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Materials and NDE Book A MQPS 0-2

ABCD Lloyds Register of Shipping 2002. All rights reserved Book A MQPS 0-2 Rev. 1 1

Materials and Qualification Procedures for Ships

Procedure 0-2

Guidelines for Welder Qualification

1 Introduction

1.1 Scope

1.1.1 These guidelines are based on ISO 9606 and are intended for use in ship constructionand repair yards where recognized equivalent qualification procedures do not exist.They specify requirements, ranges of approval, test conditions, acceptancerequirements and certification for the approval testing of welder performance for thewelding of steels and aluminium alloys. The recommended format for the certificate ofapproval testing is given in Appendix A.

1.1.2 During the approval tests, the Surveyors are to be satisfied that the welders showadequate skill in the welding processes, for which they are seeking approval.

1.1.3 Operators of fully mechanised and fully automatic processes are not included.

1.1.4 These guidelines cover approval testing of welders for work on semi-finished andfinished products made from wrought, forged, or cast material types listed in 5.4 and5.5.

1.2 Related standards and Rules

1.2.1 These guidelines refer to various standards containing provisions which provide thebasis for parts of these guidelines. Where these standards relate to methods of testingand inspection, the procedures used should satisfy the requirements of the relevantstandard. All standards are subject to revision. Consequently the shipyard is responsiblefor applying the most recent editions of the standards indicated.

1.2.2 The following are referred to within the body of these guidelines:

ISO 857-1 Welding and allied processes - Vocabulary Part 1: Metal weldingprocesses.

ISO 1106-1 Recommended practice for Radiographic examination of fusion weldedJoints Part 1: Fusion welded butt joints in steel plates up to 50 mmthick.

ISO 1106-2 Recommended practice for Radiographic examination of fusion weldedjoints Part 2: Fusion welded butt joints in steel plates thicker than 50mm and up to and including 200 mm in thickness.

ISO 1106-3 Recommended practice for Radiographic examination of fusion weldedjoints Part 3: Fusion welded circumferential joints in steel pipes of upto 50 mm wall thickness.

ISO 2437 Recommended practice for the X-ray inspection of fusion welded buttjoints for aluminium and its alloys and magnesium and its alloys 5 mmto 50 mm thick.

ISO 3452 Non-destructive testing -Penetrant testing - General principles.

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ISO 4063 Welding and allied processes Nomenclature of processes andreference numbers for symbolic representation on drawings.

ISO 5173 Destructive tests on welds in metallic materials Bend tests.

ISO 6520-1 Welding and allied processes Classification of geometricimperfections in metallic fusion welds.

ISO 6947 Welds Working positions Definitions of angles of slope and rotation.

1.2.3 Reference is also made in these guidelines to LR's Rules for the Manufacture, Testingand Certification of Materials (hereafter referred to as the Rules for Materials).

1.3 Equivalents

1.3.1 Where the fabricator has already established approval practices based on national orother published standards, these may be accepted by the Surveyor provided they areequivalent to these guidelines. As a minimum the welder is required to demonstrate hisskill by performing a test weld of the appropriate type, which is subjected to non-destructive examination and /or destructive mechanical testing with satisfactory results.

This applies equally to those standards cross-referenced in this document.

2 Definitions

2.1 Personnel

2.1.1 Welder. Person who performs the welding. This is a collective term used for bothmanual welders and welding operators. It does not cover operators for fully mechanizedand fully automatic welding processes.

2.1.2 Manual welder.Welder who holds and manipulates the electrode holder, welding gun,torch or blowpipe by hand. (Manual and semi-automatic welding).

2.1.3 Welding operator. Welder who operates equipment with partly mechanized relativemovements between the electrode holder, welding gun, torch or blowpipe and theworkpiece. (For example, submerged arc welding in which either the work or thewelding head is traversed mechanically, but the joint line is followed with manualassistance).

2.1.4 Fully mechanised or fully automated welding. Welding process in which manualadjustment of welding variables during the welding is not possible.

2.1.5 Examiner or test body.Person or organization appointed, or agreed by LR,to verifycompliance with these guidelines.

2.2 Documentation

2.2.1 Welding procedure specification (WPS).Document specifying the variables for aspecific application to assure repeatability.

2.3 Variables and tests

2.3.1 Essential variable.Any part of the welder's qualification which if changed requires thewelder to be re-qualified.

2.3.2 Range of approval. Extent of approval for an essential variable.

2.3.3 Test assembly .Welded assembly which is used in the approval test.

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4 Essential variables for approval testing

4.1 General

4.1.1 The criteria specified in this Section are to be examined in order to identify the ability ofthe welder in these areas. Each criterion is considered to be a significant factor in theapproval testing.

4.1.2 The welder's approval test is to be carried out on test pieces and not by way ofproduction welding.

4.2 Welding processes

4.2.1 The welding processes listed below are defined in ISO 857 and the reference numbersof these welding processes for symbolic representation are listed in ISO 4063.Reference to these standards is not necessary in respect of these guidelines.

4.2.2 These guidelines cover the following processes:

111 metal-arc welding with covered electrode114 flux-cored wire metal-arc welding without gas shield12 submerged arc welding

131 metal-arc inert gas arc welding (MIG welding)135 metal-arc active gas welding (MAG welding)136 flux-cored wire metal-arc welding with active gas shield141 tungsten inert gas arc welding (TIG welding)15 plasma arc welding

311 oxy-acetylene welding.

4.2.3 The guidelines may be used to cover other fusion welding processes, by agreementwith LR.

4.3 Joint types (butt and fillet welds)

4.3.1 Test assemblies are to be produced for butt weld (BW) and fillet weld (FW) in plates (P)or pipes, tubes, hollow sections (T) for approval tests in accordance with Section 6,appropriate to the qualification range required.

4.4 Material groups

4.4.1 In order to minimize unnecessary multiplication of technically identical tests, materialswith similar metallurgical and welding characteristics are grouped for the purpose of awelder's approval, see Table 0-2.4.1and 5.4.

4.4.2 In general, a welder's approval test is to involve depositing weld metal having achemical composition compatible with any of the materials in the particular parent metalgroup(s).

4.5 Filler metal, shielding gas and flux

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4.5.1 When a welder's test has been carried out using a filler metal, shielding gas or fluxsuitable for that material group, this test will confer approval on the welder to useother

similar consumables (metal, shielding gas or flux) for the same material group.4.6 Dimensions

4.6.1 The welder approval test should be based on the thickness of the material (platethickness or wall thickness of pipe) and pipe diameters which the welder will use inproduction. An approval is given based on the plate thickness, or pipe wall thicknessand pipe diameter, as specified in Tables 0-2.4.4and 0-2.4.5taking note of thedifferences between steel and aluminium.

4.6.2 It is not intended that thicknesses or diameters should be measured precisely but ratherthat the values given in Tables 0-2.4.4and 0-2.4.5should be applied in respect of thethickness stated on the steel certificate.

4.7 Welding positions

4.7.1 For the purpose of these guidelines, the welding positions are identified inFigs. 0-2.4.1and 0-2.4.2according to the ISO designations. For cross-referencebetween LR, ISO and AWS terminology and abbreviations, see Appendix B. The anglesof slope and rotation for straight welds in these welding positions are to be inaccordance with either ISO 6947 or general practice.

5 Range of approval

5.1 General

5.1.1 Generally, the qualification test approves the welder not only for the conditions used in

the test, but also for all joints which are considered easier to weld. The range ofapproval for each type of test is given in the following sub-sections and tables. In thesetables, the range of approval is indicated in the same horizontal line.

5.2 Welding process

5.2.1 Each test normally approves one process. A change of process requires a new approvaltest. However, it is possible for a welder to be approved for more than one weldingprocess by a single test or by two separate approval tests. For example, in a casewhere approval is required for a single-side butt joint with the root to be welded by TIG(141) without backing and to be filled by metal-arc welding with covered electrode (111),the welder may be approved by either of the following routes:

(a) Successful completion of an approval test simulating the multi-process joint, i.e. theroot run welded by TIG (141) without backing, subsequent runs or layers welded bymetal-arc welding with covered electrode (111) within the limits of the range of approval.

(b) Successful completion of separate relevant approval tests, one for TIG (141) withoutbacking for the root run and a separate test for the fill by metal-arc welding with coveredelectrode (111) with backing or welded from both sides with or without backing.

5.2.2 The range of approval for thickness in the case of a multi-process qualification test is tobe based on the thickness of the test plates used, not on the actual thickness of weldmetal deposited by each process.

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5.3 Joint types

5.3.1 Depending on the test assembly, the range of welds for which the welder is approved isshown in Table 0-2.5.1. The following criteria are applicable:

(a) Approval for butt welds in pipes includes welds in plates.

(b) Approval for butt welds in plates in all relevant positions includes butt welds on pipeshaving an outside diameter greater than or equal to 500 mm; for rotating pipes (c)applies.

(c) Approval on test butt joints in plates welded in the flat (PA) or horizontal (PC) positionincludes approval for butt joints in rotating pipes of outside diameter greater than orequal to 150 mm welded in similar positions according to Table 0-2.5.2.

(d) Butt welds include approval for fillet welds for similar welding conditions. Where theproduction work is predominantly fillet welding, the welder should be approved also byan appropriate fillet welding test.

(e) Approval for butt welds in pipes without backing includes approval for branchconnections within the same range of approvals as in Tables 0-2.4.4and 0-2.4.5.For a branch weld, the range of approval is based on the diameter of the branch.

5.3.2 Where the production work is either predominantly branch welding or involves acomplex branch connection, or where access is restricted, it is recommended that thewelder should receive special training, and the welder approval test should be on a testassembly of representative complexity and accessibility.

5.4 Steel parent metal groups

5.4.1 According to the material group of the test piece, the range of materials for which awelder is approved is shown in Table 0-2.4.1, and as detailed below. For any materialnot covered by any of the groups, the welder's test on that material gives approval onlyfor that material.

5.4.2 Normalized, controlled-rolled, thermomechanically controlled processed (TMCP) andquenched and tempered steels: For the welding of steels in the range from normalstrength up to and including those with a specified minimum yield strength of 690N/mm

2, qualification at any strength level also qualifies the welder to weld any lower

strength steels within the other limits of the welder's qualification.

5.4.3 Low temperature nickel steels:- Qualification on either 1 Ni or 3 Ni qualifies thewelder for the other. Similarly, qualification on either 5 Ni or 9 Ni qualifies for the other.

5.4.4 The satisfactory welding of any one material in a group confers approval of the welderfor the welding of all other materials within the same group.

5.4.5 When welding parent metals from two different groups which do not give approval toeach other according to Tables 0-2.4.2and 0-2.4.3, an approval for the combination asa separate group is required.

5.4.6 When the filler metal is dissimilar to the parent metal group, an approval for thatcombination of parent metal group and filler metal is needed, except when permitted byTables 0-2.4.2and 0-2.4.3.

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5.5 Aluminium parent metal groups

5.5.1 Non-heat treatable alloys:

Qualification on any of the aluminium-magnesium alloys (5000 series) qualifiesfor welding any of the other alloys in this group.

5.5.2 Heat-treatable alloys:

Qualification on any of the 6000 series alloys qualifies for welding any of theother alloys in this group and any non-heat treatable alloys (5000 series).

5.6 Covered electrodes

5.6.1 For shielded metal arc welding (111) a change in the type of electrode coating mayrequire a change in the welder's technique. An approval test of one electrode coatingwill include approval of the welder for other coatings as specified in Table 0-2.5.3.

5.7 Shielding gas and flux

5.7.1 A change of shielding gas or flux is permitted (see 4.5).However, a change from active(CO2, Ar-CO2, Ar-O2, Ar-CO2-O2, etc.) to inert (Ar, He, Ar-He, etc.) shielding gas or frominert to active shielding gas requires a new approval test for the welder.

5.8 Filler metal and shielding gas

5.8.1 An approval test made with a specific filler metal and shielding gas (pure gas or mixture

or combination) includes approval to weld with any other filler metal compatible with theparent metal group when using the same welding process and a shielding gas (pure gasor mixture or combination) which does not require a change in the welder's technique.

5.9 Dimensions

5.9.1 The range of approval according to plate thickness or wall thickness of pipe and/or pipediameter is shown in Tables 0-2.4.4 and 0-2.4.5.

5.10 Welding positions

5.10.1 The range of approval for each welding position is given in Table 0-2.5.2. The weldingpositions and codes refer to Figs. 0-2.4.1and 0-2.4.2,andAppendix B.

6 Examination and testing

6.1 Supervision

6.1.1 The welding and testing of the qualification test assembly are to be witnessed by an LRSurveyor, or an examiner or test body acceptable to LR and other contracting parties.

6.1.2 The test assemblies are to be marked with the identification of the examiner and thewelder before welding starts.

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6.1.3 The examiner or test body may stop the test if the welding conditions are not correct or ifit appears that the welder does not have the technical competence to achieve therequired standard, e.g. where there are excessive and/or systematic repairs.

6.2 Shape and dimensions of test assemblies

6.2.1 The shape and dimensions of test assemblies (see 4.6) are to be as shown inFigs. 0-2.6.1 to 0-2.6.4.

6.3 Welding conditions

6.3.1 The approval test for the welder is to correspond to the conditions used in production(see also 5.3.2) and follow a WPS (see 2.2) prepared in accordance with Materials andQualification Procedures for Ships, Procedure 0-1.

6.3.2 When preparing the welders qualification test, the following conditions are to apply:

(a) The test is to be carried out with the welding process(es) to be used in production.

(b) Filler metals are to be compatible with the particular welding process(es) andposition(s).

(c) The edge preparation of plate and/or pipes for the test assembly is to be representativeof that to be used in production; cleaning and degreasing is to be applied, asappropriate to the materials involved.

(d) The dimensions of the test assembly are to be in accordance with Tables 0-2.4.4and0-2.4.5and Figs. 0-2.6.1 to 0-2.6.4.

(e) The welding equipment should be similar to that used in production.

(f) The welding is to be carried out in the position(s), and angle(s) of branch connections,normally used in production (see Figs. 0-2.4.1 and 0-2.4.2).

(g) The combination of parent metal, filler metal, flux, shielding gas and any auxiliarymaterials are to correspond to those used in production.

(h) The weld is to be assessed in accordance with the rest of this Section and Section 7.

(j) The welding time for the qualification test assembly is to correspond to the working timeunder usual production conditions.

(k) The test assembly is to have at least one stop and one restart in the root run and in

the top capping run and these are to be marked for identification in theinspection length to be examined.

(l) Any preheat or controlled heat input required in the WPS is mandatory for thewelder's test assembly.

(m) Any post-weld heat treatment and/or ageing required in the WPS may be omitted unlessbend tests are included in the examination of the welder's test assembly.

(n) Identification of the test assembly with a unique reference number.

(o) The welder is to be allowed to remove minor imperfections, except on the surface layer,by grinding, gouging or any other method used in production, provided the prior

approval of the examiner or test body is obtained.

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6.4 Test methods

6.4.1 Each completed weld is to be examined visually in the as welded condition, prior toproceeding with the tests required in Table 0-2.6.1. Visual examination can besupplemented by magnetic particle, dye penetrant (see ISO 3452) or other testmethods, and macro tests on butt welds.

6.4.2 If acceptable by visual inspection, additional radiographic, fracture tests and/or macrotests are then required (see Table 0-2.6.1).

6.4.3 The macro specimen is to be prepared and etched on one side to reveal the weld metaland fusion boundaries, to enable the identification of those defects which could beattributed to the welder.

6.4.4 When radiography is used, bend tests are always to be applied to butt welds made byMIG or MAG (131,135) or by oxy-acetylene (311) welding.

6.4.5 Where backing strips are used, they are to be removed prior to mechanical testing. Thetest assembly can be sectioned by thermal cutting or by mechanical means. Any

thermal cutting must be at least 20 mm away from the test length of any mechanical testspecimen, or macro-section, and remaining surplus material is then to be removedmechanically. In sectioning the weld for test specimens, the first and last 25 mm of thetest assembly can be discarded (see Figs.0-2.6.5 and 0-2.6.6).

6.5 Tests for butt welds in plate

6.5.1 When radiography is used, (see Table 0-2.6.1) the whole inspection length of the weldin the test assembly is to be radiographed in the as-welded condition in accordance withISO 1106-1 or 1106-2 for steels and ISO 1106-3 for aluminium, using class B techniquein all cases.

6.5.2 When fracture testing is used, (see Table 0-2.6.1) the full test assembly inspection

length is to be tested and to do this, the test assembly is to be cut into several testspecimens (see Fig. 0-2.6.5(a)). The length of any fracture test specimen is to beapproximately 40 mm. If necessary, the weld reinforcement of the test specimen may beremoved and additionally the weld edges may be notched to a depth of approximately 5mm to facilitate fracture in the weld metal (see Fig. 0-2.6.5(b)). In the case of single-sided welding without backing, half of the inspection length is to be tested against theface side and the other half against the root side (see Figs. 0-2.6.5(c) and (d)).

6.5.2 When transverse bend testing is used (see Table 0-2.6.1), for plate thickness greaterthan or equal to 3 mm, two root bend test specimens and two face bend test specimensare to be tested in accordance with the following :

a) Steel

Testing shall be in accordance with ISO 5173. The diameter of the former or inner roller(Df) is to be based on the requirements of the Rules for Materials, Ch 11 appropriate tothe welding process and material:

Df=(F+1)t mm

WhereF = value of the bend test ratio, (D/t) in

Tables 11.3.3, 11.4.3, 11.8.2 asapplicable of the Rules for Materials, Ch 11.

t = thickness of the bend test specimen.

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Each test specimen is to be bent through an angle of at least 120.

b) Aluminium

Testing shall be generally in accordance with ISO 5173. Each specimen shall be bentround a former with a diameter as specified in the Rules for Materials, Chapter 11,Section 9, through an angle of 180.

6.5.4 For plate thicknesses greater than or equal to 12 mm, the four transverse bend tests(two face, two root) may be substituted by four side bend tests.

6.6 Tests for fillet welds on plate

6.6.1 Fracture tests are preferred and the test assembly may be cut, if necessary, into severaltest specimens (see Fig. 0-2.6.6(a)). Each test specimen is to be positioned for breakingas shown in Fig 0-2.6.6(b), and examined after fracture.

6.6.2 When macro examination is used, four test specimens are to be taken equally spaced inthe inspection length.

6.7 Tests for butt welds in pipe

6.7.1 When radiography is used, the whole inspection length of the weld in the testassembly is to be radiographed in the as-welded condition using agreed procedures.

6.7.2 When fracture testing is used, the full test assembly inspection length is to be tested andto do this the test assembly is to be cut into at least four test specimens (see Fig. 0-2.6.7(a)). If the pipe diameter is too small to provide the required number of testspecimens, two or more test assemblies are to be welded.

6.7.3 The inspection length of any test specimen is to be approximately 40 mm. If necessary,the weld reinforcement of the test specimen may be removed and additionally the weld

edges may notched to be a depth of approximately 5 mm to facilitate fracture in the weldmetal (see Fig. 0-2.6.7(b)). In the case of single-side welding without backing half of theinspection length of the test assembly (see Fig. 0-2.6.7(a)) is to be tested against theface side and the other half against the root side (see Figs. 0-2.6.7(c) and (d)).

6.7.4 When transverse bend testing is used for wall thickness greater than or equal to 3 mm,two root bend test specimens and two face bend test specimens are to be tested. Thediameter of the former or the inner roller is to be as given in 6.5.3 and the angle of bendis to be at least 120.

6.7.5 For the sectioning of test assemblies welded in position PF, PG and H-L045 (see Fig. 0-2.4.2), test specimens are to be taken from different welding positions around thecircumference of the weld joint.

6.7.6 For wall thickness greater than or equal to 12 mm, the four transverse bend tests maybe substituted by four side bend tests.

6.8 Testsfor fillet welds on pipe

6.8.1 Fracture tests are preferred and the test assemblies are to be cut into four or more testspecimens and fractured (see Fig. 0-2.6.8).

6.8.2 When macro examination is used, at least four test specimens are to be taken equallyspaced around the pipe.

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7 Evaluation and acceptance requirements

7.1 Evaluation

7.1.1 Test assemblies are to be evaluated according to the acceptance requirementsspecified for relevant types of imperfections. A full explanation of these imperfections isgiven in ISO 6520.

7.2 NDE evaluation

7.2.1 The acceptance requirements for imperfections found by test methods in accordancewith these guidelines are to be in accordance with Table 0-2.6.1. A welder will be approved if theimperfections in the test assembly are within the specified limits in Table 0-2.7.1.

7.3 Evaluation of destructive tests

7.3.1 After performing a bend test there should be no defect present on the tension surface

exceeding 3 mm in any direction. Flaws appearing at the corners of the test specimenmay be ignored provided these are not associated with welding defects such as slag orporosity.

7.3.2 After fracture testing, any defects present on the fracture faces are to be evaluated inaccordance with the NDE acceptance criteria specified in Table 0-2.7.1.

7.3.3 The macro-section is to be examined for defects, which shall be assessed inaccordance with the NDE acceptance criteria specified in Table 0-2.7.1.

7.4 Acceptance criteria

7.4.1 If any imperfections in the welder's test assembly, or test specimens exceed the

permitted maximum, then the welder is not to be approved.

7.4.2 Documented procedures are to be used for destructive and non-destructiveexaminations.

8 Re-tests

8.1 General

8.1.1 If any test fails to comply with the acceptance requirements, the welder may bepermitted to weld another test assembly.

8.1.2 If it is established that failure is attributed to the welder's lack of skill, the welder shouldundergo further training before re-testing.

8.1.3 If it is established that failure is due to metallurgical or other extraneous causes andcannot be directly attributed to the welder's lack of skill, an additional test is required inorder to assess the quality and integrity of the new test material and/or new testconditions.

8.2 Additional test specimens

8.2.1 If a bend test specimen fails, two additional test specimens may be prepared either fromthe same test assembly, if there is sufficient material available or, if necessary, from anadditional test assembly and subjected to the same tests. Both test specimens are to be

tested with satisfactory results.

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8.2.2 If a fracture test specimen shows unacceptable imperfections, two additional testspecimens may be prepared and tested as specified in 8.2.1.

8.2.3 If one of these additional test specimens in accordance with 8.2.1 and 8.2.2 does notcomply with the acceptance requirements, the cause of failure is to be established.

8.2.4 If a bend or fracture test specimen from a pipe welded with fixed axis fails, twoadditional test specimens are to be taken from the equivalent position.

8.2.5 If a macro-section is unacceptable, two additional test specimens may be prepared andexamined as specified in 8.2.1 and 8.2.4.

9 Period of validity

9.1 Initial approval

9.1.1 The validity of the welder's approval begins from the date when all the required tests aresatisfactorily completed (Date of test'). This date may be different from the date of issuemarked on the certificate.

9.1.2 A welder's approval is to remain valid for a period of two years providing that therelevant certificate is signed at six month intervals by the employer or co-ordinatorresponsible for weld quality, and that all the following conditions are fulfilled:

(a) The welder is engaged with reasonable continuity on welding work within thecurrent range of approval. An interruption for a period no longer thansix months is permitted.

(b) The welder's work is generally in accordance with the technical conditions underwhich the approval test was carried out.

(c) There is no specific reason to question the welder's skill and knowledge.

9.1.3 If any of these conditions are not fulfilled, the approval is to be cancelled.

9.2 Extension of validity

9.2.1 The validity of the approval on the certificate may be extended by the LR Surveyor forfurther periods of two years (subject to renewal at six month intervals, as in 9.1.2), withinthe original range approved, provided each of the following conditions in accordancewith 9.1 are fulfilled for each prolongation period:

(a) The production welds made by the welder are of the required quality.

(b) Records of tests, e.g. documentation about X-ray or ultrasonic inspections ortest reports about fracture tests, are maintained on file with the welder'sapproval certificate.

9.2.2 The Surveyor is to verify compliance with the above conditions and sign theprolongation of the welder's approval test certificate.

10 Certification

10.1 Welder approval certificate

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10.1.1 It is to be certified that the welder has successfully passed the approval test. All relevanttest conditions are to be recorded on the certificate. If the welder fails any of theprescribed tests, no certificate is to be issued.

10.1.2 The certificate is to be issued under the sole responsibility of the LR Surveyor and is tocontain all the information detailed inAppendix A. The format ofAppendix A isrecommended to be used as the welder's approval test certificate. This is available asLR Form 5208.

10.1.3 If any other form of welder's approval test certificate is used, it is to contain theinformation required inAppendix A.

10.1.4 The welder's approval test certificate is to be issued at least in English.

10.1.5 Each change of the essential variables for the approval testing beyond the permittedranges will require a new test and a new approval certificate.

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Table 0-2.4.1 Welder Qualification Steel Approval Groupings

MaterialGroup

Material Description Typical LR GradesRules for Materials

ReferenceW 01

Low carbon un-alloyed, C-Mn or

low alloy steels Re360 N/mm2

Ni steels >5.0% Ni

AH to FH 40 to 69LT-AH to LT-FH 40

1Ni , 3 Ni2Ni, 3Ni castingsU3, R3, R3S, R4

Ch3.3 Ch3.10Ch3.6

Ch3.6, Ch6.4Ch4.7Ch3.9, Ch10.2,

W 04 Ferritic or martensitic stainlesssteels, 12-20% Cr

13%Cr (Martensitic) Ch4.5 (Martensitic)

W 05 Ferritic low temperature steels5Ni 9% Ni

5Ni, 9Ni Ch 3.6

W 11 Austenitic stainless steelsDuplex (austenitic-ferritic)

stainless steels

304.316,317,321,347S31260, S31803, S32550,

S32750

Ch3.7Ch3.7, Ch4.8, Ch6.5

Table 0-2.4.2 Range of approval for parent metal

Range of ApprovalMaterial Groups ofapproval test W 01 W 02 W 03 W 04 W 05 W 11

W 01

W 02 x

W 03 x x

W 04

W 05

W 11 x*

x* x

* x

* x

*

Key to Table indicates the material group for which the welder is approved from the

approval test.

X indicates those material groups for which the welder is also approved. indicates those material groups for which the welder is not approved.

* material groups approved when using filler metal from group W11 test.

Note: This table applies when the filler material used for the approval test is in the same groupas the base material. Where these are different the test only approves the combination tested.

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Table 0-2.4.3 Range of approval for dissimilar joints

Material group of approvaltest

Range of approval

W 02 W 02 welded to W 01 (see note 1)

W 03

W 02 welded to W 01 (see note 1)

W 03 welded to W 01 (see note 1)W 03 welded to W 02 (see note 1)

W 04W 02 welded to W 01 (see note 1)W 04 welded to W 01 (see note 1)W 04 welded to W 02 (see note 1)

W 05W 05 welded to W 01 (see note 1)W 05 welded to W 03 (see note 1)

W 11

W 11 welded to W 01 (see note 2)W 11 welded to W 02 (see note 2)W 11 welded to W 03 (see note 2)W 11 welded to W 04 (see note 2)W 11 welded to W 05 (see note 2)

Notes:1. For dissimilar metal joint the filler metal is to correspond to the group of one of the

parent materials.2. When using a filler metal appropriate for material group W 11.

Table 0-2.4.4 Test assembly (plate or pipe) and range of approval

Material Test assembly thickness, tmm Range of approval

Steel

t 3

3 12

tto 2t(see Note 1)3mm to 2t(see Note 2)

5mm

Aluminium

t 6

6

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Table 0.2.4.5 Test assembly diameter and range of approval

MaterialTest assembly diameter, D mm

(See Note 1)Range of approval

Steel

D 25

25 150

D to 2D(see Note 1)0.5Dto 2D (25 mm min)

0.5 D

AluminiumD 125

D > 125

0.25 to 2D

0.5 D

Note:

For structural hollow sections, Dis the dimension of the smallest side.

Table 0-2.5.1 range of approval for tests on butt joints (Details of weld type)

Range of approval

Butt welds in plate Butt welds inpipe

Welded fromone side

ss

Welded fromboth sides

bs

Welded fromone side

ss

Details of weld type

Withbacking

mb

Nobacking

nb

Withgouging

gg

Nogouging

ng

Withbacking

mb

Nobacking

nb

Withbacking

mb X SeeNote Welded fromone side ss No

backingnb X X X

SeeNote

SeeNote

Withgouging

gg X SeeNote

Buttweld inplate

Welded fromboth sides bs No

gougingng X X

SeeNote

Withbacking

mb X X Buttwelds inpipe

Welded fromone side ss No

backingnb X X X X X

Key

indicates those weld for which the welder is approved in the approval test

X indicates those welds for which the welder is also approved indicates those welds for which the welder is not approved

Note:See 5.3.1(b)and 5.3.1(c)

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Range of approval according to welding positionRange of approval

Plates

Butt welds

Pip

rotating fixed Butt welds Fillet welds

0 90 45

Welding position of approval assembly

PA PC PG PF PE PA PB PG PF PD PA PG PF PC H-L04

PA X X X

PC X X X X X

PG X

PFX X X X X

Butt welds

PEX X X X X X X X

PA

PB X

PG

PF X X

Plates

Fillet welds

PD X X X

rotatingPA

X X X

PG X X 0

PFX X X X X X X X

90PC

X X X X X

H-LO45X X X X X X X X X X X

Butt

weldsfixed

45J-LO45

X X X

rotating 45PA

X

Note 1PB

X X

PG X

Pipes

Filletwelds

Pipe

axis andangle

fixed 0PF

X X X X

Notes: 1. PB for pipes may be welded in two versions Key indicates those weld for which the welder is approved in ta) pipe: rotating; axis: horizontal; weld: horizontal vertical X indicates those welds for which the welder is also approve

b) pipe: fixed; axis: vertical; weld: horizontal vertical indicates those welding positions for which the welder is n

2. This is an approved position and is covered by other related tests

Table 0-2.5.2 Range of approval according to welding position

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Table 0-2.5.3 Range of approval for electrode coating

Range of approvalType of covered electrodes ofapproval test assembly A; RA R; RB;RC; RR B C S

A; RA

R; RB; RC; RR X

B X X

C

S (seeNote 1) Key

indicates the covered electrode type for which the welder is approved in the approval testX indicates those electrode groups for which the welder is also approved indicates those electrode groups or which the welder is not approved

NoteS only gives approval for the specific type of electrode coating used in the test.

Table 0-2.6.1 Test methodsTest Method Butt weld plate Butt weld pipe Fillet weld

Visual

Radiography see Notes 1&2

see Notes 1&2X

Bend see Notes 3 see Notes 3 X

Fracture see Notes 1

see Notes 1

see Notes 4&5Macro(without polishing)

X X see Notes 5

Magneticparticle/dyepenetrant

X X X

Key indicates that the test method is mandatoryX indicates that the test method is not mandatory

NOTES1.. Radiography or fracture test is to be used , but not both.2. The radiographic test may be replaced by an ultrasonic test for thickness

greater than or equal to 12 mm on ferritic steels only.3. When radiography is used, then the bend tests are mandatory for the

processes 131, 135 and 311.4. The fracture test should be supported by magnetic particle/dye penetranttesting when required by the examiner or the test body.

5. The fracture test may be replaced by a macro examination of at least foursections.

Table 0-2.7.1 NDE Acceptance criteriaThe following table specifies the minimum acceptance criteria for welding imperfections detected by the non-destructive examination during qualification testing.

Acceptance Limits

Imperfection

Type

Commentary2 Steel Aluminium

Cracks Cracks, tears, etc. Not permitted Not permitted

Lack of fusion Lack of root, side wall, inter-run Not permitted Not permitted

Lack of

penetration

Lack of penetration in square edge buttwelds and fillet welds

Lack of penetration in the root of singlesided welds

Not permitted

Depth 0.1t,

Length tMax 25

Not permitted

Depth 0.1t,

Length tMax 25(CONTINUED OVERLEAF)

Porosity single Single pores, elongated cavities and d 0.25t for butt welds d 0.2t for butt welds

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pores wormholes d 0.25a for fillet welds

Max. d 3.0Min. separation 2.5d

Length 6.0

d 0.2a for fillet welds

Max. d 2.0

Porosity

localised(clustered)

The area of weld affected (i.e. length ofcluster by width of weld)

Not exceeding 2.0% of thetotal weld area.

Single pore d 2.0

Not exceeding 25 in any100 weld.

Single pore d 1.5

Porosity uniformly

distributed

Uniformly distributed along weld length Not permitted Single pore d 1.0

Porosity linearMay be accepted if it can be shown thatit is not associated with other defects(i.e. lack of penetration or fusion)

See limits for single poresor localised porosity

See limits for singlepores or localised porosity

Solid inclusions

Slag, oxide

Copper

Tungsten

Width 0.3t,Max. 3.0

Length t,Max. 25mm

Not permitted

See limits for single pores

Not permitted

Not permitted

d

t/20,Max. d 0.8

Root concavityand shrinkage

Acceptable within the limits statedprovided it is intermittent and has asmooth transition

Depth 1.0 Depth 0.1t,Max. 1.5

Undercut Provided it is intermittent Depth 0.5 Depth 0.5

Excessivereinforcement andconvexity

Acceptable within the limits statedprovided weld blends smoothly with thebase material

Height 0.2b,Max. 6.0

Height 1.5 + 0.2b,Max. 5.0

Excessive root

penetration

Acceptable within the limits statedprovided it blends smoothly with thebase material

Height 0.2b,Max. 3.0

Height 3.0

Excessiveasymmetry

Excessive asymmetry in the leg lengthsof fillet welds provided it is intermittent

Max difference inmeasured leg lengths 2.0

Max. difference inmeasured leg lengths 2.0

Under fill

Incomplete fill, undersize weld permitted

if it blends smoothly with base material

Depth 1.0,

Max. length t/2

Height 0.05t,

Max. 1.0Overlap Cold lap Length t Not permitted

MisalignmentButt weld misalignment Not exceeding 0.15t,

Max. 3.0Not exceeding 0.1t,Max. 2.5

Arc strikes &

Spatter

These may be removed prior toinspection, with the agreement of theSurveyor

Not permitted Not permitted

Notes to table:1. Symbolsa ~ fillet weld throat thicknessb ~ weld widthd ~ diameter or width of imperfectiont ~ material thickness

2. The table specifies actual imperfection dimensions, it maybe necessary to perform additional NDE, in some instances, inorder to determine defect dimensions and evaluateacceptability.3. All dimensions are in mm.

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PA (flat)

PA (flat) PD (horizontal overhead)

PG (vertical downward) PF (vertical upwards)

PB (horizontal vertical)

PE (overhead) PC (horizontal)

PG (vertical downward) PF (Vertical upwards)

(a) Butt welds

(b) Fillet welds

4607/01

Fig. 0-2.4.1 Welding positions for plates

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Pipe : rotating

Pipe : rotating

Pipe : fixed

Pipe : fixed Pipe : fixed

Pipe : fixed

45

Pipe : fixed

Pipe : fixed

Pipe : fixed

Pipe : fixed

(b) Fillet welds4607/02

(a) Butt welds

PA Axis : horizontalWeld : flat

PF Axis : horizontalWeld : vertical upwards

PG Axis : horizontalWeld : vertical downwards

H L045 Axis : inclined

Weld : upward

PC Axis : vertical

Weld : horizontal vertical


PC Axis : vertical

Weld : vertical upwards

PF Axis : horizontal

Weld : vertical downwards

PG Axis : horizontal

Weld : horizontal overhead

PD Axis : vertical


PB Axis : vertical

Fig. 0-2.4.2 Welding positions for pipes

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125 mm 125 mm

300 mm

t4607/38

(300)

(150)(150)

z= a 2

a

z

125 mm

150 mm

125 mm

For t6 mm, a0,5t

For t< 6 mm, 0,5tat

(z= 0,7t)

t

t

4607/39

(150)

(300)

(150)

Fig. 0-2.6.1 Fig. 0-2.6.2

Dimensions for test assembly for a butt weld in plates Dimensions for test assembly for a fillet weld(s) in plates

(dimensions in brackets are for assemblies in aluminium) (dimensions in brackets are for assemblies in aluminium)

125 mm

125 mm

t

D4607/42

(150)

(150)

4607/43

z= a 2

a

z

D

t

t

l1

l1

0,5Dmin.

50 mm max.

0,5Dmin.

50 mm max.

125 mm

tcorresponds to the thinner partFor t 6 mm, a0,5t

For t< 6 mm, 0,5 tat

(z= 0,7t)

(150)

Fig. 0-2.6.3 Fig. 0-2.6.4Dimensions for test assembly for a butt weld in pipe Dimensions for test assembly for a fillet weld. in pipe

(dimensions in brackets are for assemblies in aluminium) (dimensions in brackets are for assemblies in aluminium)

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4607/40

= 2 mm = 2 mm

= 40 mm= 5 mm = 5 mm

Inspection length

of the test piece

25 mm 25 mml2

l1

l1

(a)

Sectioning into an even-numbered quantity of test specimens

(b)

Preparation

(c)Fracture testing root bend test

(d)Fracture testing face bend test

Fig.0-2.6.5 Preparation and fracture testing of test specimens for a butt weld in plate

Inspection lengthof the test piece

25 mm

25 mm

4607/41

(a)

Sectioning into an even-numbered quantityof test specimens

(b)

Fracture testing(The fillet weld may be notched if necessary)

Fig. 0-2.6.6 Preparation and fracture testing of test specimens for a fillet weld in plate

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4607/44

Inspection lengthof the test piece

= 2 mm = 2 mm

= 40 mm= 5 mm = 5 mm

Inspection length

of test specimen

= 40 mmInspection length

of the test specimen

(a)

Sectioning into at least four

test specimens

(b)

Preparation

(c)

Fracture testing root bend test

(d)

Fracture testing face bend test

Fig. 0-2.6.7 Preparation and fracture testing of test specimens for a butt weld in pipe

4607/45

(a)Sectioning into test specimens

(b)Fracture testing

Fig. 0-2.6.6 Preparation and fracture testing of test specimensfor a fillet weld in pipe

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Appendix A to be inserted

Appendix A to be inserted

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APPENDIX B

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ABCD

Welding positions and codes

Table 0-2.B.1 Equivalent welding positions description and identifying codes

LR ISO AWS

Butt Fillet Butt Fillet Butt Fillet

Downhand D DX Flat PA PA Flat 1G 1F

Horizontal-vertical X X Horizontal-vertical PC PB Horizontal 2G 2F

Vertical-upward Vu Vu Vertical-upward PF PF Vertical 3G* 3F

*

Vertical-downward Vd Vd Vertical-downward PG PG Vertical 3G* 3F

*

Overhead O O Overhead O O Overhead 4G 4F

Horizontal-overhead - PD

Fixed pipe inclined 45 H-LO45upward

Fixed inclined pipe 6G

Fixed pipe inclined 45 J-LO45downwards

Fixed inclined pipe 6G

Key* These codes need further identification of the direction of progression; upward or downward In ISO, these codes apply equally to plate and pipe welds. In the latter, the position referred to bythe code

is that of the weld, not the pipe.

mqps0 2 (lloyds)

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