Procedure for Welder Test
Prior to testing:
The weldersmust wear safety shoes & glasses and bring with themselves the required tools,such as grinding wire wheel,etc
Material and size of test coupon:
Material should be seamless pipe SA106Gr B or equivalent
Diameter(2 inches NPS or 2-1/2 inches NPS, pipe schedule{for 2 inches pipe schedule XXS(11 mm)}, for heavy wall pipe it needs to be used 2-1/2 inches NPS the thickness should be 16mm or 19 mm and position (6G) of each weld test. Welder may bring with himself the special pipe, like 1 inches NPS.
6 inches with schedule 80 (11 mm) thickness
Weld coupon preparation:
Test coupon land width at discretion of welder.
Root opening is at discretion of welder.
2(two) root tack may be required for 2 inches test coupon, 4(four) root tack may be required for 6 inches test coupon and may not be removed –(max ¼ inch long) The tacks become a part of the weldment; bridge tacks are not allowed.
Must tack coupon and obtain inspector’s approval prior to proceeding.
After coupons are tacked they need to be stamped by welding inspector for traceability.
Weld test set-up:
Tack coupon to position and adjust height to welder’s preference
Inspector marks/stamps must face the top end of the pipe
6 inches pipe test coupon shall be completed in the 5G and horizontal position.
2 inches pipe test coupon shall be completed in the 6G position.
Plate test coupon shall be completed in the 1G/2G/3G/4G position.
Position height on the stand welding booth may be moved or adjusted during test.
Welding test coupon
Weld root pass;obtain inspector approval prior to proceeding.After welder is ready to proceed to the next filler metal, the weld examiner will first measure the amount of weld deposited for accuracy with the WQR {i.e. 3 mm deposited for E6010(SMAW) or ER70-S(GTAW)}. If there is not enough, or too much deposited, the examiner shall instruct the welder to run another pass or remove some of the metal for accuracy to the actual values according to the WQR.
Inspect welder on the different inspection fit up points at completion of root weld and final inspection of cap at completion of welding
Weld out coupon (hot pass, fill and cap). A grinder wire wheel may be used during welding.
Completed weld requires inspector’s approval before proceeding for zip cut or flame cut of test coupon
Weld test specimen preparation:
Remove test coupon from position.
If the thickness of test coupon is 0.625 inch(5/8 inch) or 0.750 inch of 2 inches pipe or plate then it needs to be RT inspected to ASME IX QW-191.2
There is no allowed RT Exam for 6 inches pipe test coupon as the bend test is the only acceptable test for an initial.
The inspector marks location of test coupon 2 inches and 6 inches pipe or plate and identifies which are root and face bends.
Welder cuts test specimen from test coupon
Welder grinds both cap and root weld reinforcement off test specimen. Also need to round edges of test specimen to avoid tearing from a notch
Welded/grinded area shall be flush with the base metal; welder should not ‘chase’ indications into original base metal thickness.
Guided bend test:
Inspector bends either root or face as per stamp on test specimen.
Inspector is to use ASME IX, QW-163 as an acceptance criterion. No opening greater than 1/8” is allowed in any direction
RT report requirements as per ASME IX:
NDE Inspection companyshould be specified in the RT report following:
The size of test coupon diameter and thickness of test coupon
Welder name and his symbol
IQI number
ASME IX
The level II technician with CGSB number shall sign the RT report.
If the information and data in RT report is found incorrect this is the responsibility of NDE Inspection company to correct any mistake, not TSASK