2 - nr 476 - approval testing of welders - november 2001
TRANSCRIPT
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APPROVAL TESTING of WELDERS
Rule NoteNR 476 DTM R00 E
November 2001
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Tel. 33 (0) 1 42 91 52 91 Fax. 33 (0) 1 42 91 53 20Email : [email protected]
Web : http://www.veristar.com
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MARINE DIVISION GENERAL CONDITIONS
BV Mod. Ad. ME 545 h - 06/2000
ARTICLE 1
1.1. - BUREAU VERITAS is a Society the purpose of whose Marine Division (theSociety) is the classification ( Classification ) of any ship or vessel or structure of anytype or part of it or system therein collectively hereinafter referred to as a Unit whetherlinked to shore, river bed or sea bed or not, whether operated or located at sea or ininland waters or partly on land, including submarines, hovercrafts, drilling rigs, offshoreinstallations of any type and of any purpose, their related and ancillary equipment, subseaor not, such as well head and pipelines, mooring legs and mooring points or otherwise asdecided by the Society.The Society: prepares and publishes Rules for classification, Guidance Notes and other
documents ( Rules );
issues Certificates, Attestations and Reports following its interventions( Certificates );
publishes Registers.
1.2. - The Society also participates in the application of National and International
Regulations or Standards, in particular by delegation from different Governments. Thoseactivities are hereafter collectively referred to as Certification .
1.3. - The Society can also provide services related to Classification and Certificationsuch as ship and company safety management certification; training activities; allactivities and duties incidental thereto such as documentation on any supporting means,software, instrumentation, measurements, tests and trials on board.
1.4. - The interventions mentioned in 1.1., 1.2. and 1.3. are referred to as Services .The party and/or its representative requesting the services is hereinafter referred to as the Client .
The Services are prepared and carried out on the assumption that the Clients are
aware of the International Maritime and/or Offshore Industry (the Industry)
practices.
1.5. - The Society is neither and may not be considered as an Underwriter, Broker inships sale or chartering, Expert in Units valuation, Consulting Engineer, Controller, NavalArchitect, Manufacturer, Shipbuilder, Repair yard, Charterer or Shipowner who are notrelieved of any of their expressed or implied obligations by the interventions of theSociety.
ARTICLE 2
2.1. - Classification is the appraisement given by the Society for its Client, at a certain
date, following surveys by its Surveyors along the lines specified in Articles 3 and 4hereafter on the level of compliance of a Unit to its Rules or part of them. Thisappraisement is represented by a class entered on the Certificates and periodicallytranscribed in the Societys Register.
2.2. - Certification is carried out by the Society along the same lines as set out in Articles
3 and 4 hereafter and with reference to the applicable National and InternationalRegulations or Standards.
2.3. - It is incumbent upon the Client to maintain the condition of the Unit after
surveys, to present the Unit for surveys and to inform the Society without delay ofcircumstances which may affect the given appraisement or cause to modify its
scope.
2.4. - The Client is to give to the Society all access and information necessary for the
performance of the requested Services.
ARTICLE 3
3.1. - The Rules, procedures and instructions of the Society take into a ccount at the
date of their preparation the state of currently available and proven technical
knowledge of the Industry. They are not a code of construction neither a guide for
maintenance or a safety handbook.
Committees consisting of personalities from the Industry contribute to the development ofthose documents.
3.2. - The Society only is qualified to apply its Rules and to interpret them. Any
reference to them is void unless it involves the Societys intervention.
3.3. - The Services of the Society are carried out by professional Surveyors according tothe Code of Ethics of the Members of the International Association of ClassificationSocieties (IACS).
3.4. - The operations of the Society in providing its Services make use of random
inspections and are absolutely exclusive of any monitoring and thorough verification.
ARTICLE 4
4.1. - The Society, acting by reference to its Rules:
reviews the construction arrangements of the Units as shown on the documentspresented by the Client;
conducts surveys at the place of their construction;
classes Units and enters their name in its Register;
surveys periodically the Units in service to note that the requirements for themaintenance of class are met.
The Client is to inform the Society without delay of circumstances which may cause
the date or the extent of the surveys to be changed.
ARTICLE 5
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obligation bearing on the Society to obtain a result or in a wa rranty.
5.2. - The certificates issued by the Society pursuant to 5.1. here above are a
statement on the level of compliance of the Unit to its Rules or to the documents of
reference for the Services provided for.
In particular, the Society does not engage in any work relating to the design,
building, production or repair checks, neither in the operation of the Units or in theirtrade, neither in any advisory services, and cannot be held liable on those accounts.
Its certificates cannot be construed as an implied or express warranty of safety,
fitness for the purpose, seaworthiness of the Unit or of its v alue for sale, insurance
or chartering.
5.3. - The Society does not declare the acceptance or commissioning of a Unit, that
being the exclusive responsibility of its owner.
5.4. - The Services of the Society cannot create any obligation bearing on the
Society or constitute any warranty of proper operation, beyond any representation
set forth in the Rules, of any Unit, equipment or machinery, computer software of any
sort or other comparable concepts that has been subject to any survey by the
Society.
ARTICLE 6
6.1. - The Society accepts no responsibility for the use of information related to its
Services which was not provided for the purpose by the Society or with its assistance.
6.2. - If the Services of the Society cause to the Client a damage which is proved to
be the direct and reasonably foreseeable consequence of an error or omission of the
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for the Service having caused the damage. This limit is subject to a minimum of fifty
thousand (50.000) French francs, and to a maximum which is the greater of five
millions (5.000.000) French francs and one and a half times the above mentioned fee.
The Society bears no liability for indirect or consequential loss such as e.g. loss of
revenue, loss of profit, loss of production, loss relative to other contracts and
indemnities for termination of other agreements.
6.3. - All claims are to be presented to the Society in writing and on pain of
debarment by right, within three months of the date the Serv ices were supplied or of
the date the events which are taken advantage of were first known.
ARTICLE 77.1. - Requests for Services are to be in writing.
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by prior written notice according to paragraph 7.3., for convenience, and without
prejudice to the provisions in Article 8 hereunder.
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is of three calendar months and conversely, of ten banking days.
7.4. - The class granted to the concerned Units and the previously issued certificatesremain valid until the date of effect of the notice issued according to 7.2. hereabovesubject to compliance with 2.3. hereabove and Article 8 hereunder.
ARTICLE 8
8.1. - The Services of the Society, whether completed or not, involve the payment of feeupon receipt of the invoice and the reimbursement of the expenses incurred.
8.2. - The class of a Unit may be suspended in the event of non-payment of fee after a
first unfruitful notification to pay.
ARTICLE 9
9.1. - The documents and data provided to or prepared by the Society for its Services, and
the information available to the Society, are treated as confidential. However: Clients have access to the data they have provided to the Society and to the reports
and certificates which have been prepared for them;
copy of the documents made available for the classification of the Unit can behanded over to another Classification Society Member of the InternationalAssociation of Classification Societies (IACS) in case of the Units transfer of class;
the data relative to the evolution of the Register, to the class suspension and to thesurvey status of the Units are passed on to IACS according to the associationworking rules;
technical records and history related to specific class notations may be transferred tothe new owner in case of change of ownership;
the certificates, documents and information relative to the Units classed with theSociety are passed on upon order of the flag authorities of the Unit or of a Courthaving jurisdiction.
The documents and data are subject to a file management plan.
ARTICLE 10
10.1. - Any delay or shortcoming in the performance of its Services by the Society arising
from an event not reasonably foreseeable by or beyond the control of the Society shall bedeemed not to be a breach of contract.
ARTICLE 1111.1. - The Society may designate another Surveyor at the request of the Client in case of
diverging opinions during surveys.
11.2. - Disagreements of a technical nature between the Client and the Society can besubmitted by the Society to the advice of its Classification Committee.
ARTICLE 12
12.1. - Disputes over the Services carried out by delegation of Governments are assessedwithin the framework of the applicable agreements with the States, internationalConventions and national rules.
12.2. - Disputes arising out of the payment of the Societys invoices by the Client aresubmitted to the Court of Nanterre, France.
12.3. - Other disputes over the present General Conditions or over the Services of
the Society are exclusively submitted to arbitration in London according to the
London arbitration procedural rules in force. English law applies.
ARTICLE 13
13.1. - These General Conditions constitute the sole contractual obligations binding
together the Society and the Client, to the exclusion of all other representation,
statements, terms, conditions whether express or implied. They may be varied inwriting by mutual agreement.
13.2. - The invalidity of one or more stipulations of the present General Conditions does
not affect the validity of the remaining provisions.
13.3. - The definitions herein take precedence over any definitions serving the same
purpose which may appear in other documents issued by the Society.
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November 2001
RULE NOTE NR 476
APPROVAL TESTING of WELDERS
Section 1 Approval Testing and Certification of Welders for Fusion Welding
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2 Bureau Veritas November 2001
NR 476 Approval Testing of Welders
Section 1 Approval Testing and Certification of Welders for Fusion Welding
1 General 3
1.1
2 Welders employed for steel hull 3
2.1 Variables for approval testing2.2 Range of approval2.3 Welding of approval test pieces2.4 Examinations and tests2.5 Certification
3 Welders employed for aluminium alloys structures 83.1 Variables for approval testing3.2 Range of approval3.3 Welding of approval test pieces3.4 Examinations and tests3.5 Certification
4 Welders employed for other productions 12
4.1 Approval tests and range of approval4.2 Certification
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NR 476, Sec 1
November 2001 Bureau Veritas 3
SECTION 1 APPROVAL TESTING AND CERTIFICATION OFWELDERS FOR FUSION WELDING
1 General
1.1
1.1.1 This document gives approval testing conditions,
acceptance requirements and range of approval of welders
employed for fusion welding when specified by Bureau Ver-
itas Rules for the Classification of Steel Ships.
1.1.2 Approval testing of welder is required for fusion
welding processes designated as manual or semi-automatic
welding processes where the quality of the welded joint
depends mainly on the manual skill of the welder. Opera-
tors using fully mechanized and fully automatic welding
processes are to be suitably trained and experienced.
1.1.3 After satisfactory completion of approval tests under
the supervision of a Society surveyor, the Society will issue
an approval certificate on appropriate form (see annex).
1.1.4 Alternative standards or procedures for approval test-
ing considered as equivalent to the provisions set in this
document may be used upon special consideration of theSociety.
2 Welders employed for steel hull
2.1 Variables for approval testing
2.1.1 Welding processes
Manual or semi-automatic welding processes commonlyused are listed as follows :
Metal arc welding with covered electrodes (SMAW, ISO
4063 ref. number 111)
Metal arc inert gas welding (MIG, ISO 4063 ref. number
131)
Flux cored wire metal arc welding with active gas shield
or without gas shield (FCAW, ISO 4063 respective ref.number 136 and 114)
Change of welding process shall require new approval test-
ing.
2.1.2 Welding consumables
In general approval tests are carried out using filler metal of
grade matching the base material strength.
2.1.3 Type of weld joint
A change of type of weld joint to type for which the welder
is not approved shall require new approval testing.
2.1.4 Type and dimensions of base products
Welding of base products with dimensions out of theapproved range shall require new approval testing.
2.1.5 Welding position
A change in the position of welding to one for which the
welder is not approved shall require new approval testing.
The welding positions for plates are identified in Fig 3.
2.2 Range of approval
2.2.1 Welding process
Approval tests are to be performed for each process.
2.2.2 Welding consumables
Approval is extended to the use of any consumables similar
to the type used for the approval tests and suitable for the
materials to be welded and processes used.
A change in the type of covered electrode may require a
change in the welders technique. Approval tests performedwith a type of covered electrode may extend approval to the
use of other types of covered electrode as specified in Tab
1.
Table 1 : Range of approval for electrode coating
2.2.3 Range of thickness
According to the thickness of approval test pieces, the range
of approval for plate thickness is given in table 2. The limits
are not to be understood as strict conditions.
Table 2 : Approval test piece thickness and range of
approval
Type of covered electrode
used for approval test pieces
Type of covered electrode
which may be used for pro-
duction work
Acid or rutile-acid covering Acid or rutile-acid covering
Rutile or rutile-basic or
rutile-cellulosic or rutile-
thick covering
Acid or rutile-acid covering
or rutile or rutile-basic or
rutile-cellulosic or rutile-
thick covering
Basic covering Acid or rutile-acid covering
or rutile or rutile-basic or
rutile-cellulosic or rutile-
thick covering or basic cov-
ering
Cellulosic covering Cellulosic covering
Approval test piece thick-
ness t (mm)
Range of approval for pro-
duction works
t 3 mm t to 2 t
3 mm < t 12 mm 3 mm to 2 t
t > 12 mm t 5 mm
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NR 476, Sec 1
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2.2.4 Welding positions and type of weld joint andproducts
Approval tests performed on butt welds in horizontal (PC),
vertical upwards (PF), overhead (PE) positions and on fillet
welds in horizontal overhead (PD), vertical upwards (PF)
positions extend approval to butt and fillet production
welding in all positions except vertical downwards. This setof tests also extends approval to production fillet welding of
fixed hollow sections to plate in positions PB, PF and PD as
shown in Fig 4.
Approval tests performed on butt welds in horizontal (PC),
vertical upwards (PF) positions and on fillet welds in vertical
upwards (PF) position extend approval to butt and fillet pro-
duction welding in positions tested and in flat (PA) and hor-
izontal vertical (PB) positions. This set of tests also extendsapproval to production fillet welding of fixed hollow sec-
tions to plate in positions PB and PF as shown in Fig 4.
Other sets of approval tests confer approval for production
welding in positions tested and type of joint welded.
2.2.5 Steel category
Base materials for approval tests are to be of normal
strength (grades A, B, D or E) or higher strength (AH32 to
FH40) hull steel grades. Approval is extended to production
welding of all hull steel grades.
2.2.6 Backing and gouging conditions
Backing and gouging range of approval is as follows :
Satisfactory approval test pieces welded from one sidewithout backing extend approval to welding from one
side with backing and welding from both sides with or
without gouging.
Satisfactory approval test pieces welded from one sidewith backing extend approval to welding from both
sides with gouging.
Satisfactory approval test pieces welded from both sides
without gouging extend approval to welding from oneside with backing and welding from both sides with
gouging.
2.3 Welding of approval test pieces
2.3.1 General
The welder is to have suitable practical experience and pro-
fessional knowledge of the welding process including the
regulation of the parameters of the welding equipment used
The surveyor may stop the test if the welding conditions are
not correct or if it appears that the welder does not have the
technical competence to achieve the required standard.
2.3.2 Number, shape and dimensions of test pieces
The number, shape and dimensions of test pieces madewith plates are to be selected so as to cover the production
welding work taking into account the welding variables in
[2.1] and the range of approval in [2.2].
The shape and dimensions of test pieces are shown in Fig 1and Fig 2.
Figure 1 : Dimensions of test piecefor a butt weld in plate
(dimensions in mm)
Figure 2 : Dimensions of test piecefor fillet weld(s) on plate
(dimensions in mm)
2.3.3 Welding conditions
The approval tests are to correspond to the conditions used
in production welding and follow a welding procedure
specification representative of production practice.
3
0
0
t
1 2 5 1 2 5
t
12
5
t
1 2 5
1
5
0
z
a
z = a 2
F o r t 6 m m a 0 , 5 t F o r t < 6 m m 0 , 5 t a t( z ~ 0 , 7 t )
~
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In general the following condition apply :
The time for the welding of the test piece is to corre-
spond to the usual working condition;
The test piece shall have at least one stop and restart in
the root run and in the top capping run which has to beidentified for further examination;
Any preheat or controlled heat input specified in thewelding procedure is required for the test piece;
Any post-weld heat treatment specified in the weldingprocedure may be omitted unless bend tests are
required;
The test pieces are to be suitably identified with the
mark of the surveyor and the identification of the welder
before welding starts;
The welder is allowed to remove minor imperfections,
except on the surface layer, by grinding or any other
method used in production upon surveyor's agreement;
The appearence of each pass, both for butt and fillet
welds, is to be of appropriate geometry and practically
free from undercuts, convexities and sizeable local
defects; the surface is to be sufficiently regular.
Similarly the back of the weld is to be free from sizeable
undercuts, excessive convexities and lack of penetra-
tion; in particular for the welders to be qualified for one
side welding without backing the root penetration of the
samples is to be regular and constant.
Figure 3 : Welding positions for plates
P B H o r i z o n t a l v e r t i c a l
P A F l a t
P G V e r t i c a l d o w n w a r d s
P E O v e r h e a d
P C H o r i z o n t a l
P F V e r t i c a l u p w a r d s
P A F l a t
P D H o r i z o n t a l o v e r h e a d
P G V e r t i c a l d o w n w a r d s
P F V e r t i c a l u p w a r d s
a ) B u t t w e l d s
b ) F i l l e d w e l d s
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Figure 4 : Welding positions for hollow sections
2.4 Examinations and tests
2.4.1 General
The non destructive examinations and destructive tests to be
performed are indicated in Tab 3.
Prior to mechanical tests, backing strips where used are to
be removed. The test piece can be sectioned by thermal
cutting or by mechanical means discarding the first and last
25mm of the test piece at the end of the plates.
Table 3 : Examinations and tests
P i p e : r o t a t i n g
A x i s : h o r i z o n t a l
W e l d : h o r i z o n t a l v e r t i c a l
2 *
P i p e : f i x e d
A x i s : h o r i z o n t a l
W e l d : v e r t i c a l u p w a r d s
2 .
P i p e : f i x e d
A x i s : v e r t i c a l
W e l d : h o r i z o n t a l o v e r h e a d
2 ,
Type of examination or test
Extent of the examination or test
Butt weld plate Fillet weld
Visual examination 100% 100%
Radiographic test 100% (1)
Bend tests (2) 2 face, 2 root
Fracture tests 1 sample (1) 1 sample (3) (4)
Macroexamination 4 sections (4)
(1) Radiographic or fracture test is to be used (not both).
(2) For processes 131 (MIG) and 135 (MAG), bend tests are mandatory when radiography is used; face and root bend tests may be
substituted by 4 side bend tests for t 12 mm.
(3) Magnetic particle/liquid penetrant tests are also to be carried out if required by the surveyor
(4) The fracture test may be replaced by a macro examination, one of which in start/stop position.
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November 2001 Bureau Veritas 7
2.4.2 Test pieces and test specimens
Details of the type, dimensions and preparation of testpieces and test specimens are given in Fig 5 and Fig 6.
For butt welds in plates, the following conditions apply :
When radiographic test is used the inspection length of
the weld in the test pieces shall be radiographed in theas-welded condition in accordance with ISO 1106-1 orISO 1106-2 using class B technique;
When fracture testing is used, the full test piece inspec-tion length shall be tested and to do this, the test piece
shall be cut into several test specimens (Fig 5a). The
length of any fracture test specimen shall be about
50mm. If necessary, the weld reinforcement of the test
specimen may be removed and additionally the weld
edges may be notched to a depth of about 5mm to ini-tiate fracture in the weld metal (Fig 7b). In the case of
single-sided welding without backing, half of the
inspection length shall be tested against the face sideand the other half against the root side (Fig 5c and 5d).
When transverse bend testing is used for plate thickness
greater than 3mm, 2 root bend test specimens and 2face bend test specimens shall be tested in accordance
with EN 910 or equivalent standard. The mandrel diam-
eter is to be 4t and the bending angle at least 120.
For plate thickness greater than 12mm, the transverse
bend tests may be substituted by 4 side bend tests.
For fillet welds on plates, the following conditions apply :
For fracture tests the test piece may be cut, if necessary,into several test specimens (see Fig 6a). Each test speci-
men shall be positioned for breaking as shown in Fig 6b,
and examined after fracture.
When macro examination is used, 4 test specimens
shall be taken equally spaced in the inspection length.
Figure 5 : Preparation and fracture testing of test specimens for a butt weld in plate
(dimensions in mm)
2
2 5
2 5
I n s p e c t i o n l e n g t h
o f t h e t e s t p i e c e
1
1
a ) S e c t i o n i n g i n t o a n e v e n - n u m b e r e d q u a n t i t y
o f t e s t s p e c i m e n s
b ) P r e p a r a t i o n
c ) F r a c t u r e t e s t i n g f a c e b e n d t e s t d ) F r a c t u r e t e s t i n g r o o t b e n d t e s t
I n s p e c t i o n l e n g t h
o f t e s t s p e c i m e n
~
2
~
~ 5 0
~
~ 5
~
~ 5
~
~
2
~
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8 Bureau Veritas November 2001
Figure 6 : Preparation and fracture testing of test specimens for a fillet weld on plate
(dimensions in mm)
2.4.3 Acceptance criteria
During the testing for butt welds in plates, the test speci-
mens are not to reveal any open defect, in any direction,greater than 3mm. Defects appearing at the corner of the
test specimen may be disregarded.
The acceptance requirements for imperfections found by
visual and radiographic examination or fracture are to be
assessed in accordance with ISO standard 5817.
The imperfections are to be within the specified limits of
level B in ISO standard 5817 except for imperfections type
as follows : excess weld metal, excessive convexity, excess
throat thickness and excessive penetration, for which level
C is acceptable.
2.4.4 Re-testing
The test sample is to be repeated if any test piece fails to
comply with the requirements.
When the failure of the repeated test is due to the welder
lack of skill, the welder is to be adequately trained and usu-ally will not be permitted to perform new approval tests
unless at least a month has elapsed since the previous
examination.
2.5 Certification
2.5.1 General
Upon satisfactory completion of the approval tests an
approval certificate is issued stating approval tests per-
formed and range of approval.
2.5.2 Initial approval
The validity of the welders approval begins from the date
when all the required tests are satisfactorily completed.
The approval shall remain valid for a period of two years
unless the welder is not engaged in a given welding process
for which he is approved for a period exceeding six months
and unless there is specific reason to question the welders
ability. The employer/welding supervisor is to endorse therelevant certificate at six months interval to confirm that theconditions of validity are fulfilled.
2.5.3 Prolongation
In order to renew the certificate for another two-year
period, approval tests as per initial approval are to be per-
formed. Alternative procedure may be used upon special
consideration by the Society.
Approval tests may be reduced where records of X-ray or
ultrasonic inspections or test reports about fracture tests
from production welds made by the welder are available
and maintained on file with the welders approval certifi-cate.
3 Welders employed for aluminiumalloys structures
3.1 Variables for approval testing
3.1.1 Welding processes
Manual or semi-automatic welding processes commonly
used are listed as follows :
Metal arc inert gas welding (MIG, ISO 4063 ref. number
131)
Tungsten inert gas welding (TIG, ISO 4063 ref. number
141)
Change of welding process shall require new approval test-
ing.
3.1.2 Welding consumables
Approval tests are to be carried out using suitable filler
metal and gas shield compatible with the parent metal and
the process.
3.1.3 Type of weld joint
A change of type of weld joint to type for which the welder
is not approved shall require new approval testing.
3.1.4 Type and dimensions of base products
Welding of base products with dimensions out of theapproved range shall require new approval testing.
2
5
b ) F r a c t u r e t e s t i n g
( T h e f i l l e t w e l d m a y b e n o t c h e d i f n e c e s s a r y )
I n s p e c t i o n l e n g t h
o f f i l l e t w e l d
a ) S e c t i o n i n g i n t o a n e v e n - n u m b e r e d
q u a n t i t y o f t e s t s p e c i m e n s
2
5
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3.1.5 Welding position
A change in the position of welding to one for which the
welder is not approved shall require new approval testing.
The welding positions for plates are identified in Fig 3.
3.2 Range of approval
3.2.1 Welding process
Approval tests are to be performed for each process.
3.2.2 Welding consumables
Approval is extended to the use of any consumables similar
to the type used for the approval tests and suitable for the
materials to be welded and processes used.
3.2.3 Range of thickness
According to the thickness of approval test pieces, the range
of approval for plate thickness is given in table 4. The limits
are not to be understood as strict conditions.
Table 4 : Approval test piece thickness and range of
approval
3.2.4 Welding positions and type of weld joint andproducts
Approval tests performed on butt welds in horizontal (PC),vertical upwards (PF), overhead (PE) positions and on fillet
welds in horizontal overhead (PD), vertical upwards (PF)
positions extend approval to butt and fillet production
welding in all positions except vertical downwards. This setof tests also extends approval to production fillet welding of
fixed hollow section to plate in positions PB, PF and PD as
shown in Fig 4.
Approval tests performed on butt welds in horizontal (PC),
vertical upwards (PF) positions and on fillet welds in vertical
upwards (PF) position extend approval to butt and fillet pro-duction welding in positions tested and in flat (PA) and hor-
izontal vertical (PB) positions. This set of tests also extends
approval to production fillet welding of fixed hollow sec-tion to plate in positions PB and PF as shown in Fig 4.
Other sets of approval tests confer approval to productionwelding in positions tested and type of joint welded.
3.2.5 Aluminium alloys category
Approval tests are made on plates of a typical marine alu-minium alloy grade (usual 5083, 5086, 5754) and confer
approval to production welds on plates and/with extruded
products made of alloys 6005A, 6061and 6082.
3.2.6 Backing and gouging conditions
Backing and gouging range of approval is as follows :
Satisfactory approval test pieces welded from one sidewithout backing extend approval to welding from one
side with backing and welding from both sides with orwithout gouging.
Satisfactory approval test pieces welded from one side
with backing extend approval to welding from both
sides with gouging.
Satisfactory approval test pieces welded from both sideswithout gouging extend approval to welding from oneside with backing and welding from both sides with
gouging.
3.3 Welding of approval test pieces
3.3.1 General
The welder is to have suitable practical experience and pro-
fessional knowledge of the welding process including the
regulation of the parameters of the welding equipment used
The surveyor may stop the test if the welding conditions are
not correct or if it appears that the welder does not have thetechnical competence to achieve the required standard.
3.3.2 Number, shape and dimensions of test pieces
The number, shape and dimensions of test pieces made
with plates are to be selected so as to cover the production
welding work taking into account the welding variables in
[3.1] and the range of approval in [3.2].
The shape and dimensions of test pieces required are shown
in Fig 7 and Fig 8.
Figure 7 : Dimensions of test piecefor a butt weld in plate
(dimensions in mm)
Approval test piece thick-
ness t (mm)
Range of approval for pro-
duction works
t 6 mm 0,7 t to 2,5 t
6 mm < t 15 mm 6 mm to 40 mm
3
0
0
t
1 5 0 1 5 0
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10 Bureau Veritas November 2001
Figure 8 : Dimensions of test piecefor fillet weld(s) on plate
(dimensions in mm)
3.3.3 Welding conditions
The approval tests are to correspond to the conditions usedin production welding and follow a welding procedure
specification representative of production practice.
In general the following condition apply :
The time for the welding of the test piece is to corre-
spond to the usual working condition;
The test piece shall have at least one stop and restart inthe root run and in the top capping run which has to be
identified for further examination;
Any preheat or controlled heat input specified in the
welding procedure is required for the test piece;
The test pieces are to be suitably identified with the
mark of the surveyor and the identification of the welderbefore welding starts;
The welder is allowed to remove minor imperfections,except on the surface layer, by grinding or any other
method used in production upon surveyor's agreement;
The appearence of each pass, both for butt and fillet
welds, is to be of appropriate geometry and practically
free from undercuts, convexities and sizeable localdefects; the surface is to be sufficiently regular.
Similarly the back of the weld is to be free from sizeableundercuts, excessive convexities and lack of penetra-
tion; in particular for the welders to be qualified for one
side welding without backing the root penetration of the
samples is to be regular and constant.
3.4 Examinations and tests
3.4.1 General
The non destructive examinations and destructive tests to be
performed are indicated in Tab 5.
Prior to mechanical tests, backing strips where used are to
be removed. The test piece can be sectioned by thermal
cutting or by mechanical means discarding the first and last
25mm of the test piece at the end of the plates.
3.4.2 Test pieces and test specimens
Details of the type, dimensions and preparation of testpieces and test specimens are given in Fig 9 and Fig 10.
For butt welds in plates, the following conditions apply :
When radiography is used the inspection length of the
weld in the test pieces shall be radiographed in the as-
welded condition in accordance with ISO 2437 using
class B technique;
When fracture testing is used, the full test piece inspec-
tion length shall be tested and to do this, the test piece
shall be cut into several test specimens (Fig 5a). The
length of any fracture test specimen shall be about50mm. If necessary, the weld reinforcement of the test
specimen may be removed and additionally the weld
edges may be notched to a depth of about 5mm to ini-tiate fracture in the weld metal (Fig 7b). In the case of
single-sided welding without backing, half of the
inspection length shall be tested against the face sideand the other half against the root side (Fig 5c and 5d).
When transverse bend testing is used for plate thicknessgreater than 3mm, 2 root bend test specimens and 2
face bend test specimens shall be tested. The mandrel
diameter is to be 6t for alloys 5083, 5086 and 5383, 7t
for alloys 6005A, 6061 and 6082 in temper condition
T5 or T6 and the bending angle 180.
For plate thickness greater than 12mm, the transverse
bend tests may be substituted by 4 side bend tests.
For fillet welds on plates, the following conditions apply :
For fracture tests the test piece may be cut, if necessary,
into several test specimens (see Fig 6a). Each test speci-men shall be positioned for breaking as shown in Fig 6b,
and examined after fracture.
When macro examination is used, 4 test specimens
shall be taken equally spaced in the inspection length.
t
1
5
0
t
1 5 0
3
0
0
z
a
z = a 2
F o r t 6 m m a 0 , 5 t
F o r t < 6 m m 0 , 5 t a t
( z ~ 0 , 7 t )
~
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NR 476, Sec 1
November 2001 Bureau Veritas 11
Table 5 : Examinations and tests
Figure 9 : Preparation and fracture testing of test specimens for a butt weld in plate
(dimensions in mm)
Type of examination or test
Extent of the examination or test
Butt weld plate Fillet weld
Visual examination 100% 100%
Radiographic test 100% (1)
Bend tests (2) 2 face, 2 root
Fracture tests 1 sample (1) 1 sample (3) (4)
Macro examination 4 sections (4)
(1) Radiographic test or fracture test is to be used (not both).
(2) Only mandatory in addition to radiographic test for process 131 (MIG).
(3) When required by the surveyor, liquid penetrant examination is also to be carried out.
(4) The fracture test may be replaced by a macro examination, one of which in start/stop position.
2
2 5
2 5
I n s p e c t i o n l e n g t h
o f t h e t e s t p i e c e
1
1
a ) S e c t i o n i n g i n t o a n e v e n - n u m b e r e d q u a n t i t y
o f t e s t s p e c i m e n s
b ) P r e p a r a t i o n
c ) F r a c t u r e t e s t i n g f a c e b e n d t e s t d ) F r a c t u r e t e s t i n g r o o t b e n d t e s t
I n s p e c t i o n l e n g t h
o f t e s t s p e c i m e n
~
2
~
~ 5 0
~
~ 5
~
~ 5
~
~
2
~
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NR 476, Sec 1
12 Bureau Veritas November 2001
Figure 10 : Preparation and fracture testing of test specimens for a fillet weld on plate
(dimensions in mm)
3.4.3 Acceptance criteria
During the testing for butt welds in plates, the test speci-
mens are not to reveal any open defect, in any direction,
greater than 3mm. Defects appearing at the corner of thetest specimen may be disregarded.
The acceptance requirements for imperfections found by
visual and radiographic examination or fracture are to be
assessed in accordance with ISO standard 10042.
The imperfections are to be within the specified limits of
level B in ISO standard 10042 except for imperfections type
as follows : excess weld metal, excessive convexity, excess
throat thickness and excessive penetration, for which levelC is acceptable.
3.4.4 Re-testing
The test sample is to be repeated if any test piece fails to
comply with the requirements.
When the failure of the repeated test is due to the welder
lack of skill, the welder is to be adequately trained and usu-ally will not be permitted to perform new approval tests
unless at least a month has elapsed since the previous
examination.
3.5 Certification
3.5.1 General
Upon satisfactory completion of the approval tests an
approval certificate is issued stating approval tests per-formed and range of approval.
3.5.2 Initial approval
The validity of the welders approval begins from the date
when all the required tests are satisfactorily completed.
The approval shall remain valid for a period of two years
unless the welder is not engaged in a given welding process
for which he is approved for a period exceeding six monthsand unless there is specific reason to question the weldersability. The employer/welding supervisor is to endorse the
relevant certificate at six months interval to confirm that the
conditions of validity are fulfilled.
3.5.3 Prolongation
In order to renew the certificate for another two-year
period, approval tests as per initial approval are to be per-
formed. Alternative procedure may be used upon special
consideration by the Society.
Approval tests may be reduced where records of X-ray or
ultrasonic inspections or test reports about fracture tests
from production welds made by the welder are availableand maintained on file with the welders approval certifi-
cate.
4 Welders employed for other produc-tions
4.1 Approval tests and range of approval
4.1.1 For productions not included in [2] and [3] (such assome welded components, boilers and pressure vessels,
pressure piping systems...), the extent of the approval tests
and examinations with their acceptance criteria and therange of approval are to be based on the relevant require-
ments of a suitable standard recognized by the Society, e.g.
ISO 9606 series, EN 287 series, ASME Section IX,ANSI/AWS D1.1.
4.2 Certification
4.2.1 Upon satisfactory completion of the approval tests
performed under the supervision of a Society surveyor an
approval certificate is issued stating approval tests per-
formed and range of approval.
4.2.2 The conditions set in [2.5.2] and [2.5.3] are applica-ble.
2
5
b ) F r a c t u r e t e s t i n g
( T h e f i l l e t w e l d m a y b e n o t c h e d i f n e c e s s a r y )
I n s p e c t i o n l e n g t h
o f f i l l e t w e l d
a ) S e c t i o n i n g i n t o a n e v e n - n u m b e r e d
q u a n t i t y o f t e s t s p e c i m e n s
2
5
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NR 476, Sec 1
13
ANNEX Form of the approval certificate
Certificate number :
Employer's name and address :
Welder's name :
Identification :
Method of identification :
Date and place of birth :
Production type Steel hull Aluminium alloys structures Others (1)
(1) Approval conditions are based on following recognized standard :
Type of test and examination
Visual examination
Radiography test
Magnetic particle test
Dye penetrant test
Macrography
Fracture test
Bend test
Others
Welding variables
Welding process
Welding consumable
Base material group
Type of base product
Type of weld joint
Range of thickness
Welding positions
Backing and gouging condition
Others
Date and place of issue : This certificate expires on :
BV Mod. Ad.E 636 - 10/01
This Certificate is delivered within the scope of the General Conditions of BUREAU VERITAS Marine Division. Any person not a party to the contract
pursuant to which this document is delivered may not assert a claim against Bureau Veritas for any liability arising out of errors or omissions which may be
contained in said document, or for errors of judgment, fault or negligence commited by personnel of the Society or of its Agents in establishment or issuance
of this document, and in connection with any activities for which it may provide.
Employer's endorsment to confirm the validity for the following
six months (date, name, position, signature) :
This is to attest that the welder identified above has passed the approval tests, under the supervision of Bureau
Veritas, in accordance with Rule Note NR 476 and Bureau Veritas Rules for the Classification of Steel ships.
WELDER APPROVAL TEST CERTIFICATE
according to Bureau Veritas Rules
Manufacturer's Welding Procedure(s) Specification number
for the Classification of Steel Ships
Range of approval
Welder's
photograph
(optional)
Surveyor's name, signature and stamp :
Not performed / Performed & Test report number