Welder Qualification Procedure

PROCEDURE FOR WELDER QUALIFICATION

PROCEDURE FOR WELDER QUALIFICATION 1.0 : Scope 1.1 : This procedure details the method for the qualification of welder for structural welding and IBR welding and acceptance criteria required for it. 2.0

3.0

4.0

: References 2.1

: ASME SECTION IX

2.2

: AWS D1.1

: Contents 2.3

: Qualification procedure

2.4

: Positions of welding

2.5

: Range qualified

2.6

: Acceptance of weld and Destructive Testing .

:

Records of the Welder Tests .

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PROCEDURE FOR QUALIFICATION 1.0 : BASE METALS 1.1 : The material used for the qualification shall be same as material used on job or equivalent material listed in table QW -422 of ASME IX . 2.0 : TEST COUPONS 2.1 : Depending upon the range to be qualified , choose appropriate test coupon size .Refer Table - 1 2.2 For plate butt welds, details of edge preparation shall be as per Figure- 3 2.3 For pipe butt welds, details of edge preparation shall be as per Figure-.3 3.0 REQUIREMENT OF TESTS: 3.1 For Structural Tack Welders: 3.1.1 Break Test as per Figure-4. 3.2 For Plate Butt Welds: 3.2.1 Minimum of 4 specimens for bend test; two for root bend and other two for face bend. Width of specimen shall be 38 mm for plate thickness upto 9.5 mm. For thickness greater than 9.5 mm, width of specimens shall be 10 mm and they shall be side bend tested. Fig-5 3.3 For Pipe Welder : 3.3.1 The order of removal of test specimens shall be as per Figure-. 3.3.2 For width and number of bend specimens, refer table below: OD in mm

Width in mm Thickness in

Bend specimens required

mm ≤ 100 50 ≤ OD ≤ 100 ≤ 50

Root

Face

19

T ≤ 10

01

01

10

10 ≤ T ≤ 19

01

01

Actual ##

T ≥ 19

Side

** 02

(**) - side bend shall be substituted for root & face bend test . (##) - after cutting into 4 pieces considering machining allowance .

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4.0 : Essential Variables Changes in these variables requires the requalification of welder 4.1 : Process Change from one process to another 4.2 : Change in the higher F number in case of SMAW welding 4.3 : Change in the position not qualified 4.4 : To a diameter or thickness not qualified 4.5 : Change to the vertical progression of welding 4.6 : To the multiple electrodes 5.0 : Acceptance Criteria 5.1 : For structural Tack Welding 5.1.1 - free from overlaps , cracks 5.1.2 - under cut not exceeding 1.0 mm 5.1.3 – no porosity on surface 5.1.4 – no incomplete fusion 5.1.5 – any inclusion or porosity larger than 2.5 mm 5.2 : For Plate welding 5.2.1 - free of cracks. 5.2.2 -Undercut shall not exceed 1 mm. 5.2.3 – At root of the weld, no evidence of cracks, incomplete fusion, or Inadequate joint penetration. 5.2.4 - The Requirement of Bend Test for acceptance : The convex surface of the bend test specimen shall be Visually examined for surface d discontinuities. For acceptance,the surface shall contain no discontinuities exceeding the following dimensions: (1) 3 mm measured in any direction on the surface (2) 10 mm - the sum of the greatest dimensions of all discontinuities exceeding 1 mm, but less than or equal to 1/8 in. 3 mm (3) 6 mm—the maximum corner crack, except when that corner crack results from visible slag inclusion or other fusion type discontinuity, then the 3 mm maximum shall apply .

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* Radiographic examination of test welds may be carried out in lieu of bend tests with prior approval of welding engineer. Acceptance criteria for radiography shall be as per ASME Sect V . 6.0 : Retest Retest shall be carried out for welder who fail in tests or whose welding in question. However an acceptance criterion remains same for retest. 6.1 : Immediate Retest : welder failed in one or more test or welding skill is in doubt then immediate retest shall be carried out 6.2 : Retest After Further Training or Practice : After further training or practice of welding , welder may be allowed for the retest. 6.3 : Retest After Lapse of Qualification Period : after lapse or qualification period or welder who is not in work with welding for more than one month shall be re-qualified . 7.0 : Validity When a welder meets the requirements of the above procedure , he shall be declared as qualified welder and his validity shall remain as one year subject to above 6.0 requirement . 8. RECORDS: 8.1 The welding in charge at site shall maintain the following records: a) Record of Welder Performance qualification Test . Refer Annexure 01 b) Register of qualified welders (employer-wise) containing the following details: 1) Name of welder. 2) Age. 3) Tested for pipe / tube / plate / tack. 4) Performance Test No. 5) Validity. 6) Welder Code. 7) Remarks. 8) Radiography Reports and Bend Test reports. 9) Copies of welder Id card .

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Table -1

Welder Qualification Requirements Test coupons Sl.No

01

02

Test For

Base Material

Plate welder , OD ≥ 600 mm

Weld Positions

thickness , OD 10

Plate welder for structural welding

dimension ,

P1 G1 P1 G1

04

Pipe welder

10 ≤ T ≤ 25

3G , 4G

≥ 25

Tack Welders

25 ≤ OD ≤ 73

P1 G1

OD ≥ 73 Thk = 10 mm

Mm

qualified

3 ≤ T ≤ 2T

ALL

unlimited

10 mm

P1 G1

Position

3 ≤ T ≤ 20

2G, 3G, 4G

OD ≤ 25 , 03

Range qualified

2G, 5G 6G 3F , 4F

Unlimited OD = Test piece dia 25 ≤ OD ≤ 73 OD ≥ 73 T = unlimited

ALL ALL

ALL

Note : 1) For plate welder of structural welding , position also qualifies for fillet joints . 2) Separate procedure for welder qualification shall be used for P-91 material and qualification in position or range does not apply for P-91 material . 3) For a particular base metal , corresponding electrode are to be chosen . For GTAW , corresponding filler wire shall be used .

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Fig-2 Positions for Welding

7

Fig -3 Edge Preparation for pipe and plate

8

Fig -5 Requirements of Tests

9

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Annexure : 01

RECORD OF WELDER PERFORMANCE – QUALIFICATION TEST Performance Test No. -------------------

Date:

Site:-----------------------------Welder’s Name & Address: ------------------------------------------------------------------------------------------------------------------Material : -----------------

Welder Code: ------------

Welding Process:

Thickness Qualified: ------------

Position(s) Qualified:

TEST MATERIAL Specification:

Filler Material:

Thickness (and Dia. of pipe):

SFA No.:

Shielding Gas(es) :

AWS Classification:

PROCESS VARIABLES Position of test weld:

Current:

Pre-heat temp:

Inter Pass Temp:

Polarity: Post-heat Temp:

Test Joints Test Results : Type Bend Type Bend Type Bend Type Bend

: : : :

Results Results Results Results

Radiography Ref. & Results: (sketch) : This is valid upto __________________________ Signature of Welder

Signature of JPL Rep.

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TESTS REQUIRED FOR STRUCTURAL PLATE WELDING 1) Plate to Plate (Butt Joints ) Sl.No

Thickness

Tests Required Root 01 ---

Range Qualified

Face 01 10 mm 01 02 10 < T < 25 -03 25 mm -2) Plate to Plate (Fillet Joints ) A welder who qualifies in above Butt joints also qualifies for the fillet joint . Sl.No

Thickness

01

Break Test

Macro Etch

01

01

3 mm - unlimited

--

01

3mm - unlimited

12 mm

Diameter

01

≤ 100 mm

02

> 100 mm

03

> 100 mm

04

≥ 150 mm

Thickness

Tests Required

Tests Required

For 1G AND 2G Face Root Side Thk

3-20 mm max 3- 2T max 3- unlimited

Range Qualified

02 > 3 mm (tube to plate ) 3) Tube or Pipe Joints Sl.No

Side ** 02 02

For 5G AND 6G Face Root Side

Range Qualified Thk

01

01

**

02

02

**

3-20max

01

01

**

02

02

**

5-20max

> 10 mm

--

--

02

--

--

04

≥ 12 mm

--

--

04

unlimited ≤ 10 mm

** - side bend test shall be substituted for each Face and Root bend test. 12

Irrespective of position

5unlimited 5-20max

Dia 20- 100 max 100unlimited 100unlimited 100unlimited

TESTS REQUIRED FOR IBR WELDING 1) Groove Welding in Pipes and Tubes Sl.No 01 02 03 04

Thickness 1.5 mm – 10 mm 10 < T < 19 19 < T < 38 T > 38

Tests Required Root 02 02 ---

Face 02 02 ---

Range Qualified Side ** ** 04 04

1.5 – 2T max 5- 2T max 5-2T max 5-200 mm

2) Fillet Joints in pipes and Tubes A welder who qualifies in above Groove joints also qualifies for the fillet joint . Sl.No

Thickness

Range Qualified Break Test

01

Irrespective of thickness

Macro Etch 01

** - side bend test shall be substituted for each Face and Root bend test. To qualify using positions 5G or 6G, a total of four bend specimens are required. To qualify using a combination of 2G and 5G in a single test coupon, a total of six bend specimens are required. See QW302.3. The type of bend test shall be based on weld metal thickness.

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3 mm - unlimited