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APPROVAL TESTING of WELDERS

Rule Note NR 476 DTM R00 E November 2001

17 bis, Place des Reflets La Dfense 2 92400 Courbevoie Postal Address : 92077 Paris La Dfense Cedex Tel. 33 (0) 1 42 91 52 91 Fax. 33 (0) 1 42 91 53 20 Email : veristarinfo@bureauveritas.com Web : http://www.veristar.com

MARINE DIVISION GENERAL CONDITIONS


ARTICLE 1 1.1. - BUREAU VERITAS is a Society the purpose of whose Marine Division (the Society) is the classification ( Classification ) of any ship or ve ssel or structure of any type or part of it or system therein collectively hereinafter referred to as a Unit whether linked to shore, river bed or sea bed or not, whether operated or located at sea or in inland waters or partly on land, including submarines, hovercrafts, drilling rigs, offshore installations of any type and of any purpose, their related and ancillary equipment, subsea or not, such as well head and pipelines, mooring legs and mooring points or otherwise as decided 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. Those activities are hereafter collectively referred to as Certification . 1.3. - The Society can also provide services related to Classification and Certification such as ship and company safety management certification; training activities; all activities 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 in ships sale or chartering, Expert in Units valuation, Consulting Engineer, Controller, Naval Architect, Manufacturer, Shipbuilder, Repair yard, Charterer or Shipowner who are not relieved of any of their expressed or implied obligations by the interventions of the Society. 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 4 hereafter on the level of compliance of a Unit to its Rules or part of them. This appraisement is represented by a class entered on the Certificates and periodically transcribed 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 International Regulations 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 of circumstances 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 of those 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 to the Code of Ethics of the Members of the International Association of Classification Societies (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 documents presented 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 the maintenance of class are met. The Client is to inform the Soc iety without delay of circumstances which may cause the date or the extent of the surveys to be changed. ARTICLE 5 5.1. - The Society acts as a provider of services. This cannot be construed as an obligation bearing on the Society to obtain a result or in a warranty. 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 their trade, 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, seaworth iness of the Unit or of its value 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 Society, its liability towards the Client is limited to ten times the amount of fee paid 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 Services were supplied or of the date the events which are taken advantage of were first known. ARTICLE 7 7.1. - Requests for Services are to be in writing. 7.2. - Either the Client or the Society can terminate as of right the requested Services by prior written notice according to paragraph 7.3., for convenience, and without prejudice to the provisions in Article 8 hereunder. 7.3. - The notice due by the Society to the Client to exercise the possibility under 7.2. is of three calendar months and conversely, of ten banking days. 7.4. - The class granted to the concerned Units and the previously issued certificates remain valid until the date of effect of the notice issued according to 7.2. hereabove subject 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 fee upon 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 be handed over to another Classification Society Member of the International Association 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 the survey status of the Units are passed on to IACS according to the association working rules; technical records and history related to specific class notations may be transferred to the new owner in case of change of ownership; the certificates, documents and information relative to the Units classed with the Society are passed on upon order of the flag authorities of the Unit or of a Court having 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 be deemed not to be a breach of contract. ARTICLE 11 11.1. - 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 be submitted 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 assessed within the framework of the applicable agreements with the States, international Conventions and national rules. 12.2. - Disputes arising out of the payment of the Societys invoices by the Client are submitted 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 oblig ations 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 in writing 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.

BV Mod. Ad. ME 545 h - 06/2000

RULE NOTE NR 476

APPROVAL TESTING of WELDERS

Section 1

Approval Testing and Certification of Welders for Fusion Welding

November 2001

NR 476 Approval Testing of Welders


Section 1 Approval Testing and Certification of Welders for Fusion Welding
1 2 General
1.1

3 3

Welders employed for steel hull


2.1 2.2 2.3 2.4 2.5 Variables for approval testing Range of approval Welding of approval test pieces Examinations and tests Certification

Welders employed for aluminium alloys structures


3.1 3.2 3.3 3.4 3.5 Variables for approval testing Range of approval Welding of approval test pieces Examinations and tests Certification

Welders employed for other productions


4.1 4.2 Approval tests and range of approval Certification

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Bureau Veritas

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NR 476, Sec 1

SECTION 1

APPROVAL TESTING AND CERTIFICATION OF WELDERS FOR FUSION WELDING

1
1.1

General

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.

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 Veritas 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. Operators 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 testing considered as equivalent to the provisions set in this document may be used upon special consideration of the Society.

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 performed with 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
Type of covered electrode used for approval test pieces Acid or rutile-acid covering Type of covered electrode which may be used for production work Acid or rutile-acid covering Acid or rutile-acid covering or rutile or rutile-basic or rutile-cellulosic or rutilethick covering Acid or rutile-acid covering or rutile or rutile-basic or rutile-cellulosic or rutilethick covering or basic covering Cellulosic covering

2
2.1

Welders employed for steel hull


Variables for approval testing
Rutile or rutile-basic or rutile-cellulosic or rutilethick covering Basic covering

2.1.1 Welding processes Manual or semi-automatic welding processes commonly used 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 testing. 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 the approved range shall require new approval testing.

Cellulosic covering

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
Approval test piece thickness t (mm) t 3 mm 3 mm < t 12 mm t > 12 mm Range of approval for production works t to 2 t 3 mm to 2 t t 5 mm

November 2001

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NR 476, Sec 1

2.2.4

Welding positions and type of weld joint and products 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 set of 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 production welding in positions tested and in flat (PA) and horizontal vertical (PB) positions. This set of tests also extends approval to production fillet welding of fixed hollow sections 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 side without 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 side with 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 one side with backing and welding from both sides with gouging.

The shape and dimensions of test pieces are shown in Fig 1 and Fig 2. Figure 1 : Dimensions of test piece for a butt weld in plate
(dimensions in mm)

125

125

Figure 2 : Dimensions of test piece for fillet weld(s) on plate


(dimensions in mm)

125

2.3

Welding of approval test pieces


z = a2 For t

2.3.1 General The welder is to have suitable practical experience and professional 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 made with 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].

6 mm

For t < 6 mm (z ~ ~ 0,7t)

0,5t

0,5t at

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.

Bureau Veritas

125
50

November 2001

300

NR 476, Sec 1

In general the following condition apply : The time for the welding of the test piece is to correspond 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 be identified for further examination; Any preheat or controlled heat input specified in the welding procedure is required for the test piece; Any post-weld heat treatment specified in the welding procedure 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 penetration; 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

PA

Flat
PC

Horizontal

PE

Overhead

PG

Vertical downwards
a) Butt welds

PF

Vertical upwards

PB

Horizontal vertical

PA

Flat

PD

Horizontal overhead

PG

Vertical downwards
b) Filled welds

PF

Vertical upwards

November 2001

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NR 476, Sec 1

Figure 4 : Welding positions for hollow sections

Pipe : rotating

Pipe : fixed

2*

Axis : horizontal Weld : horizontal vertical

2.

Axis : horizontal Weld : vertical upwards

Pipe : fixed

2,

Axis : vertical Weld : horizontal overhead

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


Extent of the examination or test Type of examination or test Visual examination Radiographic test Bend tests (2) Fracture tests Macroexamination (1) (2) (3) (4) Butt weld plate 100% 100% (1) 2 face, 2 root 1 sample (1) Fillet weld 100% 1 sample (3) (4) 4 sections (4)

Radiographic or fracture test is to be used (not both). 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. Magnetic particle/liquid penetrant tests are also to be carried out if required by the surveyor The fracture test may be replaced by a macro examination, one of which in start/stop position.

Bureau Veritas

November 2001

NR 476, Sec 1

2.4.2 Test pieces and test specimens Details of the type, dimensions and preparation of test pieces 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 the as-welded condition in accordance with ISO 1106-1 or ISO 1106-2 using class B technique; When fracture testing is used, the full test piece inspection 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 initiate 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 side and 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 2 face bend test specimens shall be tested in accordance with EN 910 or equivalent standard. The mandrel diameter 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 specimen 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 ~

~ 5 ~
Inspection length

25

of the test piece

25

~ 50 ~
Inspection length

of test specimen

a) Sectioning into an even-numbered quantity of test specimens

b) Preparation

c) Fracture testing face bend test

d) Fracture testing root bend test

~ 2 ~ ~ 5 ~

November 2001

Bureau Veritas

NR 476, Sec 1

Figure 6 : Preparation and fracture testing of test specimens for a fillet weld on plate
(dimensions in mm)

Inspection length of fillet weld

25

25

a) Sectioning into an even-numbered quantity of test specimens

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

2.4.3 Acceptance criteria During the testing for butt welds in plates, the test specimens 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 usually will not be permitted to perform new approval tests unless at least a month has elapsed since the previous examination.

2.5.3

Prolongation

In order to renew the certificate for another two-year period, approval tests as per initial approval are to be performed. 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 certificate.

Welders employed for aluminium alloys structures


Variables for approval testing
Welding processes

3.1
3.1.1

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)

2.5

Certification

2.5.1 General Upon satisfactory completion of the approval tests an approval certificate is issued stating approval tests performed 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 the relevant certificate at six months interval to confirm that the conditions of validity are fulfilled.

Change of welding process shall require new approval testing. 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 the approved range shall require new approval testing.

Bureau Veritas

November 2001

NR 476, Sec 1

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.

side with backing and welding from both sides with or without 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 sides without gouging extend approval to welding from one side with backing and welding from both sides with gouging.

3.2
3.2.1

Range of approval
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

3.3
3.3.1

Welding of approval test pieces


General

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
Approval test piece thickness t (mm) t 6 mm 6 mm < t 15 mm Range of approval for production works 0,7 t to 2,5 t 6 mm to 40 mm

The welder is to have suitable practical experience and professional 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. 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 piece for a butt weld in plate
(dimensions in mm)

3.2.4

Welding positions and type of weld joint and products

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 set of 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 production welding in positions tested and in flat (PA) and horizontal vertical (PB) positions. This set of tests also extends approval to production fillet welding of fixed hollow section to plate in positions PB and PF as shown in Fig 4. Other sets of approval tests confer approval to production welding in positions tested and type of joint welded. 3.2.5 Aluminium alloys category

150

150

Approval tests are made on plates of a typical marine aluminium 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 side without backing extend approval to welding from one

300
9

November 2001

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NR 476, Sec 1

Figure 8 : Dimensions of test piece for fillet weld(s) on plate


(dimensions in mm)

150

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 penetration; 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.
t

00

150

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 test pieces and test specimens are given in Fig 9 and Fig 10.

z = a2 For t

6 mm

For t < 6 mm (z ~ ~ 0,7t)

0,5t

0,5t at

3.3.3

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. In general the following condition apply : The time for the welding of the test piece is to correspond 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 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 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

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 aswelded condition in accordance with ISO 2437 using class B technique; When fracture testing is used, the full test piece inspection 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 initiate 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 side and 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 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 specimen 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.

10

Bureau Veritas

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NR 476, Sec 1

Table 5 : Examinations and tests


Extent of the examination or test Type of examination or test Visual examination Radiographic test Bend tests (2) Fracture tests Macro examination (1) (2) (3) (4) Butt weld plate 100% 100% (1) 2 face, 2 root 1 sample (1) Fillet weld 100% 1 sample (3) (4) 4 sections (4)

Radiographic test or fracture test is to be used (not both). Only mandatory in addition to radiographic test for process 131 (MIG). When required by the surveyor, liquid penetrant examination is also to be carried out. The fracture test may be replaced by a macro examination, one of which in start/stop position.

Figure 9 : Preparation and fracture testing of test specimens for a butt weld in plate
(dimensions in mm)

~ 2 ~

~ 5 ~
Inspection length

25

of the test piece

25

~ 50 ~
Inspection length

of test specimen

a) Sectioning into an even-numbered quantity of test specimens

b) Preparation

c) Fracture testing face bend test

d) Fracture testing root bend test

~ 2 ~ ~ 5 ~

November 2001

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11

NR 476, Sec 1

Figure 10 : Preparation and fracture testing of test specimens for a fillet weld on plate
(dimensions in mm)

Inspection length of fillet weld

25

25

a) Sectioning into an even-numbered quantity of test specimens

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

3.4.3

Acceptance criteria

During the testing for butt welds in plates, the test specimens 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 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 level C is acceptable. 3.4.4 Re-testing

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 performed. 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 certificate.

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 usually will not be permitted to perform new approval tests unless at least a month has elapsed since the previous examination.

Welders employed for other productions


Approval tests and range of approval

4.1

3.5
3.5.1

Certification
General

Upon satisfactory completion of the approval tests an approval certificate is issued stating approval tests performed and range of approval. 3.5.2 Initial approval

4.1.1 For productions not included in [2] and [3] (such as some welded components, boilers and pressure vessels, pressure piping systems...), the extent of the approval tests and examinations with their acceptance criteria and the range of approval are to be based on the relevant requirements 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

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 the

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 performed and range of approval. 4.2.2 The conditions set in [2.5.2] and [2.5.3] are applicable.

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Bureau Veritas

November 2001

NR 476, Sec 1

ANNEX

Form of the approval certificate


Certificate number :

WELDER APPROVAL TEST CERTIFICATE according to Bureau Veritas Rules for the Classification of Steel Ships
Employer's name and address : Welder's photograph (optional)

Welder's name : Identification : Method of identification : Date and place of birth : Production type Steel hull Aluminium alloys structures (1) Approval conditions are based on following recognized standard : Manufacturer's Welding Procedure(s) Specification number Others (1)

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

Not performed / Performed & Test report number

Range of approval

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. Date and place of issue : Surveyor's name, signature and stamp : This certificate expires on : Employer's endorsment to confirm the validity for the following six months (date, name, position, signature) :

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.

BV Mod. Ad.E 636 - 10/01

November 2001

Bureau Veritas

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