5EN287PED

EN 287

• The “harmonized standard” for notified body and third party organization approval of welding (permanent joining) personnel for category II, III and IV pressure equipment under the PED, Annex I, Section 3.1.2.

Hartford Steam Boiler International GmbH

Welder Approval

• Welder approval is carried out under the auspices of HSB inspection quality . (HSB IQ), which has this capability within its scope as a notified body.

• HSB IQ is located in the United Kingdom and has notified body identification number 0878.

The “Inspecting Engineer” Is HSB IQ's Reference to the PED Inspector –

• Satisfactory material identification

• Stamp the test piece with personal mark

• Welder ID to be stamped on test piece

• Verify qualification standard and equipment used

• Calibration to national standards

• A2LA certification

• VT by the PED inspector

• Review NDE & destructive test results

• Welding & testing shall be witnessed by inspector

Procedure IQ.027 Is to Be Used for Guidance, Together With EN 287.

From: alex garbolevsky <alex_garbolevsky@hsb.Com

To: hsb@btinternet.Com <hsb@btinternet.Com

Sent: wednesday, july 12, 2000 6:26 PM • Question: is it required that the PED-required

destructive tests for welding procedure and welder performance by witnessed by the inspector if these tests are performed at an A2LA accredited lab?

• Reply: no, provided that we have a copy of the lab’s accreditation and we appoint them as an HSB accepted "subcontractor”.

Document Flow Form E3

• Certificate to manufacturer

• HSB Lingen file

• HSB IQ should retain a copy.

EN 287 ¶ 0

• – The test weld may be used to approve a welding procedure and a welder provided that all relevant requirements (e.G. Test piece dimensions) are satisfied.

Previous Approvals

• It is possible to use welder qualifications previously approved by another notified body or third party organization (TPO).

EN 287-1 ¶ 1

• For approval of welders for fusion welding of steels. It covers manual and partly mechanized welding. It does not cover fully mechanized or fully automatic processes.

¶ 3 Definitions:

WELDER –

• A person who performs the welding. A collective term used to mean manual welders and welding operators.

Manual Welder –

• A welder who holds and manipulates the electrode holder, welding gun, torch or blowpipe by hand.

Welding Operator

• – A welder who operates welding equipment with partly mechanized relative movement between the electrode holder, welding gun, torch or blowpipe and the workpiece.

Test Piece –

• The welded assembly which is used for the approval test.

Test Specimen –

• The part or portion cut from the test piece in order to perform a specified destructive test.

Test –

• A series of operations which will include the making of a welded test piece and subsequent non-destructive and / or destructive testing and reporting of results.

¶ 4 –Symbols and Abbreviations

• a = nominal throat thickness• BW =butt weld• D = outside diameter of pipe• FW = fillet weld• P = plate• t = wall thickness (plate or pipe)• T = pipe • z = leg length of fillet weld

Related to Consumables

• nm = no filler metal• wm = with filler metal• A = acid covering• B = basic covering• C = cellulosic covering• R = rutile covering– RA = rutile-acid covering – RB = rutile-basic covering – RC = rutile-cellulosic covering– RR = rutile thick covering

• S = other types

Miscellaneous EN 287-1 / A1:1997

• bs = welding from both sides• gg = back gouging / grinding of welds• mb = welding with BACKING MATERIAL• nb = welding without backing• ng = no back gouging / grinding

• ss = single-side welding

Welding Processes Covered by EN 287-1

Number Process111 Metal-arc welding with covered

electrode (SMAW)114 Flux-cored wire metal-arc welding

without gas shield (FCAW)121 Submerged arc welding with wire

electrode (SAW)131 Metal-arc inert gas welding (MIG)135 Metal-arc active gas welding

Welding Processes Covered by EN 287-1(Continued)

Number Process136 FCAW with active gas shield137 FCAW with inert gas shield141 Tungsten inert gas arc welding

(GTAW)15 Plasma arc welding (PAW)311 Oxy-acetylene welding (OFW)

- Other fusion welding processes byagreement.

¶ 5.4 – Material Groups

• A welder’s approval test involves depositing metal having a chemical composition compatible with any of the steels in the parent metal group(s).

• The welding of any one material in a group confers approval for the welding of all other materials within the same group.

¶ 5.4 – Material Groups(Continued)

• When welding parent metals from 2 different groups, which do not give approval to each other, an approval of the combination as a separate group is required.

• There is a similar rule for dissimilar filler metals.

Material Group ChartGroup DescriptionW 01 Low-C unalloyed (C-Mn) steels and/or low-

alloyed steels. Fine grain structural steel with ayield not exceeding 360 N/mm² [52 ksi]

W 02 CrMo and/or CrMoV creep-resisting steelsW 03 Fine-grained structural steels, Q & T as well as

thermomechanically treated steels with yield >360 N/mm² [52 ksi] as well as similarly weldableNi steels (2%<Ni<5%).

W 04 Ferritic or martensitic stainless steels,12%<Cr<20%

W 11 Stainless ferritic-austenitic and austentic CrNisteels

Test Piece Range of ApprovalsMaterial Group of TestPiece

Range ofApproval

Comparison to EN288-3 steel group

for weldingprocedures

W 01 W 01 1W 02 W 01 and 02 4, 5, 6W 03 W 01, 02 and 03 2, 3, 7**W 04 W 01, 02 and 04 8W 11 W 01*, 02*, 03*,

04* and 119

NOTE: * When usingW 11 filler metal,parent and filler must be insame groupfor this table to apply.

** Steel with5<Ni%<9 is not

included. A specialwelder’s approval is

required

“Unclassified” Steels

• For any steel not covered by any of the steel groups in the table, the welder shall carry out an approval test, which approves only for that steel.

Consumables

• A test carried out using a filler metal, shielding gas or flux suitable for a material group; the welder may use any similar consumables for the same material group.

Range of Material for Dissimilar Metal JointsTABLE 5

Test Piece Range of ApprovalW 02 W 02-to-W 01W 03 W 02-to-W 01; W 03-to-W

01 and W 02W 04 W 02-to-W 01; W 04-to-W

01 and W 02W 11 W 11-to-W 01*, 02*, 03*

and 04*NOTE: * When using W 11filler metal.

¶ 5.6 DimensionsTable 1 - Approved Thickness

Test piece thickness, t(pipe or plate) in mm

Range ofApproval*

t <= 3 t to 2t3 < t <= 12 3 mm to 2tt > 12 >= 5 mm

* For OFW,substitute 1.5t for 2t

Note: Not based on DEPOSIT THICKNESS (as in Section IX)

¶ 5.6 DimensionsTable 2 - Approved Diameters

Test piece diameter, D in mm Range of Approval*D <= 25 D to 2D25 < D <= 150 0.5D to 2D (min. 25

mm)D > 12 >= 0.5DD is dimension of smallest sidefor “hollows”

¶6 Range of Approval for the Welder.

• Each test normally approves one process; however, it is possible for a welder to be approved for more than one welding process by a single test or by two separate approval tests to be used to cover a multi-process joint.

¶6 Range of Approval for the Welder.(Continued)

• Example, to approve a welder for a single-side butt joint with GTAW root (without backing) and SMAW cover passes; there are two possibilities:

1. A GTAW root without backing plus subsequent layers of SMAW in one coupon

2.One GTAW coupon without backing and a separate SMAW coupon with backing or welded from both sides with or without backing.

¶6.3 General Observations Approval for BUTT WELDS in PIPES includes

BUTT WELDS in PLATES Approval for BUTT WELDS IN PLATES in all

relevant positions covers BUTT WELDS IN PIPES WITH AN OD 500 mm and above

PA or PC welded butt joints in plate includes approval for butt joints in pipes with OD 150mm and above for similar positions.

Welding from ONE SIDE WITHOUT BACKING approves welds from ONE SIDE WITH BACKING, and from BOTH SIDES WITH & WITHOUT GOUGING

¶6.3 General Observations (Continued)

PA (flat ~1G) or PC (horizontal ~2G) welded butt joints in plate includes approval for butt joints in pipes with OD 150mm and above for similar positions.

Welding from ONE SIDE WITHOUT BACKING approves welds from ONE SIDE WITH BACKING, and from BOTH SIDES WITH & WITHOUT GOUGING

¶6.3 General Observations (Continued)

Welding from BOTH SIDES WITHOUT GOUGING covers welds from ONE SIDE with BACKING and welds from BOTH SIDES WITH GOUGING

Welding in plates or pipes WITH BACKING approves welds made from both sides BUT NOT WELDS WITHOUT BACKING

Welding from BOTH SIDES WITHOUT GOUGING approves ONE SIDE WITH BACKING and BOTH SIDES WITH GOUGING

¶6.3 General Observations(Continued)

BUTT WELDS approve FILLETS for similar welding conditions.

In cases where production work is predominantly fillet welding, an added fillet weld approval test is recommended.

Paragraph 7.3

• The approval test for the welder shall correspond to the conditions used in production and follow a WPS prepared in accordance with EN 288-2.

• The welder shall be allowed to remove minor imperfections, EXCEPT ON THE SURFACE LAYER, by grinding, gouging or any other means used in production. The approval of the test body (notified body or TPO) shall be obtained.

¶7.4 Test Methods

• Each completed weld shall be visually examined in the as-welded condition. When required (table 8) MT, PT or other test methods and macro tests on butt welds may supplement VT.

¶7.4 Test Methods(Continued)

• Once VT is acceptable, additional RT, fracture and/or macros are required.

• When RT is used, bend tests are still required for MIG, MAG and oxy-acetylene welds.

• Backing strips are to be removed prior to mechanical testing.

¶7.4 Test Methods(Continued)

• Thermal or mechanical means may be used for sectioning the test piece. The first and last 25mm of the test piece and the ends of the plates are to be discarded. (See figures 7 and 8).

Table 3: Range of Approval for Tests on Butt Joints

TEST APPROVED APPROVEDButt weldin plate

Butt welds inPlate

Butt welds inpipe

ssmb ssmb & bsgg See ¶6.3 b and cssnb ssmb, ssnb,

bsgg, bsngSee ¶6.3 b and c

bsgg ssmb, bsgg See ¶6.3 b and cbsng mbng, bsgg,

bsngssmb

Table 3: Range of Approval for Tests on Butt Joints

(Continued)

TEST APPROVED APPROVEDButt weld inpipe

Butt weld inplate

Butt weld in pipe

ssmb ssmb, bsgg ssmbssnb ssmb, ssnb,

bsgg, bsngssmb, ssnb

¶ 5.6 Welding Positions (From ISO 6947)Plate - Butt Welds

EN 288Position

EN 288 Name Section IXEquivalent

PA Plate, Butt Weld, Flat 1GPC P, BW, Horizontal vertical 2GPE P, BW, Overhead 4GPF P, BW, Vertical upwards 3GPG P, BW, Vertical downwards 3G

¶ 5.6 Welding Positions (From ISO 6947)Plate - Fillet Welds

EN 288Position

PA P, Fillet welds, Flat 1FPB P, FW, Horizontal vertical 2FPD P, FW, Horizontal overhead 4FPG P, FW, Vertical downwards 3FPF P, FW, Vertical upwards 3F

¶ 5.6 Welding Positions (From ISO 6947)Pipe - Butt Welds

EN 288Position

PA Pipe, Butt Weld, rotating,horizontal axis, flat weld

PC T, BW, fixed, vertical axis,horizontal vertical

PF T, BW, fixed, horizontalaxis, vertical upwards

PG T, BW, fixed, horizontalaxis, vertical downwards

H-LO45 T, BW, fixed, 45º axis,upward

¶ 5.6 Welding Positions (From ISO 6947)Pipe - Fillet Welds

EN 288Position

PB Pipe, Fillet Weld, rotating,horizontal axis, horizontalvertical

PB T, FW, fixed, vertical axis,horizontal vertical

PD T, FW, fixed, vertical axis,horizontal overhead

PF T, FW, fixed, horizontal axis,vertical upwards

PG T, FW, fixed, horizontal axis,vertical downwards

Table 6 – Range Of Approval For Electrode Coating

Test Piece Type Range of ApprovalA, RA A, RAR, RB, RC, RR A, RA, R, RB, RC, RRB A, RA, R, RB, RC, RR,

BC CS (specific) S (only as used in test)

A change in the type of electrode coating may require a change in technique.

A change of shielding gas or flux is permitted

¶ 7 Examination and Testing:

• The welding and testing of test pieces shall be witnessed by the notified body / TPO.

• Test pieces shall be marked by the “examiner” and welder before welding starts.

Table 7 - Plate BUTT WELD Tests(Excerpts)

Test Piece Position Range of ApprovalP,BW,PA P,BW,PA

P,FW,PAP,FW,PBT,BW, Rotated 0º, PAT,FW, Rotated 45º, PAT,FW,PB

Test Piece Position Range of ApprovalP,BW,PG P,PW,BG

P,FW,PG

Test Piece Position Range of ApprovalP,BW,PE P,BW,PA

P,BW,PCP,BW,PFP,BW,PEP,FW,PAP,FW,PBP,FW,PFP,FW,PDT,BW, Rotated 0º, PAT,FW, Rotated 45º, PAT,FW,PBT,FW, Fixed 0º, PF

Test Piece Position Range of ApprovalP,BW,PF P,BW,PA

P,BW,PFP,FW,PAP,FW,PBP,FW,PFT,BW, Rotated 0º, PAT,FW, Rotated 45º, PAT,FW,PBT,FW, Fixed 0º, PF

Table 7 - Pipe BUTT WELD Tests(Excerpts)

Test Piece Position Range of ApprovalT,BW, Rotated 0º, PA P,BW,PA

P,FW,PAP,FW,PBT,BW, Rotated 0º, PAT,FW,45º Rotated, PAT,FW,PB

Test Piece Position Range of ApprovalT,BW, Fixed 0º, PG P,BW,PG

P,FW,PGT,BW, Fixed 0º, PGT,FW, Fixed 0º, PG

Test Piece Position Range of ApprovalT,BW, Fixed 0º, PF P,BW,PA

P,BW,PFP,BW,PEP,FW,PAP,FW,PBP,FW,PFP,FW,PDT,BW, Rotated 0º, PAT,BW, Fixed 0º, PFT,FW, Rotated 45º, PAT,FW,PBT,FW, Fixed 0º, PFT,FW, Fixed 90º, PD

Test Piece Position Range of ApprovalT,BW, Fixed 90º, PC P,BW,PA

P,BW,PCP,FW,PAP,FW,PBT,BW, Rotated 0º, PAT,BW, Fixed 90º, PCT,FW, Rotated 45º, PAT,FW,PB

Test Piece Position Range of ApprovalT,BW, Fixed 45º, H-L045 P,BW,PA

P,BW,PCP,BW,PFP,BW,PEP,FW,PAP,FW,PBP,FW,PFP,FW,PDT,BW, Rotated 0º, PAT,BW, Fixed 0º, PFT,BW, Fixed 90º, PCT,BW, Fixed 45º, H-L045T,FW, Rotated 45º, PAT,FW,PBT,FW, Fixed 0º, PFT,FW, Fixed 90º, PD

¶ 7.2Shapes and Dimensions of Test Pieces

• For butt welds in plate

• 125mm or more from plate end to weld edge of centerline

• Length of plate, minimum 300mm

• For pipe

• 125mm minimum distance is from pipe end to circumferential weld prep

Paragraph 7.3 Requires...

• “The test piece shall have at least one stop and re-start in the root run and the top capping run and be identified in the inspection length to be examined”

Examination RequirementsTABLE 8

• Test / • Examination method butt weld plate butt weld pipe fillet weld

• Visual X X X

• RT *1)5) *1)5) not mandatory

• Bend *2) *2) not mandatory

• Fracture *1) *1) *3)4)

• Macro not mandatory not mandatory not mandatory4)

• MT or PT not mandatory not mandatory not mandatory

• *1) RT or fracture test shall be used, but not both.

• *2) when RT is used, bends are mandatory for processes 131, 135 & 311.

• 3) fracture test

• 4) fracture test may be replaced by a macro of at least 4 sections, one of which taken from the stop/start location.

• 5) RT may be replaced by UT for ferritc steels with t = 8mm or more.Plus MT or PT when required by the examining body.

Examination Details

• RT should be in accordance with EN 1435 class B technique for butt welds in plate and ISO 1106-3 class B for pipe.

• Acceptance requirements:

– ISO 5817 level B imperfections; level C is used for excess weld metal, excessive convexity, throat thickness and excess penetration

¶ 9 Retests

• If any piece fails, the welder shall produce another one.

• If “lack of skill” – further training is needed before re-testing.

• If “metallurgical” or “other extraneous cause” – an additional test is required.

¶ 9 Retests(Continued)

• If a bend specimen fails: 2 additional test specimens, both satisfactory are required.

• If a fracture specimen is unacceptable: 2 additional test specimens are required.

• If any one of the 2 re-tests fail, the cause of failure must be determined.

¶ 10 Period of Validity

• Initial approval begins on the date when all required tests are satisfactorily completed – it may be different from the date of issue of the certificate.

¶ 10 Period of Validity(Continued)

• Remains valid for 2 years as long as the manufacturer signs the certificate at 6-month intervals. ALL of the following conditions must be met:

The welder shall be engaged with reasonable continuity on welding work within the current range of approval. Interruption exceeding 6 months is not permitted.

The welder’s work shall be in general accordance with the technical conditions under which the test approval is carried out.

There shall be no specific reason to question the welder’s skill and knowledge.

Prolongation

• The validity may be prolonged for further periods of 2 years provided:

The production welds are of the required quality Records of tests (RT, UT, fracture, comments) are

maintained on file

• Prolongation is signed by the examining body on the approval certificate after verification of compliance.

• A change in essential variables for the approval testing beyond the permitted ranges requires a new test and new approval certificate.

Certification & Documentation

• ANNEX B provides an example of the welder’s certificate. It is issued under the sole responsibility of the examining (notified or TPO) or test body [¶ 11].

• HSB IQ IQ.027 clause 5.2.8 certification states that the certificate shall be issued by the design manager (or nominee) of HSB IQ, reference IQ Form 79.

¶ 12 Designation

• Shorthand format- (generally seen at the top of the welder’s certificate)

• Xx xxxxx, xxx, x, xx, xxx, xx, xxx, xxxx, xxxxxx, xx, xx

• The order signifies: • Number of the standard, welding process, product, joint

type, material group, filler metal, size of test piece, position, details of weld type

¶ 12 Designation(Continued)

Example:

• EN 287-1 111 P BW W11 B t09 PF ss nb meansEN 287-1 welder approval

SMAW process

Butt weld

W 11 material group

Basic coated filler metal

9mm test plate thickness

Weld position: butt weld on plate, vertical up

Single side, no backing

5EN287PED

test piece

plate includes

backing approves

test piece

hsb iq

butt weld

butt joints

similar positions

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