an end-use that is prohibited by Part 744 of the Export
Administration Regulations (15 C.F.R. Parts 744).

.
ECCN EAR99 DEP 37.81.21.30-Gen.
February 2012Page 2

PREFACE
DEP (Design and Engineering Practice) publications reflect the views, at the time of publication, of Shell Global Solutions
International B.V. (Shell GSI) and, in some cases, of other Shell Companies.
These views are based on the experience acquired during involvement with the design, construction, operation and
maintenance of processing units and facilities. Where deemed appropriate DEPs are based on, or reference international,
regional, national and industry standards.
The objective is to set the standard for good design and engineering practice to be applied by Shell companies in oil and
gas production, oil refining, gas handling, gasification, chemical processing, or any other such facility, and thereby to help
achieve maximum technical and economic benefit from standardization.
The information set forth in these publications is provided to Shell companies for their consideration and decision to
implement. This is of particular importance where DEPs may not cover every requirement or diversity of condition at each
locality. The system of DEPs is expected to be sufficiently flexible to allow individual Operating Units to adapt the
information set forth in DEPs to their own environment and requirements.
When Contractors or Manufacturers/Suppliers use DEPs, they shall be solely responsible for such use, including the
quality of their work and the attainment of the required design and engineering standards. In particular, for those
requirements not specifically covered, the Principal will typically expect them to follow those design and engineering
practices that will achieve at least the same level of integrity as reflected in the DEPs. If in doubt, the Contractor or
Manufacturer/Supplier shall, without detracting from his own responsibility, consult the Principal.
The right to obtain and to use DEPs is restricted, and is granted by Shell GSI (and in some cases by other Shell
Companies) under a Service Agreement or a License Agreement. This right is granted primarily to Shell companies and
other companies receiving technical advice and services from Shell GSI or another Shell Company. Consequently, three
categories of users of DEPs can be distinguished:
1) Operating Units having a Service Agreement with Shell GSI or another Shell Company. The use of DEPs by these
Operating Units is subject in all respects to the terms and conditions of the relevant Service Agreement.
2) Other parties who are authorised to use DEPs subject to appropriate contractual arrangements (whether as part of
a Service Agreement or otherwise).
3) Contractors/subcontractors and Manufacturers/Suppliers under a contract with users referred to under 1) or 2)
which requires that tenders for projects, materials supplied or - generally - work performed on behalf of the said
users comply with the relevant standards.
Subject to any particular terms and conditions as may be set forth in specific agreements with users, Shell GSI disclaims
any liability of whatsoever nature for any damage (including injury or death) suffered by any company or person
whomsoever as a result of or in connection with the use, application or implementation of any DEP, combination of DEPs
or any part thereof, even if it is wholly or partly caused by negligence on the part of Shell GSI or other Shell Company. The
benefit of this disclaimer shall inure in all respects to Shell GSI and/or any Shell Company, or companies affiliated to these
companies, that may issue DEPs or advise or require the use of DEPs.
Without prejudice to any specific terms in respect of confidentiality under relevant contractual arrangements, DEPs shall
not, without the prior written consent of Shell GSI, be disclosed by users to any company or person whomsoever and the
DEPs shall be used exclusively for the purpose for which they have been provided to the user. They shall be returned after
use, including any copies which shall only be made by users with the express prior written consent of Shell GSI. The
copyright of DEPs vests in Shell Group of companies. Users shall arrange for DEPs to be held in safe custody and Shell
GSI may at any time require information satisfactory to them in order to ascertain how users implement this requirement.
All administrative queries should be directed to the DEP Administrator in Shell GSI.
ECCN EAR99 DEP 37.81.21.30-Gen.
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TABLE OF CONTENTS
1. INTRODUCTION................................................................................................ 4
1.1 SCOPE............................................................................................................... 4
1.2 DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS. .4
1.3 DEFINITIONS.................................................................................................... 4
1.4 CROSS-REFERENCES.....................................................................................5
1.5 SUMMARY OF MAIN CHANGES......................................................................5
1.6 COMMENTS ON THIS DEP..............................................................................5
1.7 DUAL UNITS...................................................................................................... 6
1.8 PROJECT DOCUMENTATION REQUIREMENTS............................................6
2. GENERAL.......................................................................................................... 7
2.1 UNDERLYING INDUSTRY SPECIFICATION (DNV-OS-E302).........................7
2.2 PREQUALIFICATION........................................................................................7
2.3 QUALITY REQUIREMENTS..............................................................................7
2.4 CONTRACTOR/SUBCONTRACTOR CHAIN AND ACCESSORY
PROCUREMENT SPECIFICATION...................................................................7
2.5 APPROVAL OF MANUFACTURERS/SUPPLIERS AND MANUFACTURING
FACILITIES AND SUBCONTRACTED CHEMICAL ANALYSIS OR
MECHANICAL TESTING LABORATORIES......................................................7
2.6 LOWEST ANTICIPATED SERVICE TEMPERATURE (LAST)..........................7
2.7 DESIGN LIFE AND CORROSION PROTECTION.............................................7
2.8 CHAIN TYPE AND GRADE, DIMENSIONS AND SPECIAL ATTRIBUTES.......8
2.9 TRACEABILITY.................................................................................................. 8
2.10 PRE-PRODUCTION MEETING.........................................................................8
2.11 SUBMITTALS..................................................................................................... 8
3. MATERIALS...................................................................................................... 9
3.1 GENERAL.......................................................................................................... 9
3.2 BARS................................................................................................................. 9
3.3 FORGINGS...................................................................................................... 10
3.4 CASTINGS....................................................................................................... 10
3.5 STUDS............................................................................................................. 11
4. MOORING CHAIN CABLES AND ACCESSORIES........................................12
4.1 GENERAL........................................................................................................ 12
4.2 MOORING CHAIN............................................................................................ 12
4.3 CHAIN ACCESSORIES...................................................................................13
5. TESTS AND INSPECTION OF FINISHED CHAIN AND ACCESSORIES......14
5.1 GENERAL........................................................................................................ 14
5.2 TESTING AND INSPECTION OF MOORING CHAIN......................................14
5.3 TESTS AND INSPECTION OF ACCESSORIES.............................................16
6. PACKING, HANDLING AND TRANSPORT....................................................16
7. REFERENCES................................................................................................. 17

APPENDICES
APPENDIX 1 SUBMITTALS REQUIRING ACTION BY THE PRINCIPAL...................18
APPENDIX 2 INCLUSION RATING LIMITS..................................................................20
ECCN EAR99 DEP 37.81.21.30-Gen.
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1. INTRODUCTION

1.1 SCOPE
This new DEP specifies minimum requirements and gives recommendations for
manufacture, testing, and inspection of permanent mooring system chain and accessories
for deepwater structures. This DEP is based on DNV-OS-E302, Offshore Mooring Chain.
This DEP supersedes the former local Deepwater standard of the same number
(DEP 37.81.21.31-EPP) dated August 2007; see (1.5) regarding the changes.

1.2 DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS

Unless otherwise authorised by Shell GSI, the distribution of this DEP is confined to Shell
companies and, where necessary, to Contractors and Manufacturers/Suppliers nominated
by them. Any authorized access to DEPs does not for that reason constitute an
authorization to any documents, data or information to which the DEPs may refer.
This DEP is intended for use in facilities related to oil and gas production, gas handling, oil
refining, chemical processing, gasification, distribution and supply/marketing. This DEP
may also be applied in other similar facilities.
When DEPs are applied, a Management of Change (MOC) process shall be implemented;
this is of particular importance when existing facilities are to be modified.
If national and/or local regulations exist in which some of the requirements could be more
stringent than in this DEP, the Contractor shall determine by careful scrutiny which of the
requirements are the more stringent and which combination of requirements will be
acceptable with regard to the safety, environmental, economic and legal aspects. In all
cases, the Contractor shall inform the Principal of any deviation from the requirements of
this DEP which is considered to be necessary in order to comply with national and/or local
regulations. The Principal may then negotiate with the Authorities concerned, the objective
being to obtain agreement to follow this DEP as closely as possible.

1.3 DEFINITIONS
1.3.1 General definitions
The Contractor is the party that carries out all or part of the design, engineering,
procurement, construction, commissioning or management of a project or operation of a
facility. The Principal may undertake all or part of the duties of the Contractor.
The Manufacturer/Supplier is the party that manufactures or supplies equipment and
services to perform the duties specified by the Contractor.
The Principal is the party that initiates the project and ultimately pays for it. The Principal
may also include an agent or consultant authorised to act for, and on behalf of, the
Principal.
The word shall indicates a requirement.
The word should indicates a recommendation.
1.3.2 Specific definitions

Term Definition
CTOD Crack Tip Opening Displacement
DAC Distance Amplitude Correction
DNV Det Norske Veritas
FBH Flat-Bottomed Hole
LAST Lowest Anticipated Service Temperature
ECCN EAR99 DEP 37.81.21.30-Gen.
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Term Definition
MPS Manufacturing Procedure Specification. Reference ISO 9000 Paragraphs
2.7.2.c, 2.7.2.e, 3.4.5 and 3.7.3. The MPS shall clearly define the sequence
of operations and process controls to be implemented at each
manufacturing step as well as specifically annotate any procedures,
processing parameters, or requirements that deviate from this DEP. It is
required that the MPS be approved by the Principal.
MT Magnetic Particle Testing
MTR Material Test Report, a.k.a. mill certificate. Includes results of chemical
analyses, mechanical properties test, visual and non-destructive tests and
dimensional inspections
NDT Non-Destructive Testing
PMI Positive Material Identification
QP Quality Plan. Reference ISO 9000 Paragraphs 2.7.2.b and 3.7.5. The QP
shall include inspection and test requirements and provide columns or
spaces for the Principal, to indicate 3rd party inspection activities, e.g.,
witness, monitor, hold points, etc., for the operations to be undertaken. It is
required that the QP be approved by the Principal.
UT Ultrasonic Testing
VI Visual Inspection

1.4 CROSS-REFERENCES
Where cross-references to other parts of this DEP are made, the referenced section
number is shown in brackets ( ). Other documents referenced by this DEP are listed in (7).

1.5 SUMMARY OF MAIN CHANGES

This DEP supersedes the former local Deepwater standard of the same number
(DEP 37.81.21.31-EPP) dated August 2007. The following are the main, non-editorial
changes.

Old New Change

section section
9 2.8, 4.2, 5.2 Updated specification for studless chain.
2.8, 3.2.4, Added requirements for grade R4S and grade R5 chain included.
5.2.1, 5.2.3
5 5.3 Updated the requirements of mechanical tests of test coupons taken
from full scale accessories.
7, 8 Removed approval scheme for chain Manufactures/Suppliers, and
steel mills.

1.6 COMMENTS ON THIS DEP

Comments on this DEP may be sent to the Administrator at [email protected], using
the DEP Feedback Form. The DEP Feedback Form can be found on the main page of
“DEPs on the Web”, available through the Global Technical Standards web portal
http://sww.shell.com/standards and on the main page of the DEPs DVD-ROM.
ECCN EAR99 DEP 37.81.21.30-Gen.
February 2012Page 6

1.7 DUAL UNITS

This DEP contains both the International System (SI) units, as well as the corresponding
US Customary (USC) units, which are given following the SI units in brackets. When
agreed by the Principal, the indicated USC values/units may be used.

1.8 PROJECT DOCUMENTATION REQUIREMENTS

For projects to ensure compliance with this DEP, proper documentation is required in the
Definition and Execution phases of the project.
ECCN EAR99 DEP 37.81.21.30-Gen.
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2. GENERAL

2.1 UNDERLYING INDUSTRY SPECIFICATION (DNV-OS-E302)

Steel chain shall be manufactured and tested in accordance with DNV-OS-E302.
Modifications to DNV-OS-E302 and specific deletions or identifications of non-applicable
parts are given herein. This DEP supplements the requirements defined in DNV-OS-E302
and shall be used in conjunction with DNV-OS-E302. Some statements and/or required
values in DNV-OS-E302 are repeated in this DEP for clarity or special emphasis; however,
unless specifically deleted/waived by this DEP, all provisions of DNV-OS-E302 shall apply.
Any document submitted to the selected certification or classification organization during
the course of pre-qualification or manufacture, including any Concession/Deviation
Requests, shall also be submitted to the Principal for approval.

2.2 PREQUALIFICATION
Chain Manufacturers/Suppliers, steel mills for the manufacture of bar, forges and foundries
for the manufacture of accessories shall be prequalified in accordance with the Approval
Scheme of the recognised classification society approved by project management and local
regulatory authorities. Any document submitted to the selected certification or classification
organization as part of the Approval Scheme shall also be submitted to the Principal for
approval. As part of the submission for approval, the chain Manufacturer/Supplier, steel
mill for bar, forges or foundries shall submit for approval a list of essential process control
variables and their allowable ranges which define the extent of validity for the
prequalification.

2.3 QUALITY REQUIREMENTS

The chain and accessory Manufacturer/Supplier shall implement an ISO 9001 Quality
Management System or equivalent for approval by the Principal. A Quality Plan (QP) and a
Manufacturing Procedure Specification (MPS) shall be specifically developed for each order
and shall be approved by the Principal, prior to commencement of manufacturing
operations.

2.4 CONTRACTOR/SUBCONTRACTOR CHAIN AND ACCESSORY PROCUREMENT

SPECIFICATION
This DEP may be used directly for procurement or, at the Contractor’s option, the
Contractor may prepare a detailed Procurement Specification which is compatible with the
Contractor’s document format and quality system. As a minimum, the Contractor’s
Procurement Specification shall incorporate all requirements contained herein and shall
require approval by the Principal. When the Contractor is responsible for procurement, any
actions, e.g., approval, review, etc., specified in this DEP for the Principal shall also apply
to the Contractor.

2.5 APPROVAL OF MANUFACTURERS/SUPPLIERS AND MANUFACTURING FACILITIES AND

SUBCONTRACTED CHEMICAL ANALYSIS OR MECHANICAL TESTING LABORATORIES
The chain and accessory Manufacturer/Supplier and manufacturing facilities, as identified
in the MPS, shall require approval by the Principal. Any subcontracted chemical analysis or
mechanical testing laboratories shall be approved by the Principal.

2.6 LOWEST ANTICIPATED SERVICE TEMPERATURE (LAST)

Unless otherwise specified in project or procurement documents, LAST shall be 0°C (32°F)
except that for permanently submerged components LAST shall be 4°C (40°F).

2.7 DESIGN LIFE AND CORROSION PROTECTION

Unless otherwise specified by the Principal, design life shall be assumed to be 30 years
with no possibility for replacement or in service inspection, other than visual inspection and
cathodic protection surveys of portions of the mooring system exposed in the water column.
ECCN EAR99 DEP 37.81.21.30-Gen.
February 2012Page 8

Design life shall be stated in the MPS. Chain segments shall not be specifically required to
be protected from corrosion and wear other than in an excess corrosion and wear material
allowance, which will be included in the specified chain diameter.
Chain shall not be painted or otherwise coated except as specified by the Principal.
Shackles shall be electrically isolated from connecting hardware (e.g., chain-to-rope
connectors, chain-to-closed socket connections and permanent padeyes for attaching chain
to anchors/anchor piles, etc.) using Orkot TLM® composite bushings and face plates, or
other as approved by the Principal, in order to electrically isolate chain segments from the
cathodic protection system of other mooring system components. Such electrical isolation
is not required between platform chain segments and the platform, provided the platform
cathodic protection system has been designed to account for the surface area of the
platform chain. Likewise, electrical isolation is not required between ground chain segments
and anchors/anchor piles if the anchors or anchor piles have been designed with corrosion
allowance in lieu of cathodic protection, or between chain segments if the chain-to-chain
connectors have been designed with corrosion allowance in lieu of cathodic protection.
The Orkot TLM® bushings and face plates will be supplied by the connector, closed socket
or padeye Manufacturer/Supplier, as applicable, and are not part of the chain or shackle
Manufacturer/Supplier's scope of work.

2.8 CHAIN TYPE AND GRADE, DIMENSIONS AND SPECIAL ATTRIBUTES

Chain type (e.g., studless) and Grade (e.g., R3, R3S, R4, R4S or R5), sizes, lengths,
quantities, special or additional marking requirements, special or additional dimensional
tolerances or any other requirements not covered specifically by this DEP and
DNV-OS-E302 will be conveyed to the chain and accessory Manufacturer/Supplier in the
procurement documents for the chain and accessories.

2.9 TRACEABILITY
The chain and accessory Manufacturer/Supplier and any other Manufacturer/Supplier
involved in processing the chain or accessories, shall prepare and submit for approval by
the Principal, a written materials traceability plan. As a minimum, full traceability of links
and accessories relative to ingot number or concast bar number and heat number and
heat-treat sequence or lot, shall be maintained. Each accessory shall be given a unique
serial number. The serial number shall be traceable to the heat number, ingot or bloom
number and heat-treat lot or batch number. Reference to the traceability plan shall be
included in the MPS.

2.10 PRE-PRODUCTION MEETING

A pre-production meeting shall be held at the chain, bar and accessory Manufacturer/
Supplier’s manufacturing facility prior to commencement of manufacture, in order to discuss
and assure common understanding of the QP and MPS in relation to the order. This pre-
production meeting shall be a designated Hold Point in the QP. The pre-production meeting
shall be held after all key design and quality control documents have been accepted by the
Principal.

2.11 SUBMITTALS
This DEP and DNV-OS-E302 identify various submittals requiring actions by the Principal
or classification society, e.g., approval, review, etc. All submittals, not limited to those
required by DNV-OS-E302 to be submitted to the classification society, shall be made to
the Principal in a timely manner as specified in project or procurement documents in order
to allow for the formal review and approval process. Table 1 provides a summary of
required submittals.
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February 2012Page 9

3. MATERIALS

3.1 GENERAL
Bars, forgings and castings shall be manufactured in accordance with DNV-OS-E302
Chapter 2 Section 1 except as follows.

3.2 BARS
3.2.1 Bar general requirements
Bars for all links, including common links, end links, enlarged links and accessories shall
comply with ASTM A29 except as noted herein.
3.2.2 Bar chemical composition
Bar chemical composition range shall be as approved during the prequalification Approval
Scheme and by the Principal.
3.2.3 Bar steel cleanliness
A written procedure for the detection and elimination of inclusions and segregated zones,
including cropping details for ingots and continuously cast blooms or billets shall be
submitted to the Principal for approval. Bar macroinclusion frequency and severity ratings
shall be determined to be in compliance with SAE AMS-2301K, or later, prior to shipment
from the steel mill. Additionally, bar microinclusion ratings shall be determined in
compliance with ASTM E45 Method D (Modified JK method) prior to shipment from the steel
mill. The sampling frequency defined in SAE AMS-2301K shall also be used for the
ASTM E45 Method D (Modified JK method) tests, with test position being the ingot/bar
centerline and the examined surface being parallel to the rolling direction. Microinclusion
ratings shall meet the requirements of Table 2. Whatever cropping (top and/or bottom) is
necessary to achieve acceptable results for either type of inclusion test, i.e., macroinclusion
or microinclusion, shall also be used for all material qualified by those tests. Results from
steel cleanliness tests shall be included in the MTR.
3.2.4 Bar mechanical testing requirements
Mechanical testing of bar for all links, including common links, end links, enlarged links and
accessories, is to be specifically performed on bar stock which has been simulation heat
treated in accordance with DNV-OS-E302 Chapter 2 Section 1 B 500. Additionally, a
product (check) chemical analysis shall be performed on one of the tensile test specimens
from each 50 mt test unit. Results of the product analyses shall comply with the
requirements of ASTM A29.
Bar tensile strength shall not be higher than the specified minimum tensile strength for the
bar plus 175 N/mm2 (25 ksi).
Charpy impact testing shall be conducted at a temperature no higher than LAST minus
20°C (LAST minus 5°F). For example, if LAST has been designated to be 4°C (39°F) (i.e.,
the default value for permanently submerged components), then the test temperature shall
be no higher than -16°C (3°F).
3.2.5 Bar non-destructive testing (NDT) requirements
All bar stock material shall be subjected to straight-beam Ultrasonic Testing (UT) with
100 % volumetric coverage of at least the central 2/3 core of the cross-sectional diameter.
UT procedures shall comply with ASTM E114 and ASTM A388. Calibration for UT
examination shall be accomplished using the DAC method. Reference bars shall contain
1.6 mm (1/16 in) maximum diameter x 30 mm (1.2 in) maximum length Flat-Bottomed
Holes (FBHs) drilled parallel to the bar longitudinal axis and located at 1/2 D, 1/3 D and
2/3 D as a minimum. Reference bar diameter shall be within ± 10 % of the bar diameter
being examined. As a minimum, calibration checks shall be performed just prior to
examination, at least once during each 8-hour working shift during examination and at the
end of examination of each inspection lot. If automatic UT methods are utilised, the
calibration check shall be conducted under dynamic conditions that are designed to verify
ECCN EAR99 DEP 37.81.21.30-Gen.
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the performance of the entire system under actual inspection conditions. Also, for automatic
UT methods, the uninspected length (length between the reference FBHs and the end of
the reference bar) of each end of each bar shall be re-examined using manual methods for
the full uninspected length and for 100 % of the circumference. Additionally, manual UT
inspection of 100 % of the length and circumference shall be performed on bars selected
utilising the sampling plan described in SAE AMS 2301K Clause 4.3.1. As a minimum,
rejectable defects shall be those that cause a complete loss of back reflection and those
that exceed 100 % of the Det Norske Veritas (DAC) curve. Written UT procedures for bar
and acceptance criteria shall be submitted to the Principal for approval.
All bar stock material shall be subjected to Magnetic Particle Testing (MT) examination for
longitudinal defects for 100 % of length and each bar shall be subjected to MT examination
for transverse defects for at least 10 % its length.
3.2.6 Bar size and surface finish requirements
Starting bar stock diameter shall be sufficiently oversized so that finished chain diameter,
after proof testing, still meets specified diameter requirements. Bar shall be supplied in the
surface peeled, turned or ground condition.
3.2.7 Bar material test reports (MTRs)
Bars shall be supplied with inspection certificates (a.k.a. MTRs or mill certificates) in
conformance with ISO 10474 Test Report Type 3.2.
3.2.8 Bar positive material identification (PMI)
Upon receipt at the chain or accessory Manufacturer/Supplier, each bar shall receive PMI
in accordance with ASTM E1916 Clause 4.1 or Clause 4.2.

3.3 FORGINGS
3.3.1 Forging general requirements
Forgings for shackles and bolts shall be in accordance with DEP 37.81.20.39-Gen., Service
Category C except that the chemical composition range approved during the
prequalification Approval Scheme and by the Principal, shall be utilised. If bar is used as
the starting material for shackle and bolt forgings, it shall additionally comply with (3.2).
3.3.2 Forging mechanical testing requirements
Forging tensile strength shall not be higher than the specified minimum tensile strength for
the forging plus 175 N/mm2 (25 ksi).
3.3.3 Forging NDT requirements
MT and UT requirements of DEP 37.81.20.39-Gen. shall apply except as follows. MT and
UT procedure and acceptance criteria shall be as specified in DNV-OS-E302 Chapter 2
Section 1 C 600 except that each forging shall be inspected. Written procedures for all
forms of forging NDT to be utilised shall be approved by the Principal.
3.3.4 Forging PMI
Each forging shall receive PMI in accordance with ASTM E1916 Clause 4.1 or 4.2 prior to
shipment from the Manufacturer/Supplier.

3.4 CASTINGS
3.4.1 Casting general requirements
Steel castings for shackles shall comply with DEP 37.81.20.30-Gen. except that the
chemical composition range approved during the prequalification Approval Scheme and by
the Principal shall be utilised.
3.4.2 Casting mechanical testing requirements
Casting tensile strength shall not be higher than the specified minimum tensile strength for
the casting plus 175 N/mm2 (25 ksi).
ECCN EAR99 DEP 37.81.21.30-Gen.
February 2012Page 11

3.4.3 Casting NDT requirements

MT and UT requirements of DEP 37.81.20.30-Gen. shall apply except as follows. MT
acceptance criteria shall be as specified in DNV-OS-E302. UT procedure and acceptance
criteria shall be as specified in DNV-OS-E302 except that each casting shall be inspected.
Written procedures for all forms of casting NDT to be utilized shall be approved by the
Principal.
3.4.4 Casting PMI
Each casting shall receive PMI in accordance with ASTM E1916 Clause 4.1 or Clause 4.2
prior to shipment from the Manufacturer/Supplier.

3.5 STUDS
Studs shall comply with DNV-OS-E302 Chapter 2 Section 1 E.
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4. MOORING CHAIN CABLES AND ACCESSORIES

4.1 GENERAL
Mooring chain cables and accessories shall be manufactured in accordance with
DNV-OS-E302 Chapter 2 Section 2 except the following clarifications/deviations on the
records of bar heating, flash welding and heat treatment, including specific records for any
single link heat treatment.
Welding parameters shall be recorded automatically and continuously.
Bar temperatures on both sides of the link shall also be monitored and recorded (either
continuous automatic recording or hourly manual logging) during stud insertion and setting.
Optical pyrometers with digital readouts of monitoring temperature shall be used.
Chart recorders (strip or circular) or process monitor computers shall be used to record
process parameters.

4.2 MOORING CHAIN

4.2.1 Design
Design of both stud link and studless mooring chains shall be in accordance with
DNV-OS-E302 Chapter 2 Section 2 B 200. Design documentation shall be submitted to the
Principal for approval and shall include 3-D finite element structural analysis utilising
software approved by the Principal, for all specified sizes of common links, enlarged links,
end links and accessories in order to determine peak surface stresses, bearing (contact)
stresses and linearised membrane and membrane + bending stresses at critical sections
for tension loads equal to the specified proof load test value and the specified minimum
breaking load value. Von Mises equivalent stresses shall be computed from the stress
components (i.e., x, y, z, xy, yz, zx) after they are linearised across selected sections.
Selected sections for stress linearisation shall be submitted to the Principal for approval for
all specified sizes of common links, enlarged links, end links and accessories. For guidance
on linearising across sections refer to API RP 2RD, Annex C. Peak surface stresses,
bearing (contact) stresses and linearised membrane and membrane + bending stresses for
enlarged links, end links and accessories shall all be less than or equal to those determined
for common links at tensions equal to the specified proof load test value and the specified
minimum break load value. Additionally, linearised membrane stress and average shear
stress across any section taken through a shackle bolt hole (eye) shall be less than or
equal to 0.45 times the specified minimum yield strength and 0.40 times the specified
minimum yield strength, respectively, for a tension load equal to the specified minimum
proof test load.
Chain and accessory manufacture shall be in accordance with DNV-OS-E302 Chapter 2
Section 2 B 300 as augmented/clarified by this DEP.
4.2.2 Manufacture
Requirements for flash welding shall be in accordance with DNV-OS-E302 Chapter 2
Section 2 B 400 with the following clarifications/deviations.
Procedures for ensuring parallel bar faces, proper bar gaps and proper bar end alignments
prior to commencement of flash welding shall be approved by the Principal.
Procedures for removal of bar scale from critical contact areas prior to forming, prior to
flash welding and prior to stud setting shall be approved by the Principal.
Procedures for removal of scale from the welding machine's pads/clamps prior to flash
welding shall be approved by the Principal.
Welding equipment used in the chain production process shall be calibrated and adjusted
within three (3) months prior to the start of chain manufacture. Records shall be made
available for review by the Principal if requested.
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No post heat treatment weld repair shall be allowable on any chain links. After final heat
treatment, if a mooring chain link fails in tests and inspection (5), the link shall be replaced
in accordance with (5.2.8).
4.2.3 Single (replacement) link heat treatment
A detailed procedure and monitoring process for single (replacement) link heat treatment
for the case where a replacement link is required for a failed link shall be submitted to the
Principal for approval.
4.2.4 Dimensions and dimensional tolerances
Dimensions and dimensional tolerances for links shall be in accordance with
DNV-OS-E302 Chapter 2 Section 2 B 900.

4.3 CHAIN ACCESSORIES

Chain accessories shall be manufactured in accordance with DNV-OS-E302 Chapter 2
Section 2 C 100-200.
ECCN EAR99 DEP 37.81.21.30-Gen.
February 2012Page 14

5. TESTS AND INSPECTION OF FINISHED CHAIN AND ACCESSORIES

5.1 GENERAL
Tests and inspection of finished chain and accessories shall comply with DNV-OS-E302
Chapter 2 Section 2 A 200-500, B 600-1200 and C 300-900 except as clarified or deviated
from as follows. In general, all equipment used in the manufacturing, testing and inspection
of chain shall undergo scheduled routine maintenance and calibration within three (3)
months prior to use. The chain Manufacturer/Supplier’s maintenance records and
calibration certificates shall be available for review by the Principal. Calibrations shall be
conducted by a recognised organization to recognised industry standards.

5.2 TESTING AND INSPECTION OF MOORING CHAIN

5.2.1 Proof and break load tests
The proof and break loading machine’s end blocks shall be properly contoured to match the
shoulders of the chain links. The chain Manufacturer/Supplier shall submit a written proof
and break load test procedure to the Principal for approval, which provides for routine
inspection of the blocks’ loading surfaces that may require repair or replacement due to
wear, deformation, protrusions, cracks, etc.
The entire length of each chain (including end links and enlarged links) shall be proof load
tested twice with a 180° rotation about its longitudinal axis between the two proof loadings,
unless the testing machine is vertical or unless, for horizontal machines, the catenary effect
is removed by the usage of a horizontal table.
Proof loading for both stud link chains and studless chains shall comply with DNV-OS-E302
Table C1.
Break load testing shall be conducted on common links, enlarged links and end links in
accordance with DNV-OS-E302 Chapter 2 Section 2 B 600 as applicable. Each heat (cast)
and size of common links, enlarged links and end links shall be break load tested at the
frequency specified in DNV-OS-E302 Table C2.
In the event of a break load or proof load failure, the retest and rejection provisions of
DNV-OS-E302 Chapter 2 Section 2 Para. B 705 shall apply, as applicable. In the event
that cut out becomes necessary, the length of cutout shall be approved by the Principal.
Chart recorders (strip or circular) or process monitor computers shall be utilized to provide
permanent test records.
5.2.2 Dimensions and dimensional tolerance
All required measurements shall be taken after the final proof load test.
Written chain dimensional inspection procedures shall be submitted to the Principal for
approval.
If one of the tested links fails to meet the tolerances, the failed link shall be cut out and
replaced by a replacement link using the single link heat treatment procedure (4.2.3). In
addition, the testing frequency shall be expanded to 10 % of the links for the continuous
length represented by the failed link.
If more than one link fails to meet dimensional tolerances in any continuous chain length,
then 100 % of the links in that length of chain shall be checked.
Failed links are to be cut out, replaced by a replacement link using the single link heat
treatment procedure (4.2.3) and subsequently, the two proof tests are again to be applied,
with subsequent dimensional inspection.
Length over five links measurements shall be taken while the chain is loaded to 10 % of the
minimum proof load value given in DNV-OS-E302 Table C1, or otherwise loaded with
sufficient tension to ensure complete contact between links.
ECCN EAR99 DEP 37.81.21.30-Gen.
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5.2.3 Mechanical tests

Mechanical testing shall be performed on test links that have been successfully proof load
tested to the same value as the finished chain. Mechanical testing of end links and
enlarged links is required.
Tensile strength shall not be higher than the specified minimum tensile strength plus
175 N/mm2 (25 ksi). An additional tensile test shall be taken across the flash weld with the
weld located within the tensile specimen gauge length.
Charpy impact testing from the bend region of tested links shall not be omitted or waived.
Charpy impact testing shall be conducted at a temperature no higher than LAST minus 20°C
(LAST minus 5°F). For example, if LAST has been designated to be 4°C (39°F) (i.e., the
default value for permanently submerged components), then the test temperature shall be no
higher than -16°C (3°F).
Chart recorders (strip or circular) or computer records shall be used to provide permanent
test records.
5.2.4 NDT
Non-destructive examination shall be performed in accordance with DNV-OS-E302 Chapter
2 Section 2 B 1000 with the following clarifications/deviations.
Non-destructive examination shall be performed on links that have been successfully proof
load tested to the same value as the finished chain.
NDT operators shall be certified to ASNT TC-1A Level II. Testing shall have been both
written and practical.
NDT procedures shall be qualified on link samples of the same nominal diameter,
dimensions and material grade as the finished links to which they are being applied.
Written procedures for all forms of chain NDT to be utilised shall be approved by the
Principal.
Chain shall be elevated in a well-lighted area no less than 1.2 m (4 ft) above the ground to
provide proper access for inspections.
Chain shall be sand or shot blasted prior to performance of NDT to permit a thorough
examination.
5.2.5 VI
VI shall be accomplished in accordance with DNV-OS-E302 Chapter 2 Section 2, Para.
B 1002 except that each stud shall be forcefully hit from each of two opposing directions
with a sledge hammer to confirm stud fixity. Stud looseness/movement shall not be
accepted and will result in rejection.
5.2.6 MT
MT shall be performed in accordance DNV-OS-E302 Chapter 2 Section 2 Para. B 1003
except that procedures shall comply with ASTM E1444.
MT examination shall be accomplished with the link hanging in a vertical orientation.
5.2.7 UT
UT shall be in accordance with DNV-OS-E302, Chapter 2 Section 2 Para. B 1004 -1007
and ASTM A388. 100 % of all welds shall be examined.
Calibration for UT examination shall be accomplished using the DAC method.
Any reflector exceeding 20 % of the DAC shall be further examined with additional probe
angles and manipulation in order to maximize the reflected amplitude. Any reflector whose
amplitude exceeds that of the applicable reference reflector shall result in link rejection. In
addition, any reflector deemed to be planar or crack-like in nature whose planar orientation
is within 45° of perpendicular to the longitudinal bar axis shall result in link rejection,
regardless of amplitude.
ECCN EAR99 DEP 37.81.21.30-Gen.
February 2012Page 16

The UT procedure shall include a UT scan plan which ensures full volumetric coverage
from both axial directions by angle-beam for 100 % coverage of the entire weld area and for
a length up to the start of the bend on either side of the weld. The UT procedure and scan
plan shall show the test configuration at the time of examination, ultrasonic beam paths,
coverage, transducer details (Manufacturer/Supplier and transducer designation, size,
beam angle, frequency, near field length, etc.), acceptance criteria and any special
calibration standards required.
5.2.8 Retest, rejection and repair criteria
Retest, rejection and repair criteria shall be in accordance with DNV-OS-E302 Chapter 2
Section 2 B 1100.
Only common links are allowed as replacements for failed or otherwise rejected common
links. Likewise, only enlarged links are allowed as replacements for failed or otherwise
rejected enlarged links and only end links are allowed as replacements for failed or
otherwise rejected end links. Detachable joining shackles, Kenter links, etc. shall not be
acceptable as replacements for failed or otherwise rejected long term/permanent mooring
links. A detailed replacement procedure for rejected links shall be submitted to the Principal
for approval. Replacement links shall be subjected to the same proof loading procedure as
the completed chain.
5.2.9 Identification
Identification requirements shall be in accordance with DNV-OS-E302 Chapter 2 Section 2
B 1200 using 12 mm (1/2 in) high low stress rounded “V” bottom hard stamps located on
the outer part of the non-welded side of the link in the straight section.
5.2.10Documentation and certification
Documentation and certification shall comply with DNV-OS-E302 Chapter 2 Section 2
A 500 and ISO 10474 Test Report Type 3.2. Weight and length of each chain length
assembly shall be included on the certificate.
Documentation shall be written in the English language.

5.3 TESTS AND INSPECTION OF ACCESSORIES

Tests and inspection of accessories shall be in accordance with DNV-OS-E302 Chapter 2
Section 2 C 300-900 except as follows. All accessories shall be proof load tested.
Accessories shall be break load tested at a frequency no less than once per heat (cast) per
size per 25 (twenty-five) units. Written accessory proof and break load test procedures
shall be submitted to the Principal for approval. Written accessory dimensional inspection
and gauging procedures shall be submitted to the Principal for approval.

6. PACKING, HANDLING AND TRANSPORT

A written packaging, handling and transport procedure shall be developed and submitted to
the Principal for approval.
ECCN EAR99 DEP 37.81.21.30-Gen.
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7. REFERENCES
In this DEP, reference is made to the following publications:
NOTES: 1. Unless specifically designated by date, the latest edition of each publication shall be used,
together with any amendments/supplements/revisions thereto.
2. The DEPs and most referenced external standards are available to Shell staff on the SWW (Shell
Wide Web) at http://sww.shell.com/standards/.

SHELL STANDARDS
Technical specification for manufacture, testing and inspection of DEP 37.81.20.30-Gen.
carbon and low-alloy steel castings grades 345-586 N/mm2
(50-85 ksi) for primary steel applications in deepwater offshore
structures and pipelines (based on ASTM A703)
Technical specification for manufacture, testing and inspection of DEP 37.81.20.39-Gen.
carbon and low-alloy steel forgings grades 345-586 N/mm2
(50-85 ksi) for primary steel applications in deepwater offshore
structures and pipelines (based on ASTM A788, ASTM A961 and
MSS SP-75)

AMERICAN STANDARDS
Design of risers for Floating Production Systems (FPSs) and API RP 2RD
Tension-Leg Platforms (TLPs)
Recommended practice for personnel qualification and certification ASNT TC-1A
in nondestructive testing
Standard specification for steel bars, carbon and alloy, hot- ASTM A29
wrought, general requirements for1
Standard practice for ultrasonic examination of steel forgings ASTM A388
Standard test methods for determining the inclusion content of ASTM E45
steel
Standard practice for ultrasonic pulse-echo straight-beam contact ASTM E114
testing
Standard practice for magnetic particle testing ASTM E1444
Standard guide for identification of mixed lots of metals ASTM E1916

EUROPEAN STANDARDS
Offshore mooring chains DNV-OS-E302

INTERNATIONAL STANDARDS
Quality management systems – fundamentals and vocabulary ISO 9000
Quality management systems – requirements ISO 9001
Steel and steel products - inspection documents ISO 10474
Steel cleanliness, aircraft quality magnetic particle inspection SAE AMS-2301K
procedure
issued by
Society of Automotive Engineers
ECCN EAR99 DEP 37.81.21.30-Gen.
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APPENDIX 1 SUBMITTALS REQUIRING ACTION BY THE PRINCIPAL

Table 1 Submittals requiring action by the Principal

REQUIRED TIMING OF
SUBMITTAL(1)

Quality Management System

Manufacturer/Supplier’s Quality Plan (QP)
Manufacturer/Supplier’s Manufacturing Procedure
Specification (MPS)
Contractor's procurement specification, if applicable
Manufacturer/Supplier and manufacturing facilities
Any subcontracted chemical analysis or mechanical
testing laboratories
Materials traceability plan
Bar chemical composition range
Written procedure for the detection and elimination of
inclusions and segregated zones, including cropping
details for ingots and continuously cast blooms or
billets
UT procedures for bar and acceptance criteria
Forging chemical composition range
Procedures for all forms of forging NDT to be utilized
Steel castings chemical composition range
Procedures for all forms of casting NDT to be utilized
Design documentation, including drawings, for all
specified sizes of common links, enlarged links, end
links and accessories
Description of 3-D finite element structural analysis
software
Selected sections for stress linearization for all
specified sizes of common links, enlarged links, end
links and accessories
Procedures for ensuring parallel bar faces, proper bar
gaps and proper bar end alignments prior to
commencement of flash welding
Procedures for removal of bar scale from critical
contact areas prior to forming, prior to flash welding
and prior to stud setting
Procedures for removal of scale from the welding
machine's pads/clamps prior to flash welding
Procedure and monitoring process for single
(replacement) link heat treatment
Chain proof and break load test procedure
Chain dimensional inspection procedures
ECCN EAR99 DEP 37.81.21.30-Gen.
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REQUIRED TIMING OF
SUBMITTAL(1)

Length of cutout when a proof load or break load test

failure has occurred
Procedures for all forms of chain NDT
Detailed replacement procedure for rejected links
Accessory proof and break load test procedures
Accessory dimensional inspection and gauging
procedures
Packaging, handling and transport procedure

NOTE: 1) There is a basic requirement that these submittals be made in a timely fashion such that the
required action by the Principal may be taken prior to the commencement of the applicable
activity. However, the precise timing requirements for submittals, e.g., 2 weeks after contract
award, etc., that are deemed necessary to meet project schedule will be specified in project or
procurement documents.
ECCN EAR99 DEP 37.81.21.30-Gen.
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APPENDIX 2 INCLUSION RATING LIMITS

Table 2 ASTM E45 method D (modified JK) inclusion rating limits

Inclusion Type Maximum Average Inclusion Rating Number

(at each test location)

Type A Sulfide - Thin 1.0

Type A Sulfide - Heavy 0.5

Type B Alumina - Thin 1.0

Type B Alumina - Heavy 0.5

Type C Silicate - Thin 1.0

Type C Silicate - Heavy 0.5

Type D Oxide - Thin 1.0

Type D Oxide - Heavy 0.5