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 : References 2.1 2.2 3.0 2.3 2.4 2.5 2.6 4.0 : : ASME SECTION IX : AWS D1.1 : Qualification procedure : Positions of welding : Range qualified : 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 100 50 OD 100 50 Width in mm Thickness in mm 19 10 Actual ## T 10 10 T 19 T 19 Root 01 01 Bend specimens required Face 01 01 ** 02 Side

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

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 mmthe 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 .

* 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 .

Table -1

Welder Qualification Requirements

Test coupons Sl.No Test For Base Material dimension , thickness , OD 10 P1 G1 P1 G1 10 T 25 25 10 mm OD 25 , 03 04 Pipe welder Tack Welders P1 G1 P1 G1 25 OD 73 OD 73 Thk = 10 mm 2G, 3G, 4G 2G, 5G 6G 3F , 4F 3G , 4G Weld Positions

Range qualified Mm 3 T 20 3 T 2T unlimited Unlimited OD = Test piece dia 25 OD 73 OD 73 T = unlimited

Position qualified

01

Plate welder for structural welding Plate welder , OD 600 mm

ALL

02

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 .

Fig-2 Positions for Welding

Fig -3 Edge Preparation for pipe and plate

Fig -5 Requirements of Tests

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Annexure : 01

RECORD OF WELDER PERFORMANCE QUALIFICATION TEST

Performance Test No. ------------------Site:-----------------------------Welders Name & Address: ------------------------------------------------------------------------------------------------------------------Material : ----------------Thickness Qualified: -----------TEST MATERIAL Specification: Thickness (and Dia. of pipe): Shielding Gas(es) : PROCESS VARIABLES Position of test weld: Pre-heat temp: Test Joints Test Results : Type Bend Type Bend Type Bend Type Bend : : : : Results Results Results Results Inter Pass Temp: Current: Polarity: Post-heat Temp: Filler Material: SFA No.: AWS Classification: Welder Code: -----------Date:

Welding Process: Position(s) Qualified:

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 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 01 Thickness Break Test 12 mm 01 -02 > 3 mm (tube to plate ) 3) Tube or Pipe Joints Sl.No Diameter Thickness Tests Required Root 01 --Range Qualified Side ** 02 02 3-20 mm max 3- 2T max 3- unlimited

Range Qualified Macro Etch 01 01 3 mm - unlimited 3mm - unlimited

Tests Required For 1G AND 2G Face Root Side

Tests Required For 5G AND 6G Face Root Side 02 02 -02 02 -** ** 04

Range Qualified Thk 3-20max 5-20max 5unlimited 5-20max Dia 20- 100 max 100unlimited 100unlimited 100unlimited

01 02 03 04

100 mm > 100 mm > 100 mm 150 mm

Thk unlimited 10 mm > 10 mm 12 mm

01 01 ---

01 01 ---

** ** 02 04

Irrespective of position

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

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 Face 02 02 --Tests Required Root 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 01 Thickness Break Test Irrespective of thickness Range Qualified Macro Etch 01 3 mm - unlimited

** - 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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