Rules for the classification of ships, Part 26, 2009 - crs.hr for the... · RULES FOR THE CLASSIFICATION OF SHIPS Part 26 ... No. 20(1988), No. 47(2008), No. 70(2006) International

RULESFOR THE CLASSIFICATION OF

SHIPS

Part 26 - WELDING

2009

CROATIAN REGISTER OF SHIPPING

Hrvatska (Croatia) • 21000 Split • Marasovićeva 67 • P.O.B. 187Tel.: (...) 385 (0)21 40 81 11Fax.: (...) 385 (0)21 35 81 59

E-mail: [email protected] site: www.crs.hr

By the decision of the General Commitee to the Croatian Register of Shipping,

the Rules for the Classification of Ships,

PART 26 - WELDING

enteres into force on 1st January 2009

RULES FOR THE CLASSIFICATION OF SHIPSPART 26

REVIEW OF MODIFICATIONS AND ADDITIONS IN RELATION TO2002 EDITION

RULES FOR THE CLASSIFICATION OF SHIPSPart 26. - Welding

All major changes in respect to 2002 edition throughout the text are shaded.The grammatical and print errors, have been corrected throughout the subject chapter of the Rules and are

not subject to above indication of changes.


2009

The subject Rules include the requirements of the following international Organisations:

International Association of Classification Societies (IACS)

Unified Requirements (UR):W17(2005), W23(1997), W26(2005), W28(2005)

Unified Recommendations:No. 17(1987), No. 20(1988), No. 47(2008), No. 70(2006)

International Standard Organization (ISO):CEN ISO/TR 3834-6: 2007

European Norm (EN):EN ISO 14731: 2006

European Norm with status of Croatian Norm:HRN EN 287-1: 2004/+AC: 2007 +A2: 2007, HRN EN 439: 1999, HRN EN 875: 2001,HRN EN 876: 1999, HRN EN 895: 1999, HRN EN 910: 1999, HRN EN 970: 2000,HRN EN 1289: 2000/+A1: 2003+A2: 2008, HRN EN 1290: 2000/+A1: 2003 + A2: 2008,HRN EN 1291: 2000/+A1: 2003 + A2: 2008, HRN EN 1320: 1999, HRN EN 1321: 1999,HRN EN 1481: 1999, HRN EN 1435: 2000/+A1: 2003 + A2: 2008, HRN EN 1712:2000/+A1: 2003 + A2: 2008, HRN EN 1713: 2000/+A1: 2003 + A2: 2008, HRN EN1714: 2000/+A1: 2003 + A2: 2008, HRN EN ISO 3834-1: 2007, HRN EN ISO 3834-2:2007, HRN EN ISO 3834-3: 2007, HRN EN ISO 3834-4: 2007, HRN EN ISO 3834-5:2007, HRN EN ISO 4063: 2001, HRN EN ISO 5817: 2004, HRN EN ISO 6520-1: 2008,HRN EN ISO 6947: 1999, HRN EN ISO 9606-2: 2007, HRN EN ISO 10042: 2008/+corr. 1: 2008, HRN EN ISO 13920: 1999, HRN EN ISO 15607: 2004, HRI CEN ISO/TR15608: 2008, HRN EN ISO 15609-1: 2008, HRN EN ISO 15614-1: 2007, HRN EN ISO15614-2: 2007, HRN EN ISO 17562-1: 2004, HRN EN ISO 17562-2: 2004


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Contents:Page

1 GENERAL REQUIREMENTS, PROOF OF QUALIFICATIONS, APPROVALS ......................................... 11.1 GENERAL REQUIREMENTS .....................................................................................................................................................11.2 REQUIREMENTS FOR APPROVAL OF WELDING SHOPS AND SHIPYARDS FOR PERFORMING OF WELDING

WORKS.........................................................................................................................................................................................21.3 WELDER'S QUALIFICATION TESTS .......................................................................................................................................41.4 WELDING PROCEDURE TESTS .............................................................................................................................................191.5 WELDING CONSUMABLES ....................................................................................................................................................301.6 OVERWELDABLE SHOP PRIMERS........................................................................................................................................49

2 FABRICATION AND INSPECTION OF WELDED JOINTS ......................................................................... 512.1 FABRICATION OF WELDED JOINTS.....................................................................................................................................512.2 HEAT TREATMENT..................................................................................................................................................................522.3 NON-DESTRUCTIVE TESTING OF WELDS ..........................................................................................................................542.4 MECHANICAL AND TECHNOLOGICAL TESTS ..................................................................................................................59

3 WELDING IN THE VARIOUS FIELDS OF APPLICATION......................................................................... 643.1 WELDING OF HULL STRUCTURES.......................................................................................................................................643.2 WELDING OF STEAM BOILERS AND PRESSURE VESSELS.............................................................................................693.3 WELDING OF PIPELINES ........................................................................................................................................................703.4 WELDING OF MACHINERY COMPONENTS........................................................................................................................70

APPENDIX I............................................................................................................................................................................................73APPENDIX II ..........................................................................................................................................................................................75

RULES FOR THE CLASSIFICATION OF SHIPS 1PART 26

2009

1 GENERAL REQUIREMENTS,PROOF OF QUALIFICATIONS,

APPROVALS

1.1 GENERAL REQUIREMENTS

1.1.1 General

1.1.1.1 The present Part of the Rules (hereinafter Rules)applies to all welding operations performed in the course ofnew constructions, conversion or repair:

1. ship hull, superstructure, deck houses;2. equipment and gear;3. machinery and machinery installation;4. steam boilers and pressure vessels;5. piping;when they are subject to the technical supervi-

sion by the CROATIAN REGISTER OF SHIPPING(hereinafter referred to as: the Register).Note:

The terms "welding", "welding work", welding process"etc. used in these Rules also cover all other thermaland/or mechanized joining processes such as brazingwhich, because they are deemed as "special processes"under the terms of the quality assurance standards, re-quire pre-qualification which has to be carried out byqualified personnel and constantly monitored. These Rulesshall be applied in an analogous manner to these proc-esses. The nature and scope of the quality assurancemeasures required will be specified by the Register on acase-by-case basis.

1.1.1.2 The present Part of the Rules applies to allwelding works on machinery, installations and equipment forwhich the Register has issued the Rules, guidelines or othertechnical directions where reference is made to this Rules.

1.1.1.3 The present Part of the Rules shall be appliedanalogously where other Rules, guidelines or directions issuedby the Register contain no special instructions with regard towelding works.

1.1.1.4 The present Part of the Rules may be appliedanalogously to other welding works, other than those referredto in 1.1.1, if they are subject to the supervision of theRegister. Where necessary, these cases shall be considered bythe Register in each particular case.

1.1.1.5 Exceptions to the present Part of the Rules shallbe agreed with the Register in each particular case.

1.1.1.6 The Register reserves the right to make amend-ments of the present Part of the Rules, should this prove nec-essary on the basis of more recent knowledge or operating ex-perience.

1.1.2 Other Rules, Standards andSpecifications

1.1.2.1 The Standards and Instructions mentioned in thefollowing Chapters of this Part of the Rules form an integral

part of it. The same applies to the working documents (e.g.drawings, welding specifications etc.) approved by the Regis-ter.

1.1.2.2 The application of other Rules, standards, guide-lines or other technical instructions shall be agreed with theRegister in each particular case.

1.1.2.3 If there are differences in requirements betweenthis Part of the Rules and the other relevant standards orspecifications, the requirements of this Part of the Rules shallbe applied, unless otherwise agreed.

1.1.3 Technical documentation

1.1.3.1 Technical documentation for welding whichshall be submitted to the Register for approval, prior to com-mencement of fabrication, shall contain all necessary detailsfor the preparation, execution and where applicable, the in-spection of the welds.

This information shall, as a rule, cover the fol-lowing:

− base materials, shapes and dimensions ofproducts;

− welding process and welding consumables;− shapes and dimensions of welds;− preheating and heat input during welding;− heat treatment after welding;− subsequent treatment of the welds;− methods and scope of inspection;− requirements applicable to the welded joints− (e.g. quality, evaluation category and simi-

lar)

1.1.3.2 When during the manufacture of ships struc-tures, materials, welding processes, welding consumables,shapes and dimensions of welds, comply with the normalshipbuilding practice the details referred to in 1.1.3.1. need notbe particularly specified.

1.1.3.3 For particular structures (e.g. liquefied gastanks), materials (e.g. high strength structural steels and cladplates), or welding processes, the following additional infor-mation and documentation shall be provided:

− weld preparation, assembly and auxiliary(tack) welds;

− welding positions, welding sequence(sketches);

− weld build-up (build-up of joint) number ofpasses;

− heat input during welding (heat input perunit of weld length)

1.1.4 Materials, Weldability

1.1.4.1 All materials shall be chosen in accordance withthe intended application and conditions of service and shallcomply with the Rules, Part 25 - Metallic Materials. Theirproperties shall be documented to the specified extent by testcertificates (e.g. in compliance with HRN EN 10204).

1.1.4.2 If according to 1.1.4.1., materials to be weldedand their properties are not specified in the Rules, Part 25 -Metallic Materials, the welding shop shall prove theirweldability (e.g. with respect to existing standards) or shall

2 RULES FOR THE CLASSIFICATION OF SHIPSPART 26

2009

submit the material specifications for approval. Where there isany doubt to the weldability of material, the welding shopshall specially demonstrate it in the welding procedure tests.

1.1.4.3 The welding shop shall ensure that only materi-als referred to in 1.1.4.1. and 1.1.4.2 are used and shall pro-vide proof thereof at the Surveyors request.

1.1.5 Welding Consumables

1.1.5.1 Welding consumables shall enable a weldedjoint to be appropriate to the base material and service condi-tions. They shall be tested in compliance with the chapter 1.5and shall be approved for the respective application. This pro-vision applies in analogous manner to brazing materials.

1.1.5.2 Approval shall be given, as a rule, by the Regis-ter. When, in special cases, e.g. repairs, no welding consum-ables are approved by the Register, welding consumables ap-proved by the other recognized testing bodies may be used inagreement with the Register.

1.1.5.3 The welding shop supervisor shall ensure thatonly tested welding consumables approved by the Register areused and at the Surveyors request the proof thereof shall beprovided.

1.1.6 Quality Assurance, Responsibility

1.1.6.1 The welding shop is responsible for ensuringthat the manufacturing conditions and quality comply to thoseat the time of approval as well as to the requirements of theRules and, where applicable, that the conditions stated in ap-provals and supplementary Rules shall be complied with. Theshop shall also ensure through regular inspections and teststhat the required quality is achieved. The responsibilities ofthe welding supervisors are also covered in EN ISO 14731.The tests carried out by a Surveyor to the Register shall notrelieve the welding shop from this responsibility.

The range and extent of the quality inspectionsrequired is determined by the structure in question.

1.1.6.2 When the delivery is carried out by subcontrac-tors, the welding shop shall be responsible for ensuring thatthe conditions of the present part of the Rules are compliedwith by the subcontractors.

1.1.6.3 If alterations of the approved documentation ordeviations from approved manufacture procedure becomenecessary, the welding shop shall apply for the Surveyors con-sent thereto. The Surveyor shall notify any alterations duringfabrication.

1.1.6.4 The materials shall be marked in such a way thatthey can be identified and matched up with the test certificateduring and after manufacture.

1.1.6.5 If the marking is likely to be erased duringmanufacture, the welding shop shall promptly transfer themark to another part of the product.

1.1.6.6 In the manufacture of steam boilers and pressurevessels, each weld joint shall be marked with the welderssymbol. This requirement may be dispensed with if the weld-ing shop supervisory staff keep a record of the welders nameswho execute the individual weld joint.

1.1.7 Inspection, liability

1.1.7.1 The welding shop is liable to present all compo-nents of the required intermediate and final inspections to theSurveyor. All welded joint shall be easily accessible for in-spection. Welded joints shall not be tested with coatings orprotected so as to make it difficult or impossible to inspect theweld in concern.

1.1.7.2 All the manufacturers records and documentsregarding the quality assurance shall be submitted to the Reg-ister for inspection.

These shall cover in particular:− drawings and other working documents;− material test certificates;− welders and welding procedure test certifi-

cates;− test reports and relevant documents (radio-

graphs, ultrasonographs) of non-destructivetests;

− certificates on hot-forming and heat treat-ment (where applicable);

− production test results, intermediate results(if necessary).

1.1.7.3 The Register shall give no guarantees thatwelded structures or components tested by its surveyor fullycomply with the requirements and that their manufacture hasbeen performed correctly and in accordance with the testedprocedure. Products which prove defective in service or in op-eration may be rejected even if an earlier inspection was satis-factory, if the defect or deficiency cannot be rectified.

1.2 REQUIREMENTS FOR APPROVALOF WELDING SHOPS AND SHIPYARDS

FOR PERFORMING OF WELDINGWORKS

1.2.1 Approval

1.2.1.1 Shipyards and welding shops including theirbranches and subcontractors (hereinafter organizations) whichperform welding works on structures referred to in 1.1.1., shallbe approved for these works by the Register.

The preconditions for this approval are that theorganization satisfy the requirements stated in 1.2.2, that theyare inspected by the Register in accordance with 1.2.3 and,where necessary, that the welding procedure tests are carriedout in accordance with 1.2.4.

Any approval in accordance with 1.2.1.1 coversthe most essential welding quality requirements in accordancewith the standards HRN EN ISO 3834. For certification underthe terms of these standards, the requirements set out in 1.2.2and 1.2.3 must be also met. These additional requirementsshall be regarded as having been met when the organizationhas in place a certified quality assurance system in accordancewith standard HRN EN ISO 9001.

In special cases, a welding shop may be ap-proved for performing welding works within the restrictedarea of activity, under the special procedure, previously ap-proved by the Register.


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1.2.1.2 The application for approval shall be submittedin writing to the Register. The application shall contain thefollowing data relating to the approval:

− nature and structure of components;− categories and dimensions of the materials

used;− welding procedures and positions;− heat treatments (where necessary);− pressure vessel class (for boilers and pres-

sure vessels).

1.2.1.3 If a certificate of compliance with the weldingquality requirements stipulated in HRN EN ISO 3834-2, -3 or-4 is required over and above approval in accordance withthese Rules, this must be expressly noted in the application forapproval.

1.2.1.4 Application for approval (the form is specifiedin Appendix I of the present Rules) submitted to the Registershall contain the following documentation:

− a description of organization (the form isspecified in Appendix II of the presentRules);

− copies of the qualification documents of thewelding supervisors;

− copies of the welders certificate or the list ofthe qualified welders (testing standard, test-ing body, date of testing, test category, dateof the last re-test) signed by a Surveyor.

− copies of the welding procedure certificates.

1.2.1.5 For certification in accordance with 1.2.1.3, in-formation and documents relating to the elements specified inAppendix I to HRN EN ISO 3834-1 for the respective grade ofrequirement (HRN EN ISO 3834-2 = comprehensive, -3 =standard, or -4 = elementary quality requirements) must bealso enclosed with the application for approval (e.g. in theform of relevant procedure instructions):

- contract review- design review- treatment of subcontractors- equipment maintenance- quality inspections- non conformances- calibration- identification- traceabilityIf the organization operates a certified quality

system comforming to the standard HRN EN ISO 9001, theQuality Manual (and if specified in Appendix I to HRN ENISO 3834-1) documentation relating to the quality assurancemeasures performed (quality reports) must be submitted to theRegister for inspection in place (of the above information anddocuments).

1.2.1.6 An approval granted according to these Rules orcertification in accordance with HRN EN ISO 3834 shall bevalid for three (3) years. If the welding works are constantlyperformed under the supervision of the Register, the validitymay be extended, at request of the organization, for next threeyears, without subsequent examination.

When welding works are being performed with-out the Register's supervision for more than one year, the va-lidity of the Approval Certificate may be extended for a period

of three years, after the repeated supervision of the organiza-tion.

1.2.1.7 If the conditions under which the approval wasgranted, changed (e.g. the use of unqualified welding proce-dures, materials and/or welding consumables, or if the organi-zation supervisory staff has changed), the organization shallduly notify the Register.

If the organization does not stick to the condi-tions under which the approval was granted to it, the approvalshall cease to be valid. Also in case that serious defects aredetected, the Register may carry out interim inspection and ifnecessary, may withdraw the approval.

1.2.2 Requirements1.2.2.1 Organization shall have at its disposal suitableworkshops, equipment and machinery to the extent necessaryfor proper performance of welding works. This includes, forexample, suitable storage facilities and baking equipment forthe welding consumables, preheating and heat treatmentequipment and means for weather protection of welding workin the open air. Equipment and facilities which do not belongto the organization may be taken into account when evaluatingthe capabilities of the organization provided that the condi-tions necessary for the proper manufacture are complied withand that such equipment is available without restrictions

1.2.2.2 Organization shall have at least one fully quali-fied welding supervisor who is responsible for ensuring of per-forming quality welding works.

Welding supervisor shall have experience ap-propriate to the scope of the manufacture works and shall pro-vide necessary documentary proof to the Register.

With respect to the nature and work extent, thefollowing persons shall be appointed as welding supervisors:

− welding engineers*; for fabrication of im-portant components of the hull structure andof offshore installations, also of handlingequipment, steam boilers, pressure vessels,pressure lines and engine and transmissioncomponents,

− welding technicians** for fabrication ofsimpler or less heavily stressed components.

For information relating to the qualification ofthe welding supervising staff, their tasks and responsibilities,see EN ISO 14731.

The welding supervisor shall be permanentlyemployed with the organization. Supervisions on the weldingworks by outside staff is not acceptable.

-------------------------* welding engineers (IWE, IWT, IWS) in the recommenda-

tions of the International Institute of Welding (IIW) /European Welding Federation (EWF) or engineers with onequivalent level of knowledge.

** welding technicians (IWT, IWS) as defined in the recom-mendations of the International Institute of Welding (IIW)/ European Welding Federation (EWF) or, if necessary,other persons with suitable knowledge.

1.2.2.3 Organization shall be staffed with qualifiedwelders and for automatic welding with adequately trainedoperators. The required number of qualified welders shall bedetermined by the size of organization and the scope of


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welding works performed under supervision of the Register.However, a minimum of two qualified welders are required,for each welding process. Welders for manual and semi-automatic welding shall be tested in accordance with theChapter 1.3.

The welding of a test piece in a successfullycompleted welding procedure may be taken as a proof ofmanual skill for testing of welder qualification.

Operators of fully mechanised or automaticwelding equipment shall be trained in the use of the equipmentand be capable of setting and operating the equipment in sucha way that the required weld quality is achieved. The qualifi-cation of the operators must be demonstrated in accordancewith HRN EN 1418/ISO 14732, on welded test pieces, e.g. inwelding procedure or fabrication test.

1.2.3 Inspection

1.2.3.1 Before starting the manufacture, a Surveyorshall inspect organization in compliance with the requirementsof 1.2.2.

1.2.3.2 The inspection of organization shall include alldocumentation necessary for evaluation of quality assurancewhich shall be submitted to a Surveyor. These especially in-clude the welding supervisors qualification documents, weld-ers certificates, reports on previous welding procedure tests aswell as the results of the previous tests of welded joints.

For certification according to HRN EN ISO3834, compliance with the additional quality requirementsstated in the standards shall be demonstrated to the Surveyor.

1.2.3.3 Inspection procedure, reporting and decision ofissuance Approval Certificate is in accordance with Part 4,Rules for Classification of Ships.

1.2.4 Welding Procedure Tests

1.2.4.1 If welding procedure tests are required they shallbe carried out before the approval of organization or extensionof the approval validity. Requirements for the performance ofthese tests and requirements applicable to test results are givenin Chapter 1.4 Welding procedure tests shall be performed insuch a way that the conditions of manufacture are coveredwith regard to materials, welding procedures, welding con-sumables, wall thickness, shapes of welds and heat treatment.The properties of base material for test piece shall be docu-mented by test certificate.

1.2.4.2 In general, a welding procedure test is valid onlywithin the tolerances specified in the Approval Certificate andshall not be transferable from the organization where it hasbeen performed to another organization. The Register maypermit the exemption in case of a branch organization which isunder the constant supervision of the main organization wherethe manufacture conditions are the same as well as the weld-ing processes used. Welding procedure tests performed in theworkshop are not valid at the same time for welding in thefield. In such cases the welding procedure test shall be re-peated in a whole or partly under field conditions as deter-mined by the Register. The Register may desist from the re-peated tests if the properties of the field welds are documentedby the production tests.

1.2.4.3 Welding procedure tests performed under thesupervision of other testing bodies may be accepted by theRegister in a whole or partly at the organization request if theyare acceptable on the basis of test results. In such cases, thecomplete test reports as well as the Approval Certificate issuedby other testing body shall be submitted to the Register forevaluation.

1.2.5 Certificate on Approval; Certificate ac-cording to HRN EN ISO 3834

The Register shall issue Certificate on Approvalfor the organization to carry out welding works, provided therelevant requirements are satisfied in the tests. The Certificateson Approval shall be valid within the limits specified in theCertificates. Where proof has been furnished that the addi-tional requirements listed in 1.2.1.5 according to HRN ENISO 3834 have been met, the Register issued a certificatebased on this in accordance with this standard.

If the previously issued Certificate on Approvalhas been replaced or amended, the data specified in the morerecent Certificate shall be taken as valid. This applies speciallyto the range of application, e.g. for a specific welding proc-esses.

1.3 WELDER'S QUALIFICATIONTESTS

1.3.1 General

1.3.1.1 Welders qualification tests performed on struc-tures referred to in 1.1.1 shall be carried out under supervisionof the Register in compliance with the requirements of thisChapter.

The requirements of this Chapter, relating tobase material, apply to steel materials (HRN EN 287-1) andaluminium materials (HRN EN ISO 9606-2). For other non-ferrous materials, the corresponding parts of HRN EN ISO9606, may be apply.

1.3.1.2 The requirements of this Chapter apply to thefollowing welding processes (reference numbers of weldingprocesses for symbolic representation are listed in HRN ENISO 4063):

111 manual metal arc welding;114 self-shielded tubular-cored arc welding;121 submerged arc welding with one wire

electrode;125 submerged arc welding with tubular cored

electrode;131 metal inert gas welding (MIG);135 metal active gas welding (MAG);136 tubular cored metal-arc welding with ac-

tive gas shield;137 flux cored metal arc welding with inert

shield gas;141 tungsten inert gas arc welding (TIG);15 plasma arc welding;311 oxy-acetylene welding.The welders test certificate and welding proce-

dures other than those referred to in 1.3.1.2 shall be consideredby the Register in each particular case.


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1.3.2 Symbols and Abbreviations

Instead of using the full wording in the TestCertificate of a welder, the following symbols and abbrevia-tions shall be used:

a) test piece:a - nominal throat thickness;BW- butt weldD - outside diameter of pipeFW- fillet weldP - platet - plate or pipe wall thicknessT - pipez - leg length of fillet weld

b) Consumables (including auxiliaries, e.g.shielding gas, flux)nm - no filler metalwm- with filler metalA - acid coveringB - basic covering or electrode core

basicM - electrode core-metal powderP - electrode core-rutile, fast freezing

slagC - cellulosic coveringR - rutile covering or electrode core-

rutile slow freezing slagRA - rutile-acid coveringRB - rutile-basic coveringRC - rutile-cellulose coveringRR - rutile covering (thick)S - solid wire/rodV - electrode core rutile or basic / fluo-

rideW - electrode core-basic/fluoride, slow

freezing slagY - electrode core-basic/fluoride, fast

freezing slagZ - electrode core-other types

c) Miscellaneousbs - both-side weldinglw - left ward weldingmb - welding with backing materialml - multi layernb - welding without backingrw - right ward weldingsl - single layerss - single-side welding

1.3.3 Essential variables and range of qualifi-cation

1.3.3.1 The qualification of welders is based on essen-tial variables:

- welding processes- product type (plate (P) and pipe (T))- type of weld (butt (BW) and fillet (FW))- base material group- welding consumable- dimension (material thickness and outside

pipe diameter)- welding positions- weld details (backing, single side welding,

both side welding, single layer, multilayer, left ward welding, right ward weld-ing).

For each essential variable a range of qualifica-tion is defined.

1.3.3.2 Welding processes

Welding processes are defined in 1.3.1.2. Eachqualification test normally qualifies only one welding process.

Exceptions are the changes of solid wire S(welding process 135) to metal core wire M (welding process136 or vice versa which do not require a new qualification test(see Table 1.3.3.6.1). However, it is permitted for a welder tobe qualified for two or more welding processes by welding asingle test piece (multi processes joint) or by two or moreseparate qualification test. The range of qualification for eachwelding process used and for the multi process joint for buttwelds are given in Table 1.3.3.2.

1.3.3.3 Product type

The qualification test shall be carried out onplate or pipe. The following criteria are applicable:

a) Welds in pipes, outside diameter D > 25mm, cover welds in plates.

b) Welds in plates cover welds in pipes:- of outside pipe diameter D ≥ 150 mm,

for welding positions PA, PB and PC- welding position PE for plates covers

outside pipe diameter D ≥ 500 mm inpositions PF


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Table 1.3.3.2

Thickness rangeWelding process used for the test piece

Single process joint Multi process joint

Key:1 Welding process 12 Welding process 2

according to Table 1.3.3.6.1for welding process 1:

t = s1for welding process 2:

t = s2

according to Table 1.3.3.6.1with t = s1 + s2

Key:2 Welding process 23 Welding with backing (mb)4 Welding without backing (nb)

Key:1 Welding process 1

according to Table 1.3.3.6.1for welding process 1:

t = t1for welding process 2:

t = t2

according to Table 1.3.3.6.1with t = t1 + t2

Welding process 1 only forwelding of the root area

1.3.3.4 Type of weld

The qualification shall be carried out as butt orfillet weld. The following criteria are applicable:

a) butt welds cover butt welds in any type ofjoint except branch connections (see and1.3.3.4 c);

b) in case where the majority of work is fil-let welding, the welder shall also bequalified by an appropriate fillet weldingtest, in cases where the majority of workis butt welding, butt welds qualify filletwelds;

c) butt welds in pipes without backing qual-ify branch connections with angle ≥ 60o.For a branch weld the range of qualifica-tion is based on the outside pipe diameterin branch.

d) for applications where the type of weldcannot be qualified by means of either abutt or fillet weld then a specific testpiece should be used to qualify thewelder, e.g. branch connection.

1.3.3.5 Parent material groups

1.3.3.5.1 SteelIn order to reduce the number of qualification

tests steel materials with similar welding characteristics aregrouped in 11 material group (see Table 1.3.3.5.1).


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Table 1.3.3.5.1

Group Sub-group Type of steel

Steels with a specified minimum yield strength ReH ≤ 460 N/mm 2a and with analysis in %C ≤ 0,25Si ≤ 0,60Mn ≤ 1,8Mo ≤ 0,70b

S ≤ 0,045P ≤ 0,045Cu ≤ 0,40b

1 Ni ≤ 0,5b

Cr ≤ 0,3 (0,4 for castings)b

Nb ≤ 0,06V ≤ 0,1b

Ti ≤ 0,051.1 Steels with a specified minimum yield strength ReH ≤ 275N/mm2

1.2 Steels with a specified minimum yield strength 275N/mm2 < ReH ≤ 360 N/mm2

1.3 Normalized fine grain steels with a specified minimum yield strength ReH ≤ 360 N/mm2

1.4 Steels with improved atmospheric corrosion resistance whose analysis may exceed the requirements forthe individual elements as indicated in group 1Thermomechanically treated fine-grain steels and cast steels with a specified minimum yield strengthReH > 360 N/mm2

2 2.1 Thermomechanically treated fine-grain steels and cast steels with a specified minimum yield strength360 N/mm2 < ReH ≤ 460 N/mm2

2.2 Thermomechanically treated fine-grain steels and cast steels with a specified minimum yield strengthReH > 460 N/mm2

Quenched and tempered and precipitation-hardened fine-grain steels except stainless steels with a speci-fied minimum yield strength ReH > 360 N/mm2

3.1 Quenched and tempered and precipitation-hardened fine-grain steels except stainless steels with a speci-fied minimum yield strength 360 N/mm2 < ReH ≤ 690 N/mm2

3.2 Quenched and tempered and precipitation-hardened fine-grain steels except stainless steels with a speci-fied minimum yield strength ReH > 690 N/mm2

3

3.3 Precipitation-hardened fine-grain steels except stainless steelsLow vanadium alloyed Cr-Mo (Ni) steels with Mo ≤ 0,7% and V ≤ 0,1%

4.1 Steels with Cr ≤ 0,3% and Ni ≤ 0,7%44.2 Steels with Cr ≤ 0,7% and Ni ≤ 1,5%

Cr-Mo steels free of vanadium with C ≤ 0,35%5.1 Steels with 0,75% ≤ Cr ≤ 1,5% and Mo ≤ 0,7%5.2 Steels with 1,5% < Cr ≤ 3,5% and 0,7% < Mo ≤ 0,7%5.3 Steels with 3,5% < Cr ≤ 7,0% and 0,4% < Mo ≤ 0,7%

5

5.4 Steels with 7,0% < Cr ≤ 10,0% and 0,7% < Mo ≤ 1,2%High vanadium alloyed Cr-Mo (Ni) steels

6.1 Steels with 0,3% ≤ Cr 0,75%, Mo ≤ 0,7% and V ≤ 0,35%6.2 Steels with 0,75% < Cr ≤ 3,5%, 0,7% < Mo ≤ 1,2% and V ≤ 0,35%6.3 Steels with 3,5% < Cr ≤ 7,0%, Mo ≤ 0,7% and 045% ≤ V ≤ 0,55%

6

6.4 Steels with 7,0% < Cr ≤ 12,5%, 0,7% < Mo ≤ 1,2% and V ≤ 0,35%Ferritic, martensitic or precipitation-hardened stainless steels with C ≤ 0,35% and 10,5% ≤ Cr ≤ 30%

7.1 Ferritic stainless steels7.2 Martensitic stainless steels

7

7.3 Precipitation-hardened stainless steels


2009

Table 1.3.3.5.1-continuous

Group Sub-group Type of steel

Austenitic stainless steels Ni ≤ 31%8.1 Austenitic stainless steels with Cr ≤ 19%8.2 Austenitic stainless steels with Cr > 19%

8

8.3 Manganese austenitic stainless steels with 4% ≤ Mo ≤ 12%Nickel alloy steels with Ni ≤ 10,0%

9.1 Nickel alloy steels with Ni ≤ 3,0%9.2 Nickel alloy steels with 3,0% < Ni ≤ 8,0%

9

9.3 Nickel alloy steels with 8,0% < Ni ≤ 10,0%Austenitic ferritic stainless steels (duplex)

10.1 Austenitic ferritic stainless steels with Cr ≤ 24%1010.2 Austenitic ferritic stainless steels with Cr > 24%

Steels covered by group 1c except 0,25% < C ≤ 0,85%11.1 Steels as indicated in group 11 with 0,25% < C ≤ 0,35%11.2 Steels as indicated in group 11 with 0,35% < C ≤ 0,5%

11

11.3 Steels as indicated in group 11 s 0,5% < C ≤ 0,85%Note:Based on the actual product analysis, group 2 steels may be considered as group 1.a In accordance with specification of the steel product standards ReH may be replaced by Rp0,2 or Rt0,5.b A higher value is accepted provided that Cr + Mo + Ni + Cu + V ≤ 0,75%.c A higher value is accepted provided that Cr + Mo + Ni + Cu + V ≤ 1%.

1.3.3.5.2 Range of qualification for parent metal groups-steel

The welding of any one metal in material groupconfers qualification on the welder for the welding of all

other metal within the same material group as well as othermaterial groups according Table 1.3.3.5.2.

Table 1.3.3.5.2

Range of qualification9 10 11

Materialgroupa of the

test piece1.11.21.4

1.3 2 3 4 5 6 7 8

9.1 9.2+9.3

1.1, 1.2, 1.4 X - - - - - - - - - - - -1.3 X X X X - - - - - X - - X2 X X X X - - - - - X - - X3 X X X X - - - - - X - - X4 X X X X X X X X - X - - X5 X X X X X X X X - X - - X6 X X X X X X X X - X - - X7 X X X X X X X X - X - - X8 - - - - - - - - X - X X -

9.1 X X X X - - - - - X - - X9

9.2+9.3 X - - - - - - - - - X - -10 - - - - - - - - X - X X -11 X X - - - - - - - - - - X

a Material group according to HRI CEN ISO/TR 15608.Note:X indicates those material groups for which the welder is qualified.- indicates those material groups for which the welder is not qualified.


2009

1.3.3.5.3 Aluminium and aluminium alloyIn order to reduce the number or qualification

tests, aluminium and aluminium alloy with similar welding

characteristics are grouped in 6 material group (see Table1.3.3.5.3).

Table 1.3.3.5.3

Group Sub-group Type of aluminium or aluminium alloy

21 Pure aluminium with ≤ 1% impurities or alloy contentNon-heat treatable alloys

22.1 Aluminium-manganese alloy22.2 Aluminium-manganesium alloy Mg ≤ 1,5%22.3 Aluminium-manganesium alloy 1,5% < Mg ≤ 3,5%

22

22.4 Aluminium-manganesium alloy Mg > 3,5%Heat-treatable alloys

23.1 Aluminium-manganesium-silicon alloys2323.2 Aluminium-zinc magnesium alloys

Aluminium-silicon alloys with Cu ≤ 1%24.1 Aluminium-silicon alloys with Cu ≤ 1% and 5% < Si ≤ 15%2424.2 Aluminium-silicon-magnesium alloys with Cu ≤ 1%; 5% < Si ≤ 15% and 0,1% < Mg ≤ 0,80%

25 Aluminium-silicon-copper alloys with 5% < Si ≤ 14%; 1% < Cu ≤ 5% and Mg ≤ 0,8%26 Aluminium-copper alloys with 2% < Cu ≤ 6%

Note:Groups 21 to 23 are generally for wrought materials and groups 24 to 26 are generally for cast materials.

1.3.3.5.4 Range of qualification for parent materialgroups-aluminium and aluminium alloy.

The welding of any one metal in materialgroup confers qualification on the welder for the welding ofall other metal within the same material group as well asother material groups according Table 1.3.3.5.4.

Table 1.3.3.5.4

Range of qualificationMaterial groupa

of the test piece 21 22 23 24 25 26

21 X X - - - -

22 X X - - - -

23 X X Xb - - -

24 - - - X X -

25 - - - X X -

26 - - - X X Xa Material group according to HRI CEN ISO TR 15608b Qualifying with AlMg alloy of welding consumable qualified AlSi alloy but not vice

versaNote:X indicates those material groups for which the welder is qualified.- indicates those material groups for which the welder is not qualified.


2009

1.3.3.6 Welding consumables

1.3.3.6.1 SteelThe range of qualifications for welding con-

sumables are given in Table 1.3.3.6.1. Qualification with

filler material, e.g. with welding processes 141, 15 and 311,qualifies for welding without filler metal but not vice versa.

Table 1.3.3.6.1

Range of qualificationWeldingprocess

Welding consumablesused in the testb

A, RA, RB, RC, RR, R B C

A, RA, RB, RC, RR, R x - -B x x -111C - - x

- - solid wire(S)

electrode core(M)

electrode core(B)

electrode core(R, P, V, W, Y, Z)

solid wire (S) X X - -131135136141

electrode core (M) X X - -

136 electrode core (B) - - X X114136

electrode core(R, P, V, W, Y, Z) - - - X

a The type of welding consumables used in the qualification test of welders for root run welding without back-ing (ss nb) is the type of welding consumables qualified for root run welding in production.

Note:X indicates those welding consumables for which the welder is qualified.- indicates those welding consumables for which the welder is not qualified.

1.3.3.6.2 Aluminium and aluminium alloys

Qualification with filler material e.g. withwelding processes 141 and 15, qualifies for welding withoutfiller metal but not vice versa.

Qualification with filler material of AlMg alloy,qualified filler metal of AlSi alloy but not vice versa.

For welding process 131, increasing of heliumcontent in shielding gas more than 50%, requires new qualifi-cation.

1.3.3.7 Dimensions

1.3.3.7.1 SteelRange of qualifications of butt welds for mate-

rial thickness of plate and pipe, and outside pipe diameter, aregiven in Tables 1.3.3.7.1-a and 1.3.3.7.1-b.

Table 1.3.3.7.1-a

Thicknessa

tRange of qualification

mm

t < 3 t to 2 x tb

3 ≤ t ≤ 12 3 to 2 x tc

t > 12 ≥ 5a Full multi processes s1 and s2 of Table 1.3.3.2 apply:b For oxy acetilene welding (311): t to t 1,5 x tc For oxy acetilene welding (311): 3 mm to 1,5 t

Table 1.3.3.7.1-b

Outside pipe diameter of testpiece

D

Range of qualificationmm

D ≤ 25 D to 2 x DD > 25 ≥ 0,5 x D (25 mm min.)

a For structural hollow section, D is the dimension of thesmaller side.

For fillet welds, range of qualifications, forthickness of materials are given in Table 1.3.3.7.1-c.

Table 1.3.3.7.1-c

Material thicknessof test piece

t


t < 3 t to 3t ≥ 3 ≥ 3

a See also Table 1.3.3.9.1.

1.3.3.7.2 Aluminium and aluminium alloysRange of qualifications of butt welds for mate-

rial thickness of plate and pipe, and outside pipe diameter aregiven in Tables 1.3.3.7.2-a and 1.3.3.7.2-b.


2009

Table 1.3.3.7.2-a


t


t ≤ 6 0,5 t do 2 tt > 6 ≥ 6

Table 1.3.3.7.2-b

Outside pipe diameter oftest piecea

D


D ≤ 25 D to 2 x DD > 25 ≥ 0,5 x D (25 mm min.)

a For structural hollow sections, D is the dimension of thesmaller side.

For fillet welds, range of qualifications, forthickness materials are given in Table 1.3.3.7.2-c.

Table 1.3.3.7.2-c


t


t < 3 t to 3t ≥ 3 ≥ 3

a See also Table 1.3.3.9.1.

1.3.3.8 Welding positions

1.3.3.8.1 Welding positions for plates and pipes aregiven in Figures 1.3.3.8.1-a and 1.3.3.8.1-b (in accordancewith HRN EN ISO 6947). The positions and angles used inapproval test shall be bused on the same tolerances as used inproductions.


2009

PA Flat PC Horizontal

PG Vertical downwards PE Overhead PF Vertical upwardsa) Butt welds

PA Flat PB Horizontal

PG Vertical downwards PD Horizontal overhead PF Vertical upwardsb) Fillet welds

Figure 1.3.3.8.1-aWelding positions for plates


2009

PAPipe: rotatingAxis: horizontalWeld flat

PFPipe: fixedAxis: horizontalWeld: vertical upwards

PG Pipe: fixedAxis: horizontalWeld: vertical downwards

PCPipe: fixedAxis: verticalWeld: horizontal-vertical

J-L045Pipe: fixedAxis: inclinedWeld: vertical downwards

H-L045Pipe: fixedAxis: inclinedWeld: upward

a) Butt welds

PAPipe: rotatingAxis: inclinedWeld: flat

PBPipe: rotatingAxis: horizontalWeld: horizontal-vertical

PGPipe: fixedAxis: horizontalWeld: vertical downwards

PBPipe: fixedAxis: verticalWeld: horizontal-vertical

PFPipe: fixedAxis: horizontalWeld: vertical upwards

PDPipe: fixedAxis: verticalWeld: horizontal overhead

b) Fillet welds

Figure 1.3.3.8.1-bWelding positions for pipes


2009

1.3.3.8.2 Range of qualification for welding positions isgiven in Table 1.3.3.8.2.

Table 1.3.3.8.2

Range of qualificationWeldingposition oftest piece PA PBa PC PDa PE PF

(Plate)PF

(Pipe)PG

(Plate)PG

(Pipe)H-L045 J-L045

PA x x - - - - - - - - -PBa x x - - - - - - - - -PC x x x - - - - - - - -PDa x x x x x x - - - - -PE x x x x x x - - - - -PF (Plate) x x - - - x - - - - -PF (Pipe) x x - x x x x - - - -PG (Plate) - - - - - - - x - - -PG (Pipe) x x - x x - - x x - -H-L045 x x x x x x x - - x -J-L045 xa Welding position PB and PD are only used for fillet welds and can only qualify fillet welds in other welding positions.Note:x Indicates those welding positions for which the welder is qualified- Indicates those welding positions for which the welder is not qualified

1.3.3.9 Weld details

Depending on the weld details, the ranges ofqualification are given in Tables 1.3.3.9.1 and 1.3.3.9.2.

When welding with process 311 a change ofwelding direction requires a new qualification test.

Table 1.3.3.9.1

Range of qualification

Weld details of test piece single-side welding/welding without backing

(ss nb)

single-side welding/welding with backing

(ss mb)

welding from both sides(bs)

single-side welding/welding without backing (ss nb) x x x

single-side welding/welding with backing (ss mb) - x x

welding from both sides (bs) - x xNote:x indicates those welds for which the welder is qualified.- indicates those welds for which the welder is not qualified.

Table 1.3.3.9.2

Range of qualificationTest piecea

single layer(sl)

multi layer(ml)

single layer (sl) x -multi layer (ml) x xa Throat thickness shall be in the range of 0,5 x t ≤ a ≤ 0,7 x tNote:x indicates the layer technique for which the welder is qualified.- indicates the layer technique for which the welder is not qualified.


2009

1.3.4 Welding and testing of test piece1.3.4.1 General

The welding and testing of a test piece shall bewitnessed by a Surveyor to the Register or another test bodyapproved by the Register for that purpose.1.3.4.2 Shape and dimensions of test piece

The shape and dimensions of test piece areshown in Figures 1.3.4.2-1, 1.3.4.2-2, 1.3.4.2-3 and 1.3.4.2-4.1.3.4.3 Welding conditions

The approval test for the welder shall corre-spond to the conditions in production and shall follow thewelding process specification (WPS), i.e. the following con-ditions:

a) The test shall be carried out with the weldingprocesses to be used in production.

b) Filler metal(s) shall be in accordance with thewelding procedures and positions applied.

c) The edge preparation of plates and/or pipesfor test piece shall be representative of that tobe used in production.

d) The electrical source for welding shall corre-spond to that used in production.

e) Welders qualification test shall be carried outin the welding positions and angles of branchconnections normally used in production.

f) The test piece shall have at least one stop andone re-start in the root run and in the top run.

g) The welder shall be allowed to remove minorimperfections by grinding, except on the sur-face after finishing the weld. The approval ofthe Surveyor to the Register shall be ob-tained.

h) Test piece shall be properly marked.i) Any post-weld heat treatment required by

WPS can be omitted unless bend test are re-quired.

For t ≥ 6 mm, a ≤ 0,5 tFor t < 6 mm, 0,5 t ≤ a ≤ t(z ≈ 0,7 t)

Figure 1.3.4.2-1Dimensions of test piece for weld in plate

(Dimensions in millimetres)

Figure 1.3.4.2-2Dimensions of test piece for fillet weld(s) on plate



2009

t refers to the thinner partFor t ≥ 6 mm, a ≤ 0,5 tFor t < 6 mm, 0,5 t ≤ a ≤ t(z ≈ 0,7 t)

Figure 1.3.4.2-3Dimensions of test piece for weld in pipe


Figure 1.3.4.2-4Dimensions of test piece for a fillet weld on pipe


1.3.4.4 Test methods

The completed weld shall be examined visu-ally. After satisfactory visual examination the additional testsshall be carried out in compliance with Table 1.3.4.4.1 (steel)and Table 1.3.4.4.2 (Al and Al-alloys).

When permanent backing was used in the quali-fication test it shall be removed prior to destructive testing.

The test specimen for macroscopic examinationshall be prepared and etched on one side to clearly reveal theweld. Polish is not required.

When radiographic testing of butt welds madeby welding processes 131, 135, 136 (only metal cared wires)and 311 it shall be supplemented by either two additionalbend tests (one face and one root or two side bends) or twofracture tests.

Table 1.3.4.4.1 (steel)Test method

Test method Butt weld(in plate or pipe) Fillet weld and branch connection

Visual testing according to (HRN EN 970) mandatory mandatoryRadiographic testing according to(HRN EN 1435)

mandatory 1,2,3 not mandatory

Bend test according to (HRN EN 910) mandatory 1,2,6 not applicableFracture test according to (HRN EN 1320) mandatory 1,2,6 mandatory 3,5

1) Either radiographic testing or bend or fracture tests shall be used.2) When radiographic testing is used, then additional bend or fracture tests are mandatory for welding processes 131, 135, 136

(only metal cored wire) and 311.3) The fracture tests may be replaced by macroscopic examination according to HRN EN 1321 of at least two sections.4) The radiographic testing may be replaced by an ultrasonic testing according to HRN EN 1714 for thickness ≥ 8 mm onferritic

steels only.5) The fracture tests on pipes may be replaced by radiographic testing.6) For outside pipe diameter D ≤ 25 mm, the bend or fracture tests may be replaced by a notched tensile test of the complete test

piece (example is given in Figure 1.3.4.5.1-d).


2009

Table 1.3.4.4.2 (Al and Al-alloys)Test methods

Test methods Butt weld(in plate or pipe) Fillet weld and branch connection

Visual testing according to (HRN EN 970) mandatory mandatoryRadiographic testing according to(HRN EN 1435)

mandatory 1,2 not mandatory

Bend test according to (HRN EN 910) mandatory 1,2,5 not applicableFracture test according to (HRN EN 1320) mandatory 1,2,5 mandatory 3,4

1) Except process 131, either radiographic testing or bend or fracture tests shall be used.2) When radiographic testing is used, then additional bend or fracture tests are mandatory for welding processes 131.3) The fracture tests may be replaced by macroscopic examination according to HRN EN 1321 of at least two sections.4) The fracture tests on pipes may be replaced by radiographic testing.5) For outside pipe diameter D ≤ 25 mm, the bend or fracture tests may be replaced by a notched tensile test of the complete test

piece (example is given in Figure 1.3.4.5.1-d).

1.3.4.5 Test pieces and test specimens

1.3.4.5.1 But weld in plate and pipeWhen radiographic testing is used, (see Figures

1.3.4.5.1-a, and c-1, c-2), the examination length in the testpiece shall be radiographed in the as-welded condition (with-out removal of excess weld metal).

When fracture testing is used, the test piece ex-amination length shall be cut into the test specimen of equalwidth (which must be ≥ 40 mm, see Figure 1.3.4.5.1-b). Toreach fracture in weld metal test specimen may be addition-ally notched on edges to depth ~ 5 mm.

When transverse bend testing according HRNEN 910 is used, 2 root bend test specimen and 2 face bendtest specimen shall be tested. The diameter of the former orthe inner roller shall be 4 x t, and the bending angle 180o forparent metal with elongation A ≥ 20%.

When only transverse bend test is carried out,the examination length shall be cut into test specimens ofequal width and all of them shall be tested. When only sidebend test are used, a minimum of four test specimen shall betaken equally spaced along the examination length. One ofthese side bend tests shall be taken from the start and stoparea in the examination length.

For pipes, the number of the additional fractureor transverse bend tests specimens to welding processes 131,135, 136 (only metal cored wire) or 311, using the radio-graphic testing, depends on the welding position. For allwelding positions, two root and two face bend test specimenshall be tested (see Figures 1.3.4.5.1-c1 and c-2).

a) Dimensions of test piece-plate

Inspection length of the test specimen

b) Preparation

c-1) Position and number of test pieces for PA and PC position

(1-root, 2-face)

c-2) Position and number of test pieces for PF, PG, H-L045and J-L045 positions

(1 and 3-root, 2 and 4-face)


2009

d) Tensile test of the complete test pieceFigure 1.3.4.5.1

Preparation and fracture testing of test specimens for abutt weld on plate


1.3.4.5.2 Fillet weld on plateFor the fracture test according to HRN EN

1320, the test piece may be cut, if necessary, into several testspecimens (see Figure 1.3.4.5.2). Each test specimen shall bepositioned for breaking in accordance with HRN EN 1320and examined after fracture.

When macroscopic examination is used, at leasttwo test specimen shall be taken, one macroscopic specimenshall be taken at the stop/start location.

a) Section into an even-number of test specimen b) Fracture testing(The fillet weld may be notched, if necessary)

Figure 1.3.4.5.2Preparation and fracture testing of test specimens for a fillet weld on plate

(dimensions in millimetres)

1.3.4.5.3 Fillet weld on pipeFor fracture test according to HRN EN 1320,

the test piece shall be cut into 4 or more test specimens andfractured (see Figure 1.3.4.5.3).

When macrosonic examination is used, at leasttwo test specimen shall be taken, one macroscopic specimenshall be taken from the stop/start location.

Figure 1.3.4.5.3

1.3.5 Acceptance requirements for test pieces

Test pieces shall be evaluated according to theacceptance requirements specified for relevant types of de-fects. Full explanation of these defects is given in HRN EN6520.

The acceptance requirements for defects foundby these methods according to this standard shall be assessedin accordance with HRN EN ISO 5817 for steel and in accor-dance with HRN EN ISO 10042 for aluminium alloys. Awelder is approved if the defects in the test piece are withinthe specified limits of level B in HRN EN ISO 5817 for steeland in accordance with HRN EN ISO 10042 for aluminiumalloys. Exceptions are the following defects: excess weldmetal (butt weld), excess thickness of a fillet weld, excessthroat thickness and excessive penetration, for which level Cshall apply.

If the defects in the welders test piece exceedthe permitted maximum, then the welder shall not be ap-proved.

Length of thetest piece


2009

1.3.6 Re - tests

If it is established that failure is due to the met-allurgical or other external causes and cannot be attributed tothe welders lack of skill, an additional test shall be requiredin order to assess the quality and integrity of the new test oradditional specimen material and/or new test conditions.

1.3.7 Period of validity

1.3.7.1 Initial approval

The validity of the welders approval beginsfrom the date when all the required tests are satisfactorilycompleted. This date may be different from the date of issuemarked on the certificate. The welders approval shall remainvalid for two years provided that the following conditions arefulfilled and that this is stipulated in the relevant certificate atthe 6 month intervals by the employer or the supervisor.

a) The welder shall be engaged with reason-able continuity on welding work withinthe current range of approval. Ann inter-ruption for a period no longer than 6months is permitted.

b) The welders work shall be in general ac-cordance with the same technical condi-tions as those under which the approvaltest has been carried out. If any of theseconditions are not fulfilled, the approvalshall be cancelled.

1.3.7.2 Prolongation

The validity of the Approval Test Certificatemay be prolonged for future periods of two years within theoriginal range of approval provided that:

- the production welds made by the welderare of the required quality;

- records of tests, e.g. documentation on x-ray or ultrasonic examinations as well astest reports on fracture test or remarks ofthe appointed supervisors shall be main-tained on file with the welders ApprovalCertificate.

The Surveyor to the Register shall verify com-pliance with the above conditions and sign the prolongationof the welders Approval test Certificate.

1.3.8 Welder Approval Test Certificate Form

This Certificate shall certify that the welder hassatisfied the examination tests. If one of the tests has not beensatisfied, the Certificate shall not be issued to the welder.

The Approval Test Certificate shall be issuedonly at the sole responsibility of the examiners or testingbodies.

1.4 WELDING PROCEDURE TESTS

1.4.1 General

Welding procedures applied to the manufactureand build in of structures referred to in 1.1.1 shall be tested

and approved by the Register in compliance with the re-quirements of this Chapter. This Chapter specifies the scopeand methods of the welding procedure testing for the arcwelding of steels and aluminium alloys referred to in 1.3.1.2.The welding procedure tests of other metallic materials shallbe considered by the Register in each particular case.

1.4.2 Definitions

1.4.2.1 Generala) Welding procedure specification is a

specification of materials, weld shape,method of welding and parameters em-ployed in the welding of a particular joint.

b) Welding procedure qualification is a testcarried out in order to demonstrate that aweld performed in accordance with thewelding procedure specification complieswith the given requirements.

c) Welding Production Test is a test carriedout on the test plates which are weldedunder the same conditions as the produc-tion welding in order to check the weld-ing procedure specification and the re-quired properties of the welded joint.

1.4.2.2 Welding procedure specification

The organization which apply for testing ofwelding procedure shall submit to Register preliminarywelding procedure specification containing the followingdata:

- base material (standard, conditions ofheat treatment),

- dimensions of base material (thickness,diameter),

- joint/grove design,- welding procedure,- position and direction of welding- welding consumables (grade, trade name,

wire diameter, shielding gas, flux);- number of passes (layers),- welding parameters (voltage, current,

speed);- preheat and interpass temperature,- post-weld heat treatment.

1.4.3 Test piece

1.4.3.1 General

The test piece for welding procedure test shallbe of a sufficient dimensions to ensure a reasonable heat dis-tribution (dissipation).

1.4.3.2 Materials, direction of rolling

The materials used in the welding proceduretest must be unambiguously identifiable on the basis of theirmarking and certificates. The direction of rolling of the testpiece must be ascertainable, and shall be parallel to the di-rection of welding. The orientation of the rolling directionshall be stated in the test report.


2009

1.4.3.3 Shape and dimensions of test piecea) Butt weld in plate

The test piece shall be in accordance withthe Figure 1.4.3.3-1.The length of the test piece shall be suffi-cient to provide for the appropriate testspecimens as given in Tables 1.4.4.1-1and 1.4.4.1-2.

Edge preparation and fit-up as detailed in the preliminarywelding procedure specification

a = 3 t: minimum value 150 mmb = 6 t: minimum value 350 mm

Figure 1.4.3.3-1Test piece for a butt weld in plate

b) Butt weld in pipeTest piece shall be in accordance withFigure 1.4.3.3-2. When small pipe di-ameters are used, several test pieces mayappear necessary.

Edge preparation and fit-up as detailed in the preliminarywelding procedure specification

a = minimum value 150 mmD = outside diametert = wall thickness

Figure 1.4.3.3-2Test piece for a butt weld in pipe

c) Branch connectionThe test piece shall be in accordance withFigure 1.4.3.3-3. The angle α is theminimum to be used in production. In thiscase a branch connection is considered asa fully penetrated joint.

Edge preparation and fit-up as detailed in thepreliminary welding procedure specification

a = minimum value 150 mmD1 = outside diameter of the main pipet1 = wall thickness of the main pipeD2 = outside diameter of the branch pipet2 = wall thickness of the branch pipeα = angle between main and branch pipe

Figure 1.4.3.3-3Test piece for a branch connection or a fillet weld on pipe

d) Fillet weldThe test piece shall be in accordance withFigure 1.4.3.3-4 for plates, or with Figure1.4.3.3-3 for pipes.

a = 3 t; minimum value 150 mmb = 6 t; minimum value 350 mmt1 and t2 = thickness of the plates

Figure 1.4.3.3-4Test piece for a fillet weld on plate (T-joint)

Weld one side or bothsides and fit-up asdetailed in the prelimi-nary welding procedurespecification

t


2009

1.4.3.4 Welding of test piece

Preparation and welding of test piece shall becarried out in accordance with the welding procedure specifi-cation and in the presence of a Surveyor to the Register.

1.4.4 Examination and testing

1.4.4.1 Extent of testing

The testing including non-destructive examina-tion as well as destructive testing shall be in accordance withthe Table 1.4.4.1-1 (for steel) and Table 1.4.4.1-2 (for alu-minium alloys).

Table 1.4.4.1-1 (steel)

Test piece Type of test Extent of testing Note

Butt weld with full penetrationFigures 1.4.3.3-1and 1.4.3.3-2

VisualRadiographic or ultrasonicSurface crack detectionTransverse tensile testTransverse bend test

Impact testHardness testMacro examination

100%100%100%

2 specimens2 root and

2 face specimens2 sets (each 3 specimens)

required1 specimen

-41-2

63-

T-joint with full penetrationFigure 1.4.3.3-4Branch connectionFig. 1.4.3.3-3

VisualSurface crack detectionUltrasonic or radiographicHardness testMacro radiographic examination

100%100%100%

required2 specimens

51 and 5

4,5 and 73 and 5

5

Fillet weld on plateFig. 1.4.3.3-4Fillet weld on pipeFig. 1.4.3.3-3

VisualSurface crack detectionHardness testMacro radiographic examination

100%100%

required2 specimens

51 and 53 and 5

5

Notes:1) Penetrant testing or magnetic particle testing.

For non-magnetic materials, penetrant testing.2) 2 root and 2 face bend test specimens may be substituted by 4 side bend test specimens for t ≥ 12 mm.3) Not required for parent materials subgroup 1.1 and group 8.4) Ultrasonic testing is applicable for t < 8 mm and for material groups 8 and 10.5) Testing as detailed does provide information on the mechanical properties of the joint. Where these properties are relevant to the

application an additional approval shall also be held e.g. a butt weld approval.6) 1 set in the weld metal and 1 set in the HAZ. Required only for t ≥ 12 mm and only for parent materials having specified impact

properties. If a testing temperature has not been specified, testing shall be performed at room temperature (see also 1.4.4.4-d).7) For outside diameter ≤ 50 mm, no ultrasonic test is required.

For outside diameter > 50 mm, if it is not technically possible to execute the ultrasonic examination, radiographic examinationshall be provided that the joint configuration will allow meaningful results.


2009

Table 1.4.4.1-2 (aluminium alloys)

Test piece Type of test Extent of testing Note

Butt weld with full penetrationFigures 1.4.3.3-1and 1.4.3.3-2

VisualRadiographic or ultrasonicPenetrant testTransverse tensile testTransverse bend test

Macro-examinationMicro-examination

100%100%100%

2 specimens2 root and

2 face specimens1 specimen1 specimen

----1

-2

T-joint with full penetrationFigure 1.4.3.3-4Branch connection 3)Fig. 1.4.3.3-3

VisualPenetrant testMacro-examinationMicro-examination

100%100%

4 specimens1 specimens

--42

Fillet weld on plate 3)Fig. 1.4.3.3-4Fillet weld on pipeFig. 1.4.3.3-3

VisualPenetrant testMacro-examinationMicro-examination

100%100%

2 specimens1 specimens

---2

Note:1) 2 root and 2 face bend test specimens may be preferably substituted by 4 side bend test specimens for t ≥ 12 mm.2) Only for material groups 23 and all casting alloys.3) Testing as detailed does not provide information on the mechanical properties of the joint. Where these properties are relevant to

the application an additional approval shall also be held e.g. a butt weld approval.4) For test specimen in accordance with Figure 1.4.3.3-4, only 2 macro specimens.

1.4.4.2 Location and cutting of test specimens

The location of test specimens shall be in ac-cordance with figures 1.4.4.2-1, 1.4.4.2.-2 and 1.4.4.2-3.

The cutting of test specimens shall be carriedout mechanically after the satisfactory results of the non-destructive examination (X-ray or US).

Area 1 for:- 1 tensile specimen- bend specimens

Area 2 for:- impact and additional test specimens if required


Area 4 for:- 1 macro test specimen (steel, aluminium, alloys)- 1 hardness test specimen (steel)- 1 micro test specimen (aluminium alloys)

Figure 1.4.4.2-1Location of test specimens for a butt weld in plate

Discard 25 mm

Discard 25 mm


2009


Area 2 for:- impact and additional test specimens if required

Area 3 for:- 1 tensile specimens- bend specimens

Area 4 for:- 1 macro test specimen (steel, aluminium, alloys)- 1 hardness test specimen (steel)- 1 micro test specimen (aluminium alloys)

Figure 1.4.4.2-2Location of test specimens for a butt weld in pipe

Figure 1.4.4.2-3Location of test specimens for a branch connection or a fillet weld on pipe

Top for fixed pipe

a) steel1) Specimen for macro and hardness ex-

amination to be taken in positionsA and B

2) Specimen for macro only in position B

b) aluminium alloys1) Specimen for macro to be taken

in positions A and B2) Specimen for micro only in

position A


2009

Figure 1.4.4.4-eTypical examples of hardness testing

1.4.4.3 Non-destructive examinationa) steelAfter any required post-weld heat treatment and

prior to the cutting of test specimens, all test pieces shall beexamined visually and subjected to a non-destructive exami-nation in accordance with Table 1.4.4.1-1. For non-post weldheat treated test pieces, account should be taken of the mate-rials that are susceptible to hydrogen induced cracking andconsequently the NDE should be delayed.

Depending upon joint geometry, materials andrequirements for work, the NDE shall be carried out in ac-cordance with appropriate standards (HRN EN 970 - visualexamination; HRN EN 1435 - radiographic examination;HRN EN 1714 - ultrasonic examination; HRN EN 1289penetrant testing and HRN EN 1290 - magnetic testing).

A welding procedure is approved if the imper-fections in the test piece are within the specified limits oflevel B in HRN EN ISO 5817, except for imperfection types:excess weld metal, excess convexity, excess throat thicknessand excessive penetration, for which level C in HRN EN ISO5817 shall apply.

b) aluminium alloysAfter any required post-weld heat treatment

natural or artificial ageing and prior to the cutting of testspecimens, all test pieces shall be examined visually and non-destructively in accordance with Table 1.4.4.1-2.

Depending upon joint geometry, materials andrequirements for work, the NDE shall be carried out in ac-cordance with appropriate standards (HRN EN 970 - visualexamination and HRN EN 1289 penetrant testing).

A welding procedure is approved if the imper-fections in the test piece are within the specified limits oflevel B in HRN EN ISO 10042, except for imperfection typesas follows: excess weld metal, excess convexity, excessthroat thickness and excessive penetration, for which level Cin HRN EN ISO 10042 shall apply.

1.4.4.4 Destructive testsa) Transverse tensile testing

Specimens and testing for transversal ten-sile testing for butt joints shall be in ac-cordance with 2.4.3. For pipes with out-side diameter > 50 mm, the weld rein-forcement shall be removed on both sidesto give a test specimen a thickness equal


2009

to the wall thickness of the pipe. Forpipes with outside diameter, ≤ 50 mmwhen the full section of pipe is used astest specimen, the weld reinforcementmay be left undressed on the inside sur-face of the pipe.The tensile strength on the test specimenshall normally not be less than the corre-sponding specified minimum value forthe base material (for steel).The tensile strength of the test specimenshall normally not be less than the corre-sponding specified minimum value forthe base material, in the "soft" condition(for aluminium alloys).For dissimilar materials (different alloys)tensile strength of “weaker” material injoint should be achieved.

b) Bend testingSpecimens and testing for butt joints shallbe in accordance with 2.4.4.For dissimilar materials, one root and oneface longitudinal bend test specimen maybe used instead of four transverse bendtest specimen. The diameter of the formershall be 4 x t and the bending angle 180o

(for steels).For all groups of aluminium alloys thebend angle shall be 180o using the formerdiameter given in Table 1.4.4.4-b.During testing, the test specimens shallnot reveal any cracks > 3 mm in any di-rection.

c) Macro-examinationThe test specimen shall be prepared andetched in accordance with HRN EN 1321on one side to clearly reveal the fusionline, the heat affected zone (HAZ) and thebuild up of the runs. The acceptance levelstated in 1.4.4.3-a) and -b) shall be appli-cable.

d) Impact testingTest specimen and testing for impact testsfor butt joints shall be in accordance with2.4.5. Impact tests shall cover two setscomprising 3 test specimens each(Charpy V-notch), one set with notch atthe weld centerline and the other set withnotch in the heat affected zone (1 to 2mm from the fusion line), The V-notchshall be cut perpendicular to the weld sur-face. For thickness > 50 mm, two addi-tional sets of specimens shall be taken,one form the weld metal and one from theheat affected zone below the mid thick-ness or in the weld root area. Test tem-perature and absorbed energy shall be inaccordance with the specified require-ments.For dissimilar materials, one set ofspecimens from heat affected zone shallbe carried out for each base material.

e) Hardness testingThe hardness testing shall be in accor-dance with 2.4.6. The Vickers methodHV10 shall be used. The indentation shallbe made in the weld, in the heat affectedzone and in the base material. Typical ex-amples of hardness testing are shown inFig.1.4.4.4-e. For each row of indentationthere shall be a minimum of 3 individualindentations in each part of the weld, theheat affected zone (both sides) and thebase material (both sides). The results ofthe hardness test shall meet the require-ments in Table 1.4.4.4-e.

f) Micro-examinationThe test specimen shall be prepared andetched in accordance with HRN EN 1321on one side to clearly reveal the fusionline, the HAZ and the build up of theruns.

Table 1.4.4.4-bFormer diameter of bend test (aluminium alloys)

Former diameter

Temper or condition (see EN 515)Materialgroups

0

FH112H12H22H32

H14H24H34

H16H26H36

H18H28H38

H19H29H39

T4 T5-T6 T7

21 2 t 3 t 3 t 3 t 4 t 4 t - - -22.1 3 t 3 t 3 t 4 t 5 t 5 t - - -22.2 6 t 6 t 6 t 6 t 6 t 6 t - - -23 4 t - - - - - 6 t 7 t 8 t


2009

Table 1.4.4.4-ePermitted maximum hardness values HV 10

Single run butt and fillet welds Multi-run butt and fillet weldsSteel group

HRN CEN ISO/TR15608

Non-heat treated Heat treated Non-heat treated Heat treated

1(1),2 380 320 350 320

3(2) 450 (3) 420 -

4,5 350 320 - 320

6 - 350 - 350

9.19.29.3

350450450

300350350

320400

-

300--

Notes:1) If hardness tests are required.2) For steels with min. ReH > 890 N/mm2, special values are required.

1.4.4.5 Re-testing

If the test piece fails to comply with any of therequirements for visual examination or non-destructive ex-amination referred to in 1.4.4.3-a) and -b), a new test pieceshall be subjected to the same examination. If this additionaltest piece does not comply with the relevant requirements,adequate modifications of welding procedure specificationshall be carried out prior to repeated tests.

If any test result fails to comply with the re-quirements for destructive tests referred to in 1.4.4.4, the re-test shall be carried out with double test piece. These can betaken from the same test piece if there is sufficient materialavailable, or from a new test piece. If either of these addi-tional test specimens does not comply with the relevant re-quirements, the due modifications in the welding procedurespecification shall be carried out prior to repeated tests.

1.4.5 Range of approval validity

1.4.5.1 All the conditions of validity specified in thisitem shall be considered independently of each other. Resultsoutside of the range specified, shall require a new weldingprocedure test.

1.4.5.2 An approval of welding procedure specificationobtained by a manufacturer is valid for welding in workshopsunder the same technical and quality control of that manu-facturer.

1.4.5.3 Range of qualification for steel groups and sub-groups (for base material) are shown in Table 1.4.5.3.

Table 1.4.5.3Range of qualification for steel groups and sub-groups

Material (sub) group oftest piece Range of qualification

1 - 1 1a - 1

2 - 2 2a – 2,1 – 1,2a - 1

3 - 3 3a – 3,1 – 1,2 – 1,2 –2,3a – 1,3a - 2

4 - 4 4b – 4,4b – 1,4b - 2

5 - 5 5b – 5,5b – 1,5b - 2

6 - 6 6b – 6,6b – 1,6b - 2

7 – 7 7c - 7


2009

Table 1.4.5.3-continuous

Material (sub) group oftest piece Range of qualification

7 – 3 7c – 3,7c 1,7c - 2

7 - 2 7c – 2a, 7c - 1

8 – 8 8c - 8

8 – 6 8c – 6b, 8c – 1,8c – 2,8c - 4

8 – 5 8c – 5b, 8c – 1,8c – 2,8c – 4,8c – 6.1,8c – 6.2

8 – 3 8c – 3a,8c – 1,8c - 2

8 - 2 8c – 2a,8c -1

9 - 9 9b - 9

10 - 10 10b - 10

10 – 8 10b – 8c

10 – 6 10b – 6b,10b – 1,10b – 2,10b - 4

10 – 5 10b – 5b,10b – 1,10b – 2,10b – 4,10b – 6.1,10b –6.2

10 – 3 10b –3a,10b – 1,10b - 2

10 - 2 10b – 2a,10b - 1

11 - 11 11b – 11,11b - 1

Note:a Covers the equal or lower specified yield strength steels of same group.b Covers steels in the same sub-group and any lower sub-group within the same group.c Covers steels in the same sub-group.

Table 1.4.5.4Range of qualification for aluminium and al-alloys similar and dissimilar metal joints

Material (sub-)group of the test

piece

Similar joint range(sub-) groups Dissimilar joint range (sub-) groups

21 to 21 21 to 21 Not applicable22.1 to 22.122.1 to 22.122.2 to 22.2

22.1 to 22.2

22.2 to 22.222.2 to 22.222.1 to 22.1

22.1 to 22.2

22.3 to 22.322.1 to 22.122.2 to 22.2

22.3 to 22.3

22.4 to 22.4

Combination between 22.1, 22.2, 22.3 and 22.4

22.4 to 22.422.1 to 22.122.2 to 22.2

22.4 to 22.4

22.3 to 22.3

Combination between 22.1, 22.2, 22.3 and 22.4

23.1 to 23.122.1 to 22.122.2 to 22.2a

22.3 to 22.3a

23.1 to 23.1

22.4 to 22.4a

Combination between 22.1, 22.2a, 22.3a and 22.4a


2009

Table 1.4.5.4-continuous

Material (sub-)group of the test

piece

Similar joint range(sub-) groups Dissimilar joint range (sub-) groups

23.2 to 23.2 23.2 to 23.123.1 to 23.122.1 to 22.122.2 to 22.222.3 to 22.3a

23.2 to 23.2

22.4 to 22.4a

Combination between 22.1, 22.2a, 22.3a and 22.4a

24.1 to 24.1 24.1 to 24.1 Not applicable24.2 to 24.224.1 to 24.1

24.2 to 24.2

23.1 to 23.1b

24.2 to 24.1 and 24.1 to 23.1b

25 to 25 25 to 24.124.1 to 24.1

25 to 25

24.2 to 24.225 to 24.2

26 to 2624.1 to 24.1c

24.2 to 24.2c

26 to 26

25 to 25c

26 to any of 24.1c, 24.2c or 25c

Note: The qualification is valid provided the same filler material is used.

a) Provided Al-Mg filler material is usedb) Provided Al-Si filler material is usedc) Only for castings

1.4.5.4 Range of qualification for Al and Al-alloysgroup (for base material) including dissimilar base materialare shown in Table 1.4.5.4.

1.4.5.5 Range of approval with regard to the nominalthickness of the butt joint test piece is given in Table 1.4.5.5.Nominal thickness for test pieces of different thickness’ shallbe that of the thinner test piece.

1.4.5.6 The range of approval for thickness for filletwelds is specified in such a way that in Table 1.4.5.5 therange of approval of the throat thickness a-0,75 a to 1,5 a hasbeen added, for throat thickness a ≥ 10 mm the range of ap-proval shall be for all throat thickness’ ≥ 10 mm. In this casethe nominal thickness is that of thinner fillet weld.

Table 1.4.5.5Range of approval for thickness-butt joint

Range of approval2)Thickness of the test piece,t (mm)1)

for single run or single runfrom both sides for multi-run welding

t ≤ 33 < t ≤ 12

12 < t ≤ 100t > 100

0,7 t to 1,3 t0,5 t to 1,3 t0,5 t to 1,1 t

not applicable

0,7 t to 2 t3 to 2 t

0,5 t to 2 t (max 150)0,5 t to 1,5 t

Notes:1) For multi process procedures, the recorded thickness contribution of each process may be used as

a basis for the range of approval for the individual welding process.2) For grade where impact test is required, when the test is carried out on a thickness < 12 mm

approval is < 12 mm without impact testing.


2009

1.4.5.7 Range of approval for pipe nominal thickness(less thickness of pipe wall ) and branch connections (thick-ness of branch connection wall ) has been specified in Table1.4.5.7.

Table 1.4.5.7Range of approval for pipe and branch connections

Diameter of test piece D1)2) mm Range of approvalD ≤ 168,3 0,5 D to 2 DD > 168,3 ≥ 0,5 D and plates2)3)

Notes:1) D is the outside diameter of the pipe or outside diameter

of the branch connection.2) Approval given for plates also covers pipes when the out-

side diameter is > 500 mm, or when D > 150 mm finishedin PA or PC position.

3) See also 1.4.5.9

Procedure test carried out on a branch connec-tion with angle α shall approve all branch angles α in therange of α ≤ α1 ≤ 90.

1.4.5.8 Procedure approval is valid only for the weld-ing process applied in the welding procedure test. It is notpermitted to change a multi run deposit into a single run (orsingle run on each side) or vice versa for a given process. In amulti-process procedure test the approval is only valid for theorder used during the approval test.

1.4.5.9 Range of approval for welding process whenneither impact or hardness tests are required for welded jointsin any position (plate or pipe) is valid for welding in all posi-tions (pipe or plate).

1.4.5.10 Range of approval relating to the types ofwelded joints used in the procedure tests is given in Table1.4.5.10.

Table 1.4.5.10Range of qualification for type of joint

Range of qualification

Butt joint on plateb Butt joint on pipe Branch connections

Welded from one side Welded from both sidesWelded

from oneside

Weldedfrom both

sides

Fillet weldson pipe and

plateType of joint in the test piece used in the

welding procedure test

withbacking

nobacking

withbacking

nobacking - - -

withbacking

x - x - - - xWelded from

one side nobacking

x x xa xa xa xa xBut joint onplateb

Welded fromboth sides x - x - - xa x

nobacking x - x x - xa x

withbacking

x - x - - x xBut joint on

pipeWelded from

one side nobacking

x x x x x x x

Welded fromone side - - - - - x x x

Branch con-nections Welded from

both sides - - - - - - x x

Fillet weldson pipe and

plate- - - - - - - - x

Key:x indicate those welding types of joint covered by the WPS.- indicate those welding types of joint not covered by the WPSa Plate qualifies pipe with D > 500 mmb Butt joints on plate qualify T-joints


2009

1.4.5.11 Range of approval for filler metals covers otherfiller metals of the same group and chemical composition.Change in the type of coating will require new testing.

1.4.5.12 The approval given for the type of the currentand polarity used in the welding procedure test shall be validonly for the identical conditions during the testing.

1.4.5.13 Range of approval for the heat input, preheatingtemperature, interpass temperature and post-weld heat treat-ment are specified in HRN EN ISO 15614-1 and HRN ENISO 15614-2 standards.

1.4.5.14 Changes outside of the range specified for thespecific processes are specified in HRN EN ISO 15614-1 andHRN EN ISO 15614-2 standards.

1.4.6 Welding procedure approval record

The welding procedure approval record certi-fies that the testing has been satisfactory carried out.

1.5 WELDING CONSUMABLES

1.5.1 General

1.5.1.1 All welding consumables used for welding ofstructures referred to in 1.1.1 shall be tested and approved bythe Register.

1.5.1.2 The Register shall grant the approval for thewelding consumables on the basis of the manufacturers ap-plication, technical documentation (1.5.1.3) as well as on thebasis of the results obtained from the testing carried out underthe supervision of the Register and with the approved pro-gram according to the present Chapter.

1.5.1.3 Application for approval shall be submitted tothe Register by the manufacturer of the welding consumableaccompanied with the documentation including the follow-ing:

− name of the manufacturer of the weldingconsumables,

− trade name, mark , and type ,− grade of the welding material , including

additional symbols (if necessary ) in com-pliance with these Rules,

− recommended area of application , includ-ing for example, base material, welding po-sitions and similar,

− chemical composition and mechanicalproperties of weld metal,

− sizes (diameters, lengths),− instructions manual (current, polarity),

backing, heat treatment etc.,− classification (EN, ISO etc.),− marking, packaging,− proposed testing laboratory and date of test.

1.5.1.4 On the ground of satisfactory testing results theRegister shall issue the Certificate on the type approval andtesting of welding consumables and shall enlist it in its Listof type approved products and manufacturers. With such anapproval the manufacturer is liable to ensure that, during

manufacture the composition and properties of the productscomply with those of the tested welding consumables.

1.5.1.5 The manufacturer is liable to enter the informa-tion on the approval certificate into its catalogue of the list ofapproval and testing of welding consumables.

1.5.1.6 Unless otherwise agreed, the approved weldingconsumables shall be in accordance with 1.5.2 - 1.5.8, testedannually in the presence of a Surveyor to the Register toprove that the material properties comply with those of thetested welding consumables.

1.5.1.7 In case of any change of the properties, chemi-cal composition of the approved material or the technology ofits production, the tests shall be repeated.

1.5.1.8 Welding consumables which are not covered bythese Rules (e. g. for welding of high - alloy steels etc.) shallbe tested for the approval in accordance with the special pro-gram approved by the Register.

1.5.1.9 When the results of any testing fail to meet therequirements that testing shall be repeated on duplicate re-test specimens.

For that purpose test specimen may be takenfrom the same batch as the former test pieces. In case that re-testing does not give satisfactory results, the causes shall betraced and the whole testing repeated.

1.5.1.10 Welding consumables for the welding of hullstructural steels including the relevant grades of steel forg-ings and castings and the structural steels shall be classified,marked and approved as follows:

− according to their nature ( covered elec-trode for manual and gravity welding, wire/flux combinations for two - run or multi -run welding, solid wire/gas combinationsfor arc welding or flux cored wires with orwithout gas, consumables for use in elec-troslag and electrogas vertical welding ),

− for the welding of normal strength hullstructural steels - grades 1, 2, and 3,

− for the welding of higher strength hullstructural steels with minimum yieldstrength up to 355 N/mm2 - grades 1Y, 2Y,3Y and 4Y,

− for the welding of higher strength hullstructural steels with minimum yieldstrength up to 390 N/mm2 - grades 2Y 40,3Y40 and 4Y40,

Additional markings:− for the controlled hydrogen content of the

weld metal the symbol H15 , H10 or H5(refer to grades 2, 3, 2Y, 3Y, 4Y, 2Y40,3Y40 and 4Y40 ),

− for semi-automatic welding, symbol S,− for automatic welding, symbol T (two run

technique), for welding in one pass fromeach side, symbol M (multirun technique)or symbol TM which covers both tech-niques,

− for electro-gas or electro-slag weldingsymbol V.

Note:- normal hull structural steels grades - A, B, D and E,


2009

- higher strength hull structural steels (with minimum yieldstrength 355 N/mm2) - grades A 32, D 32, E 32, A 36, D36 and E 36,

- higher strength hull structural steels (with minimum yieldstrength 390N/mm2) - grades A 40, D 40 and E 40

- higher strength hull structural steels for low temperatureapplication - grades F 32, F 36, and F 40.

1.5.1.11 The higher quality grade covers the lower gradeApproval of welding consumables for the higher strength hullstructural steels cover the grades of welding consumables forthe normal strength hull structural steels.

1.5.1.12 Where the welding consumables are intendedfor welding with direct current or alternating current, thewelding shall be performed with the alternating current. Inspecial cases, the Register may require that the specimen (testpiece) is welded with direct current (e.g. covered electrodesfor gravity welding).

1.5.1.13 Test pieces for testing of welding consumablesshall be welded at the ambient temperature.

1.5.2 Covered electrodes for the manual arcwelding

1.5.2.1 Grades

Depending on the results of impact tests,(Charpy V- notch) the covered electrodes are divided into thefollowing grades:

− for normal strength steels: grades 1, 2 and3,

− for higher strength steels with the minimumyield strength up to 355 N/mm2 grades 2 Y,3 Y and 4 Y (grade 1 Y shall not be appli-cable for the manual welding).

− for higher strength steels with the minimumyield strength up to 390 N/mm2 grades 2Y40, 3Y 40 and 4Y 40.

Figure 1.5.2.2-1

1.5.2.2 Testing the weld metal1. Two test pieces for testing the weld metal

shall be welded in the down hand weldingposition according to fig. 1.5.2.2-1, oneof the test pieces shall be welded with φ 4mm welding electrodes, the other with theelectrode with the maximum diameterproduced.When the electrodes produced are of onlyone diameter, one test piece is sufficient.Base material for preparing test piecesmay be any grade of the hull structuralsteel.

2. The weld metal shall be laid down in oneor multiple runs in accordance with thenormal welding practice and the layersshall be carried out in alternate directions.The thickness of each run shall be at least2 mm and not exceeding 4 mm. Prior to

each new run , the test piece shall becooled below 250o C, but not lower than100o C, (temperature shall be measured atthe surface of the center of the weld).Post weld heat treatment of welded testpieces shall not be permitted.

3. The chemical analysis shall be carried outfor each deposited weld metal of each testpiece.The analysis shall determine all the im-portant alloying elements and impurities.

4. One round tensile test piece shall be ma-chined from each weld metal test piece.The shape and size of the test specimenare shown in fig. 2.4.2-2. The longitudi-nal axis of the test specimen shall be lo-cated in the center of the weld at the mid -point of the plate thickness.

To remove the hydrogen content , test speci-mens may be subjected to temperature not exceeding 250o C


2009

for not longer than 16 hours. Three impact Charpy V- notchtest specimens shall be machined from each test piece ac-cording to fig. 2.4.5-1. The longitudinal axis of the testspecimen shall run through the middle of the test piece andshall be perpendicular to the weld longitudinal axis. Thenotch in the test specimen shall be perpendicular to the platesurface and shall coincide with the main vertical plane of theweld. The marking for notches shall be made on microsec-tions.

The impact value shall be determined as an av-erage for three test specimens.

If the average impact value of three test piecesfails to comply with the required value by an amount 15 percent lower than that required, three additional specimensshall be tested.

The results added to those previously obtainedto form a new average shall comply with the required value.

If the average impact value of the three testspecimens is more than 15 per cent below the required value,six additional specimens shall be tested and the average im-

pact of these new specimens shall comply with the require-ments. When the average impact value under all mentionedconditions complies with the requirements, but at least onetest specimen out of each set of three specimens demonstratesa value that is less than 70 per cent of that required, the testresults shall not be taken into consideration.

A new set of three test specimens machinedfrom the same test assembly material shall be tested insteadof them.

The temperature of the impact test specimen forgrades 2, 2 Y, 3, 3Y and 4Y shall be within ± 2o C from theprescribed test temperature given in Table 1.5.2.2.4.

The results of tensile strength and impact testshall comply with the requirements in Table 1.5.2.2-4.

Table 1.5.2.2-4

Impact testMinimum yieldstress Tensile strength

Minimumelongation(Lo = 5 do)

Test temperature Minimum averagevalue1)

Grade

(N/mm2) (N/mm2) (%) (oC) (J)123

305 400-560 22200

-20

474747

2y3Y4Y

375 490-660 220

-20-40

474747

2Y403Y404Y40

400 510-690 220

-20-40

474747

Note:1) Mean value of three specimens no individual value shall be lower that 33 J.

Figure 1.5.2.3-1


2009

Figure 1.5.2.3-2

1.5.2.3 Butt weld tests1. To determine the properties of a butt weld

in each welding position (down hand,horizontal - vertical, vertical - upward,vertical - downward and over-head) forwhich the electrodes are intended, onetest assembly shall be welded in eachposition according to fig. 1.5.2.3-1. If anelectrode meets the requirements fordownhand and vertical-upwards, buttweld in the horizontal-vertical positionneed not be tested.

2. If the electrodes are intended for thedownhand position only, two specimensshall be welded in this position.

3. The grades of steel used for the prepara-tion of the test assemblies shall be as fol-lows.

- Grade 1 electrodes: Steel grade A,- Grade 2 electrodes: Steel grade A, B, D .- Grade 3 electrodes: Steel grade A, B, D, E .- Grade 2 Y electrodes: Steel grade A32, A36, D32, D36,- Grade 3 Y electrodes: Steel grade A32, A36, D32, D36,

E32, E 36 ,- Grade 4Y electrodes: Steel grade A32, A36, D32, D36,

E32, E36, F32, F36.- Grade 2 Y 40 electrodes: Steel grade A40 , D40,- Grade 4 Y40 electrodes: Steel grade A40, D40, E40, F40.

Where higher strength steel is used with mini-mum yield strength 315 N/mm2, for grade 2Y, 3Y and 4Ytensile strength shall be not less than 490 N/mm2 and chemi-cal composition shall be demonstrated.

4. The following welding procedure shall beadopted in making the test assemblies.

Downhand (a). The first run with the 4 mm di-ameter electrode, the remaining runs (except the last two lay-ers) with the 5 mm diameter electrode in accordance with thenormal welding practice. The runs of the last two layers shallbe carried out with the largest diameter of electrode manu-factured.

Downhand (b) (when two test pieces are re-quired). The first run with the 4 mm diameter electrode, theremaining runs with the 5mm or 6 mm diameter electrodesand the last run with the largest diameter of the electrodemanufactured.

Horizontal - vertical. The first run with the 4mm or 5 mm diameter electrode, the remaining runs with the5 mm diameter electrode.

Vertical-downward and overhead. The firstrun with the 3,25 mm diameter electrode and the remainingruns with the 4 and 5 mm diameter electrode in compliancewith the normal welding practice or with the manufacturersrecommendation.

Vertical-downward. If the tested electrode isintended for welding in the downward direction, the prepara-tion of the test assembly and the electrode diameters usedshall be as recommended by the manufacturer.

5. For all assemblies the back sealing runsshall be made with the 4 mm diameterelectrode in the welding position appro-priate to each test piece after grinding outthe root run to clean metal.

6. The welding is performed in accordancewith the normal welding practice andbetween each run the assembly shall becooled below 250oC, but not lower than100oC (the temperature being taken onthe surface of the seam in the center ofthe weld). Post - weld heat treatment ofthe test assemblies shall not be permitted.

7. Butt welded assemblies prior to thepreparation of test specimens shall besubjected to the radiographic examinationto ascertain if there are any defects in theweld.

8. The test specimens shall be prepared fromeach test assembly as shown in Fig.1.5.2.3-1, except for the test specimenswelded in the overhead position wherethe impact tests are not required.

9. The shape and dimensions of the buttweld test specimens for the tensile testsare shown in Fig. 1.5.2.3-2. The bead ofthe weld shall be machined on both sidesflush with the base metal from the wholeof the specimen surface down to 1 mm.

10. The shape and dimensions of the impacttest specimens are shown in Fig. 2.4.5-1.

11. The shape and dimensions of the bendspecimens are shown in Fig. 2.4.4-1. Re-inforcement of the weld shall be ma-chined flush with the surface of basemetal. It is permitted to remove the basemetal from the whole of the specimensurface down to 1 mm. The sharp edgesof the specimen shall be rounded to a ra-dius not exceeding 2 mm. The test speci-men shall be bent over a former with di-


2009

ameter three times the thickness of thespecimen; one specimen shall be testedwith the face of the weld in tension andthe other with the root of the weld in ten-sion.

12. The results of tensile strength test, impacttest and bend test shall comply with therequirements in Table 1.5.2.3-9.

Table 1.5.2.3-9

Minimum notch impact energy (J)Quality grade of

consumables

Tensile strength(N/mm2)minimum

Test temperature(Co)

PositionsPA, PC, PE

PositionsPF, PG

Minimum bending angle,mandrel diameter = 3x

thickness of test specimen

123

400200

-20

474747

343434

2Y3Y4Y

4900

-20-40

474747

343434

2Y403Y404Y40

5100

-20-40

474747

393939

120o before the first incipientcrack, minor pore exposuresup to maximum length of 3

mm are allowed

1.5.2.4 Hydrogen test

At the request of the manufacturer, the elec-trodes may be subjected to the hydrogen test to determine thediffusible hydrogen in the weld metal.

The hydrogen content may be determined bymeans of mercury method as specified in the ISO standard3690 - 1977, or any equivalent method (e.g. glycerin method)in agreement with the Register.

Depending on the diffusible hydrogen contentand the method applied shown in Table 1.5.2.4, electrodesshall have symbols H15, H10 or H5 respectively.

Table 1.5.2.4

Added symbolMercury method

(ISO 3690 - 1977)H 15 151)

H 10 102)

H 5 5

Notes:1) 10 cm3 per 100 g, if glycerin method has been applied.2) 5 cm3 per 100 g, if glycerin method has been applied.

1.5.2.5 Electrodes for fillet welding1. Electrodes intended for fillet welding

only to which the butt weld test (1.5.2.3)shall not be applicable shall be subjectedto the initial approval test which shallconsist of the fillet weld tests as specifiedin 1.5.2.5-2 and weld metal tests as speci-fied in 1.5.2.2.

2. Where the electrodes are intended for buttand fillet welding, the initial approval testshall consist of weld metal tests (1.5.2.2)and fillet weld test (1.5.2.3) and one fillet

weld test (1.5.2.5-2) welded in downhandposition.

3. Fillet weld assemblies shown inFig.1.5.2.5-3, shall be prepared for eachwelding position for which the electrodeis recommended by the manufacturer.The length of test assembly L shall besufficient to allow at least the depositionof the entire length of the electrode beingtested. The grade of steel used for the testassemblies shall be in accordance with1.5.2.3 - 3.

Figure 1.5.2.5-3

4. The first side shall be welded using themaximum size of electrode and the sec-ond side using the electrode of the mini-mum size recommended for fillet weld-ing. Unless otherwise stipulated oragreed, each filett weld shall be made in asingle pass.

Mac

rose

ctio

nFr

actu

re te

stsp

ecim

enM

acro

sect

ion

Frac

ture

test

spec

imen

Mac

rose

ctio

n


2009

5. The weld test assembly shall be sectionedto form three macrosections each about25 mm thick and two fracture test speci-mens in accordance with 1.5.2.5-3.On macrosection the hardness of theweld, of the heat affected zone and ofbase metal shall be determined as shownin 1.5.2.5-5.

Figure 1.5.2.5-5The average of the weld metal and heat affected

zone hardness shall not exceed 350 HV (diamond pyramid,load 100 N).

The first side of the fillet weld intended forfracture testing, shall have the weld machined or cut with achisel and the second side of the other fillet weld shall besubjected to the same procedure submitting the root of theweld to tension. The fracture surfaces shall be examined andthere shall be no evidence of incomplete penetration, cracksor major porosity.

1.5.2.6 Electrodes for gravity or contact welding1. For electrodes intended solely for contact

welding using automatic gravity or simi-lar welding devices, the first test shall beeffected on weld metal. (1.5.2.2), buttweld (1.5.2.3) and, where appropriate,fillet weld (1.5.2.5-2) using the weldingprocedure recommended by the manu-facturer.

2. For electrodes intended for contactwelding, besides the normal manualwelding, fillet weld and, where appropri-ate, butt weld tests, using gravity orsimilar contact devices shall be carriedout in addition to the normal approvaltests.

1.5.2.7 Annual testing1. Annual testing of covered electrodes for

normal manual arc welding shall includethe weld testing in compliance with1.5.2.2.-1, -2, -4 and for symbols H15,H10, or H5 covered electrodes a diffusi-ble hydrogen content shall be determinedin weld metal in accordance with 1.5.2.4.This is also applicable to the electrodesintended solely for fillet welding.

2. Annual testing of covered electrodes in-tended solely for gravity or contact

welding shall include weld metal testingin compliance with 1.5.2.-1, -2, -4, usingthe gravity or other contact devices asrecommended by the manufacturer.

1.5.2.8 Upgrading and uprating of consumables1. Upgrading of the approved welding con-

sumables with respect to impact valueshall be considered at the manufacturersrequest, preferably at the annual testing(1.5.1.6).For this purpose, in addition to the normalapproval weld metal testing ,impact testof all butt weld assemblies shall be car-ried out for the welding positions as re-quired for the first approval procedure ofthe consumables. In addition, all buttweld assemblies shall be subjected to theradiographic examination.

2. Downgrading of the approved weldingconsumables to the lower grade shall beconsidered at the annual testing in casethe results of the testing fail to meet therequirements prescribed for the grade theconsumables have been approved for.Where the unsatisfactory results of earliertesting point at the possibility that thefailure of the specimens was due to de-fects in the material or the welding pro-cedure, the tests may be repeated imme-diately. If the repeated tests do not meetthe requirements, the quality grade shallbe reduced. In this case, the testing maybe repeated after 3 months, at the earliest.

3. The extension of the approval for thewelding consumables covering the weld-ing of normal strength hull structural steelto the welding of higher strength hullstructural steels (e.g. from grade 2 tograde 2Y) requires the performance of acomplete new approval test using higherstrength hull structural steel as the basematerial for butt weld tests.

4. Extension of the approval for the weldingconsumables with H15 symbol or themodification of the H15 symbol to H10 ispossible provided that the weld metal canbe proved in line with 1.5.2.4 to containthe lower quantity of diffusible hydrogenthan that specified in Table 1.5.2.4. forthe required welding procedure.

1.5.3 Wire-flux combinations for semi-automatic and for automatic welding

1.5.3.1 General1. Wire-flux combinations with single elec-

trode for semi-automatic and automaticsubmerged arc welding are divided intothe following two categories.− for use with the multi-run tech-

nique,− for use with two-run technique.


2009

Where wire - flux combination is in-tended for welding with both techniques,the tests shall be carried out for eachtechnique in particular.

2. Depending on the results of impact tests,wire - flux combinations are divided intothe following grades.− for normal strength steel: grades 1,

2, or 3,− for higher strength steel with mini-

mum yield strength up to 355N/mm2: grades 1Y, 2Y, 3Y or 4Y,

− for higher strength steel with mini-mum yield strength up to 390N/mm2: grades 2Y40, 3Y40, or4Y40.

Additional symbols T, M or TM will beadded to the grade to indicate approvalfor the two-run technique or both techi-ques respectively.

3. Multiple electrode submerged arc weld-ing wire-flux combinations for multipleelectrode submerged arc welding shall betested separately in accordance with therequirements referred to in Table 1.5.3.

4. The current for welding may be, in com-pliance with the manufacturers recom-mendation, alternating or direct current(wire is negative or positive pole).Where both currents (A and DC) are rec-ommended , the welding shall be per-formed with the alternating current.

1.5.3.2 Approval tests for multi-run technique1. One weld metal test assembly shall be

prepared as shown in Fig. 1.5.3.2-1, andas a base material of the test piece anygrade of hull structural steel may be used.

Figure 1.5.3.2-1

2. Welding shall be carried out in downhandposition and the direction of deposition ofeach run shall alternate from each end ofthe plate. After completion of each run,the flux and welding slag shall be re-moved. The thickness of each layer shallbe not less than the wire diameter nor lessthan 4 mm (whichever is greater).Between each run the assembly shall beleft in still air until it has been cooled

below 250oC, but not lower than 100oC(temperature taken on the surface of theseam in the middle of the weld).

3. The welding parameters (current, voltage,welding speed) shall be in accordancewith the manufacturers recommendationand with the normal good welding prac-tice for multi - run welding.

4. The chemical analysis of the depositedweld metal shall be made for each test as-

Discard

Cylindrical ten-siletest specimen

Charpy V-notchspecimens

Reserve

Cylindrical ten-siletest specimen


2009

sembly. The analysis shall establish thecontent of all significant alloying ele-ments and impurities.

5. Two cylindrical tensile test specimensshall be machined from the depositedweld metal (see Fig. 2.4.2-2) and threeimpact test specimens (see Fig. 2.4.5-1),in accordance with the Fig. 1.5.2.2.-1.The longitudinal axis of the cylindricaltest specimens shall, as far as possible,coincide with the main vertical plane ofthe weld and the centre of plate thickness.

The longitudinal axis of impact testspecimen shall go through the middle ofthe test assembly thickness and shall beperpendicular to the longitudinal axis ofthe weld. The notch of the test specimenshall be perpendicular to the plate surfaceand in the middle of the weld.

6. The results of all test of metal shall com-ply with the requirements of Table1.5.3.3.

Table 1.5.3

M(Multi-run technique)

T(Two-run technique)

TM(Two-run and multi-run technique)

Butt weld assemblyTwo-run technique

Depositedmetal

assembly

Butt weldassembly

Butt weldassembly(minimumthickness

Butt weldassembly

(maximumthickness)

Deposited metalassembly

Multi-runtechnique Minimum

thicknessMaximumthickness

3CV2LT

2TT4TB3CV

2TT2TB3CV1LT

2TT2TB3CV 3CV

1LT

2TT4TB3CV

2TT2TB3CV

2TT2TB3CV1LT

Symbol definitions:TT Transverse tensile test on the butt weld assemblyTB Transverse bend test on the butt weld assemblyCV Charpy V-Impact test in axis of the weldLT Longitudinal tensile test in the weld

Table 1.5.3.3

Charpy V-notch impact testGrades of welding

consumables

Yield stress(N/mm2)minimum

Tensile strength(N/mm2)

Elongation on 50 mmgauge length

(Lo = %d)% minimum

Test temperature(oC)

Average energy (J),minimum

123

305 400-560 22200

-20

343434

1Y2Y3Y4Y

375 490-660 22200

-20-40

34343434

2Y403Y404Y40

400 510-690 220

-20-40

393939


2009

Figure 1.5.3.4-1

Table 1.5.3.4

Minimum impact energyGrade of weldingconsumables

Tensile strength

(N/mm2) (J)1)Test temperature

(oC)

Minimum bending angle,mandrel diameter = 3 xthickness of specimen

123

400343434

200

-201Y2Y3Y4Y

49034343434

200

-20-40

2Y403Y404Y40

510393939

0-20-40

120o before the first incipientcrack, minor pore exposuresup to a maximum length of

3 mm are allowed

Note:1) Shows individual value of three specimens.

Discard

Flat tensile testspecimen

Bend test specimenBent test specimen

Charpy V-notchspecimens

Reserve

Bend test specimen

Bend test specimen

Tensile testspecimen

Discard


2009

1.5.3.4 Butt weld tests (multi-run technique)1. One butt weld test assembly shall be pre-

pared as shown in Fig. 1.5.3.4 -1, and thebase metal shall be a hull structural steelin compliance with 1.5.2.3-3.

2. The welding shall be carried out indownhand position by the multi-run tech-nique in accordance with 1.5.3.2-2.The back sealing run shall be applied alsoin downhand position after grinding outthe root run to clean metal. The post-weldheat treatment shall not be permitted.

3. The butt weld assemblies shall be sub-jected to radiographic examination priorto the preparation of test specimens to as-certain if there are any defects in theweld.

4. The test specimens to be prepared fromthe butt weld assembly are shown in Fig.1.5.3.4.1.The shape and dimensions of test speci-mens shall be in accordance with1.5.2.3-9, -10, -11.Results of the tensile, impact and bendtests shall comply with the requirementsof the Table 1.5.3.4.

1.5.3.5 Approval tests for two-run technique

Where approval of two-run technique is re-quired, two butt weld test assemblies shall be prepared usingthe following thickness

− for grades 1 and 1Y ........ 12 to 15 mm and20 to 25 mm,

− for grades 2, 2Y, 3 and 3Y ..... 20 to 25 mmand 30 to 35 mm,

− for grades 2Y40, 3Y40 and 4Y40 .... 20 to25 mm and 30 to 35 mm.When a wire-flux combination is recom-mended for welding a normal and highertensile strength steel, the latter shall be usedto prepare the test assemblies.

1.5.3.6 Butt weld assemblies (two-run technique)1. The edge preparation, grades of steel and

the maximum diameter of wire shall be inaccordance with the Table 1.5.3.6.

2. Each butt weld shall be welded in tworuns, one from each side, applying weld-ing parameters recommended by themanufacturer and in compliance withgood welding practice.

3. After completion of the first run, the fluxand welding slag shall be removed andthe assembly shall be left in still air untilit has cooled down to 100oC. Gouging ofthe root shall be carried out before start-ing the second run on the opposite sideaccording to the manufacturers recom-mendation.

4. The butt welded assemblies shall be sub-jected to radiographic examination to as-

certain if there are any defects in a weldprior to the preparation of test specimens.

5. The test specimens shown in Fig. 1.5.3.6shall be prepared from the butt weldedtest assemblies. The Charpy V-notch im-pact test pieces shall be machined fromthe welded assembly from the positionsas shown in Fig. 1.5.3.6-1.

Figure 1.5.3.6

Figure 1.5.3.6-1Size and dimensions of the remaining test

specimens shall be in compliance with 1.5.2.3-9, -10, -11.Results of the transverse impact testing, tensile

and bend tests shall be in accordance with the requirements


2009

specified in the Table 1.5.3.4. Longitudinal tensile test shallcomply with the requirements specified in the Table 1.5.3.3.

6. The chemical analysis of the weld metalfor each test specimen (piece) shall be

made to ascertain the content of all sig-nificant alloying elements and impurities.

Table 1.5.3.6

Edge preparation and wire diameter Testing of welding consumablesFor welding under flux For welding in shielding gas For normal strength

steelFor higher strength

steel

Plat

eth

ickn

ess,

mm

Edge preparationWire di-ameter Edge preparation

Wire di-ameter

Grade ofwelding

consumables

Grade ofsteel for testassemblies

Grade ofwelding

consumables

Grade ofsteel for testassemblies

12-15 5

see

note

* 1

-

A

-

-

1Y

-

A32A36

20-25 6

see

note

*12

3

4Y

4Y40

AA, B or D

A, B D or E

1Y2Y

2Y40

3Y

3Y40

4Y

4Y40

A32, A36A32, A36D32, D36A40, D40

A32, A36D32, D36E32, E36A40, D40,E40A32, A36D32, D36E32, E36F32, F36A40, D40E40, F40

30-35 7

see

note

*

2

3

A, B or D

A, B D or E

2Y

2Y403Y

3Y40

4Y

4Y40

A32, A36D32, D36A40, D40A32, A36D32, D36E32, E36A40, D40,E40A32, A36D32, D36E32, E36F32, F36A40, D40E40, F40

Note:*) The wire diameter and edge preparation depending on the thickness of the test assembly welded shall be chosen to the recommen-

dations of the manufacturer who has submitted the combination for testing.


2009

1.5.3.7 Annual tests1. Annual tests shall consist of:

a) wire-flux combination approved formulti-run technique, one depositedmetal assembly,

b) wire - flux combination approved fortwo-run technique, one butt weldedassembly with 20 - 25 mm platethickness.

2. The deposited metal assembly shall beprepared and tested in compliance with1.5.3.2, provided that only one longitudi-nal tensile test piece (specimen) and threeimpact test pieces are required.

3. The butt weld test assembly shall be pre-pared and tested in compliance with1.5.3.6, provided that only one transversetensile test piece (specimen), two bendtest piece (specimens) and three impacttest pieces are required.Where the wire-flux combination is ap-proved solely for two - run technique, onelongitudinal tensile test piece (specimen)shall also be prepared and tested.

4. Where wire-flux combination is approvedfor welding of normal strength steel andalso higher strength steel, the latter shallbe used as a base metal for preparing testassemblies.

1.5.3.8 Upgrading and uprating1. Upgrading of wire-flux combination in

connection with the impact propertieswill be considered as detailed in 1.5.2.8-1. and for wire - flux combinations ap-proved for two-run welding only, a butt-weld in the maximum thickness approvedshall be subjected to impact test in accor-dance with 1.5.3.6-5.

2. Upgrading of the approved wire-fluxcombination in connection with the ten-

sile properties shall be considered in ac-cordance with 1.5.2.8-3.

1.5.4 Wires and wire-gas combinations forsemi-automatic and automatic welding

1.5.4.1 General1. Wire-gas and flux-cored wires for use

with or without a shielding gas, are di-vided into the following categories for thepurposes of the approval testing.a) for use in a semi- automatic multi-run

welding,b) for use in single electrode automatic

multi-run welding,c) for use in single electrode automatic

two-run welding.2. The term semi - automatic refers to the

welding in which the weld is performedmanually by a welder holding a gunthrough which the electrode wire is con-tinuously fed.

3. Depending on the results of impact tests,wires and wire-gas combinations shall bedivided into the following grades.− for normal strength steel grades 1,

2, and 3,− for higher strength steels with yield

strength up to 355 N/mm2, grades1Y, 2Y 3Y and 4Y.

− for higher strength steels with yieldstrength up to 390 N/mm2, grades2Y40, 3Y40, and 4Y40.

Symbol S shall be added to the grademark to indicate approval for semi-automatic multi-run welding.

4. For wires intended for automatic weldingthe symbols T, M, or T M shall be addedto the grade mark to indicate approval fortwo-run, multi-run or both welding tech-niques, respectively.

Table 1.5.4.1-7

Gas composition (Vol. %)GroupCO2 O2 H2 Ar

M1 1234

> 0 to 5> 0 to 5

-> 0 to 5

--

> 0 to 3> 0 to 3

> 0 to 5---

Rest1)2)Rest 1)2)Rest 1)2)Rest 1)2)

M2 123

> 5 to 25-

> 5 to 25

-> 3 to 10> 0 to 8

---

Rest 1)2)Rest 1)2)Rest 1)2)

M3 123

> 25 to 50-

> 5 to 50> 10 to 15> 8 to 15

---

Rest 1)2)Rest 1)2)Rest 1)2)

C 12

100Rest

-> 0 to 30

--

--

Notes:1) Argon may be substituted by Helium up to 95% of the Argon content.2) Approval covers gas mixtures with equal or higher Helium contents only.


2009

5. For wires intended for both semi - auto-matic and automatic welding , both sym-bols shall be added.

6. Flux-cored wires which meet the re-quirements for grades 2, 2Y, 2Y40, 3, 3Y,3Y40, 4Y or 4Y40 may be, at the manu-facturers request , subjected to the hydro-gen test in accordance with 1.5.2.4. Sym-bols H15, H10 or H5 shall be added to thegrade mark under the same conditions asfor covered electrodes in compliance with1.5.2.4.

7. Type and composition of the shieldinggas shall be submitted to the Register bythe manufacturer.Additional approval tests shall be re-quired when a shielding gas is used otherthan that for the initial approval tests.

The approval of a wire in combination with anyparticular gas can be applied or transferred to any combina-tion of the same wire and any gas in the same numberedgroup as defined in Table 1.5.4.1-7.

1.5.4.2 Approval for semi-automatic multirunwelding1. Approval for semi-automatic multirun

welding shall be carried out generally inaccordance with the requirements of1.5.2, using semi-automatic multiruntechnique for the preparation of all testassemblies.

2. Two deposited metal test assemblies shallbe prepared in the downhand position asshown in Fig. 1.5.2.2-1, one using thesmallest diameter, and the other using thelargest diameter of wire produced for thewelding. Where only one diameter ismanufactured, only one deposited metalassembly shall be prepared.The weld metal shall be deposited ac-cording to the practice recommended bythe manufacturer and the thickness ofeach layer of weld metal shall be between2 and 6 mm.

3. The deposited weld metal in each testassembly shall be subjected to thechemical analysis. The analysis shallascertain the content of all significantalloying elements and impurities.

4. From each assembly , test pieces shall beprepared and tested in accordance with1.5.2.2 , and the test results shall complywith the requirements of the Table1.5.2.2-4.

5. Butt weld assemblies as shown inFig.1.5.2.3-1 shall be prepared for eachwelding position for which the wire orwire-gas combination is recommended(PA, PC, PF, PG and PE).

6. Test assembly for the PA position shallbe welded using, for the first run the wireof the smallest diameter and for the re-maining runs, wire of the largest diameterto be approved.

7. When the PA position is solely subjectedto approval, an additional test assemblyshall be prepared using the wires of dif-ferent diameters from those referred to in1.5.4.2-6.

8. The butt weld assemblies in positionsother than downhand (PA), shall bewelded using for the first run, wire of thesmallest diameter, and for the remainingruns, the largest diameter of wire recom-mended by the manufacturer.

9. Welded assemblies (butt welds) shall besubjected to radiographic examinationprior to the preparation of test pieces, toascertain if there are any defects in thewelds.

10. On each butt weld assembly test speci-mens shall be prepared for the mechanicaltesting in accordance with 1.5.2.3 and thetest results shall comply with the re-quirements of the Table 1.5.2.3-9 for therelevant grade.

11. Fillet weld test assemblies shall be madeand tested in accordance with 1.5.2.5.

1.5.4.3 Approval for the automatic multirun weld-ing1. Approval tests for the automatic multirun

welding shall be carried out generally inaccordance with the requirements of the1.5.3.2 and 1.5.3.4. respectively, usingthe automatic multirun technique for thepreparation of all test assemblies.

2. One deposited metal assembly shall beprepared as shown in Fig. 1.5.3.2-1.Welding shall be carried out as detailed in1.5.3.2-2, except that the thickness ofeach layer shall not be less than 3 mm.

3. Deposited weld metal of each test assem-bly shall be subjected to the chemicalanalysis.The analysis shall ascertain the content ofall significant alloying elements and im-purities.

4. Test pieces ( specimens ) shall be pre-pared from the deposited weld metal inaccordance with 1.5.3.2-5 for the me-chanical tests and test results shall com-ply with the requirements of the Table1.5.3.3.

5. One butt test assembly shall be preparedin accordance with Fig. 1.5.3.4-1.

6. Each butt weld shall be subjected to a ra-diographic examination prior to preparingof test assemblies to ascertain if there areany defects in the weld.

7. Test specimens shall be prepared from thebutt weld assembly and tested in accor-dance with 1. 5. 3. 4 - 4, and the test re-sults shall comply with the requirementsof Table 1.5.3.4.

8. At the discretion of the Register, wiresapproved for semi-automatic multirunwelding may be approved without addi-


2009

tional tests, for automatic multirun weld-ing.

1.5.4.4 Approval for automatic two-run welding1. Approval tests for automatic two-run

welding shall be carried out generally ontwo test specimens in accordance with therequirements of 1.5.3.5 and 1.5.3.6 re-spectively using the automatic two-runwelding technique for the preparation ofall test assemblies. The edge preparationof the test assemblies shall be as shown inthe Table 1.5.3.6.

1.5.4.5 Annual testsAnnual tests shall consist of:

a) wires approved for semi-automatic orfor both semi-automatic and auto-matic multirun welding: one depos-ited metal test assembly prepared inaccordance with 1.5.4.2 using a wireof diameter within the range approvedfor welding of the hull structures.

b) wires approved for automatic mul-tirun welding: one deposited metal

test assembly prepared in accordancewith 1.5.4.3-3, using a wire of di-ameter within the range approved forwelding of hull structures.

c) wires approved for automatic two -run welding: one butt weld test as-sembly prepared in accordance with1.5.3.6 using plate of 20 - 25 mm inthickness.

2. The test specimens shall be prepared andtested in accordance with 1.5.4:a) for deposited metal assemblies (semi-

automatic and automatic multiruntechnique): one tensile and three im-pact test specimens;

b) for butt weld assemblies (automatictwo-run technique): one transversetensile, two bend and three impacttest specimens.When the wire is approved solely forautomatic two-run welding, one lon-gitudinal tensile test specimen shallbe required.

Cylindrical tensile testspecimen

MacrographyCharpy V-notch in thecenter of the weld

Charpy V-notch 2 mmaway from the fusionline (in the weld metal)

Cylindrical tensile testspecimen

Macrography

Flat transversetensile testspecimenBend testspecimen

Flat transversetensile testspecimenSide bend testspecimen

V notch in the midle

V-notch 2 mm away from the fusionline (in the weld metal)


2009

Figure 1.5.5

1.5.5 Consumables for use in electroslag andelectrogas vertical welding

1.5.5.1 General1. Requirements for approval of consum-

ables used in vertical electroslag andelectrogas (including consumable noz-zles) welding are generally in compliancewith the requirements of 1.5.3.5.

2. For grades 1Y, 2Y and 3Y, 4Y, 2Y40 and4Y40 approval of consumables shall beapplicable only to higher strength steelsand the base metal shall be niobiumtreated steel.

1.5.5.2 Butt weld tests1. Two butt weld test assemblies shall be

prepared in accordance with the Fig.1.5.5, from plates of the minimum andmaximum thickness.

2. Each assembly shall be cut to give testspecimens:− two flat transverse tensile test

specimens (in accordance with1.5.2.3-2);

− two longitudinal cylindrical tensiletest specimens ( in accordance with1.5.2.2-1) ;

− two bend specimens (in accordancewith Fig. 2.4.4-1);

− two sets of impact test specimens(in accordance with Fig. 2.4.5-1);

− two transverse macro section to ex-amine the penetration and to meas-ure hardness of the weld metal andheat-affected zone.

Test results shall meet the requirements of Ta-bles 1.5.3.3 and 1.5.2.3-9.

1.5.5.3 Annual tests1. Annual tests shall consist of one butt

weld assembly of 20 - 25 mm inthickness.

2. Preparing and testing of a specimen shallbe as shown in 1.5.5.1 and 1.5.5.2 , andthe following test pieces shall be pre-pared:− one flat transverse tensile test

specimen,− one cylindrical longitudinal test

specimen,− two bend test specimens,− one set of three Charpy V-notch

impact test specimen with a notchin the axis of the weld.

1.5.6 Consumables for one-side welding withtemporary backing materialsThe present requirements apply to the testing of

welding consumables ( electrodes, wire - flux , wire-gas )when one-side welding with temporary backing materials iscarried out (manual, semi-automatic, automatic).

The scope and conditions of testing shall bedetermined in accordance with the requirements of 1.5.2 -1.5.4, depending on the welding procedures and the provi-sions stated below.

A test assembly of deposited metal shall be de-termined in accordance with Fig. 1.5.2.2-1 or 1.5.3.3, de-pending on the welding procedure (manual, semi-automatic,automatic) and a test assembly for testing of a welded joint inaccordance with Fig. 1.5.6.

Figure 1.5.6

DiscardCharpy V-notch test pieces

Reserve

Macrosection

Flat tensile test piece

Bend test piece (upper side of weld)

Bend test piece (weld root)

Discard


2009

Two butt weld test assemblies of minimum andmaximum thickness shall be prepared from steel of the gradefor which the welding consumables are approved. Gap di-mensions and edge preparation shall be in accordance withthe recommendations of the manufacturer of the weldingconsumables.

The mechanical properties of the depositedmetal shall meet the requirements of the Table 1.5.3.3, andthose of the welded joint Table 1.5.2.3-9 for appropriategrade of a welding consumable.

In case the welding consumables have been ap-proved earlier by the Register, for welding by the standardprocedure (without backing), a test assembly for testing awelded joint shall be prepared in accordance with Fig. 1.5.6.

1.5.7 Consumables for High StrengthQuenched and Tempered Steels forWelded Structures

1.5.7.1 General1. These requirements give the conditions

for approval of consumables used forhigh strength quenched and temperedsteels for welded structures with yieldstrength levels from 420 N/mm2 up to690 N/mm2 and impact grades D, E andF.

2. The welding consumables preferably tobe used for the steels concerned, are di-vided into several categories:− covered electrodes for manual

welding− wire-flux combinations for mul-

tirun* submerged arc welding− solid wire-gas combinations for arc

welding− flux cored wire with or without gas

for arc welding.* Wire-flux combinations for single or two-run

technique are subject to special consideration of the Register.3. Based on the yield strength of the weld

metal, the welding consumables con-cerned are divided into six (yield)strength groups.− Y42 - for welding steels with mini-

mum yield strength 420 N/mm2

− Y46 - for welding steels with mini-mum yield strength 460 N/mm2





4. Each of the six (yield) strength groups isfurther divided into three main grades inrespect of Charpy V-notch impact test re-quirements (test temperatures):− Grade 3, test temperature -20oC

− Grade 4, test temperature -40oC− Grade 5, test temperature -60oC

5. Analogously to the designation schemeused in 1.5.1, the welding consumablesfor high strength quenched and temperedsteels are subject to the classificationdesignation and approval, as follows:− According to 1.5.7.1-4 with the qual-

ity grade 3, 4 or 5.− With the added symbol Y and an ap-

pended code number designating theminimum yield strength of the weldmetal corresponding to 1.5.7.1-3:Y42, Y46, Y50, Y55, Y62 and Y69.

− With the added symbol H10 or H5 forcontrolled hydrogen content of theweld metal.

− With the added symbol S (semi-automatic) for semi-mechanisedwelding.

− With the added symbol M designatingmultirun technique (and is applicableto welding consumables for fullymechanised welding).

6. Each higher quality grade includes theone or (those) below. Quenched and tem-pered steels grade A... and D... are to bewelded using consumables of at leastquality grade 3, grade E... steels using atleast quality grade 4 and grade F steelsusing at least quality grade 5 (see Table1.5.7.1-6).

Table 1.5.7.1-6

Consumable Grade Steel Grades covered3 Y... D.. and A4 Y... E.., D and A5 Y... F.., E.., D and A

Welding consumables approved withgrades...Y42, .....Y46 and ...Y50 are also considered suitablefor welding steels in two strength levels below that for whichthey have been approved. Welding consumables approvedwith grades ..Y55, ..Y62 and ..Y69 are also considered suit-able for welding steels in the strength level below that forwhich they have been approved.

7. Manufacturers plant, production methodsand quality control measures shall besuch as to ensure reasonable uniformity inmanufacture.Testing and approval procedure shall bein accordance with 1.5.1 for the individ-ual categories (types) of welding con-sumables mentioned in 1.5.7.1-2, -3 and -4.

1.5.7.2 Testing of the Weld Metal

For testing of the deposited weld metal, testpieces analogous to those stated in 1.5.2.2, 1.5.3.2, 1.5.4.2 or1.5.4.3 respectively shall be prepared, depending on the typeof welding consumables (and according to the welding proc-


2009

ess). The base metal used shall be a fine-grained structuralsteel compatible with the properties of the weld metal, or theside walls of the weld shall be buttered with the weld of thesame composition.

The chemical composition of the depositedweld metal shall be determined and certified in a manneranalogous to that prescribed in 1.5.2.2-3. The results of theanalysis shall not exceed the limit values specified in thestandards or by the manufacturer, (the narrower tolerancesbeing applicable in each case).

Depending on the type of welding consumables(and according to welding process), the test specimens pre-scribed in 1.5.2.2, 1.5.3.2, 1.5.4.2 or 1.5.4.3 respectively shallbe taken from the weld metal test pieces in a similar manner.

The mechanical properties shall meet the re-quirements stated in Table 1.5.7.2-1 and 1.5.7.2-2. The provi-sions of 1.5.2.2 in analogous manner apply to the perform-ance of tests, in particular to the maintenance of the notchedbar impact test temperature and obtained test results.

Table 1.5.7.2-1

Quality grade Test temperature[oC]

Minimum notch impact energy[J1)]

3 -20 Y42 : ≥ 47Y46 : ≥ 47

4 -40 Y50 : ≥ 50Y55 : ≥ 55

5 -60 Y62 : ≥ 62Y69 : ≥ 69

1) Charpy V-notch impact test specimen,, means value of three specimens; for re-quirements regarding minimum individual values and re-tests, see 1.5.2.2.

Table 1.5.7.2-2

Symbols added to qualitygrade

Minimum yield strength[N/mm2]

Tensile strength1)

[N/mm2]Minimum elongation

[%]

Y42 420 530 - 680 20Y46 460 570 - 720 20Y50 500 610 - 770 18Y55 550 670 - 830 18Y62 620 720 - 890 18Y69 690 770 - 940 17

1) The tensile strength of weld metal may be up to 10% bellow the requirements, provided that the results obtained with the trans-verse tensile specimen taken from the welded joints meet the minimum tensile strength requirements stated in Table 1.5.7.3.The elongation is to be stated in the test report.

Note:For welding very large plate thickness’ where the "supporting effect" of the base material (metal) on either side of the weld nolonger applies and tensile strength at the weld metal also determines the tensile strength of welded joint, if may be necessary,when applying footnote1), to choose welding consumables of the next higher grade.

Table 1.5.7.3

Quality grade Added symbolTensile strength

[N/mm2]

Minimum notchimpact energy test

temperature

Minimum bendingangle1)

Bend ratio

D/t2)

Y42 530-680 4Y46 570-720 4Y50 610-670 4Y55 670-830 5Y62 720-890 5

3 to 5 inaccordance with Ta-

ble 1.5.7.2-1

Y69 770-940

Depending on thequality grade and

yield strength in ac-cordance with Table

1.5.7.2-1120o

51) Bending angle attained before the first incipient crack, minor pore exposures up to a maximum length of 3 mm , allowed.2) D = mandrel diameter, t = specimen thickness.


2009

1.5.7.3 Testing of Welded Joints1. Depending on the type of welding con-

sumables (and according to welding pro-cess), the testing on welded joints shall beperformed on butt weld test pieces inanalogous manner to that prescribed in1.5.2.3, 1.5.3.4, 1.5.4.2 or 1.5.4.3, re-spectively.

2. Depending on the type of welding con-sumables (and according to welding pro-cess), the butt weld test pieces called forin 1.5.7.3-1 shall be welded in the manneranalogous to that prescribed in 1.5.2 -1.5.4. The base metal used shall be ahigh-strength fine-grained structural steelwith an appropriate minimum yieldstrength and tensile strength and com-patible with the added symbol for whichapplication is made.

3. Depending on the type of welding con-sumables (and according to welding pro-cess), the test specimens described in1.5.2 - 1.5.4, shall be cut from the buttweld test pieces.

4. The mechanical properties shall meet therequirements stated in Table 1.5.7.3.The provisions of 1.5.2 - 1.5.4 apply inanalogous manner to the performance ofthe tests, in particular to the maintenanceof the notched bar impact test temperatureand obtained test results.

5. Where the bending angle required in Ta-ble 1.5.7.3 is not achieved, the specimenmay be considered as fulfilling the re-quirements, if the bending elongation ona gauge length Lo fulfils the minimumelongation requirements stated in Table1.5.7.2-2.

The gauge length Lo = Ls + t (Ls = width ofweld, t = specimen thickness; see Fig. 1.5.7.3 below).

Figure 1.5.7.3

1.5.7.4 Hydrogen Test

The welding consumables shall be subjected toa hydrogen test in accordance with the mercury method pre-scribed by ISO 3690, or any other equivalent method, inagreement with the Register.

The diffusable hydrogen content of the weldmetal determined in accordance with provisions of 1.5.2.4,shall not exceed the limits given in Table 1.5.7.4.

Table 1.5.7.4

Yield strengthgroup

Hydrogensymbol

Maximum hydrogen content(cm3/100 g deposited

weld metal)Y42Y46Y50

H10 10

Y55Y62Y69

H5 5

1.5.7.5 Annual Repeat Test

The annual repeat test specified in 1.5.2 - 1.5.4shall entail the preparations and testing of weld metal testpieces as prescribed under 1.5.7.2. In special cases the Reg-ister may require more extensive repeat test.

1.5.8 Consumables for welding of aluminiumalloys

1.5.8.1 General

Welding consumables for welding of alumin-ium alloys are divided into quality grades shown in the Table1.5.8.1, on the basis of their chemical composition and me-chanical properties.

Welding consumables preferably to be used forthe welding of aluminium alloys concerned are divided intotwo categories as follows:

W = wire - combination wire-gas for MIG(131), TIG (141) or plasma arcwelding (15)

R = rod - combination rod-gas for TIG(141) or plasma arc welding (15)

The Approval of a wire or a rod will be grantedin conjunction with a specific shielding gas according to Ta-ble 1.5.8.1-1. Chemical composition of the shielding gas is tobe separated.

1.5.8.2 Testing of the weld metal

The testing of weld metal shall consist of achemical analysis of the deposited weld metal. For that pur-pose a test piece according to Figure 1.5.8.2. shall be pre-pared. The size depends on the type of the welding consum-able and on the welding process and shall give a sufficientamount of pure weld metal for chemical analysis. The basemetal used shall be compatible with the weld metal in respectof chemical composition.

The chemical composition of the weld metalshall be determined as prescribed in 1.5.2.2-3. The results ofthe analysis shall not exceed the limits specified in standardsor by the manufacturers.


2009

1.5.8.3 Testing on welded joints

The testing on welded joints shall be performedas prescribed in 1.5.2.3 on butt weld test pieces in compli-ance with Fig. 1.5.8.3. The base materials shall be used as in-dicated in Table 1.5.8.1.

The plate thickness shall be 10 - 12 mm forMIG (131) and plasma arc welding (15) and for TIG (141)welding 4 - 6 mm.

Depending on the welding positions for whichthe approval is granted, the butt - weld ( shown in Fig.1.5.8.3) shall be welded in the relevant positions, the mini-mum requirement the downhand (PA) or vertical - up (PF)positions.

The wire diameters and the welding parametersshall be in accordance with recommendations of the manu-

facturer of the welding consumables. The chemical composi-tion of the shielding gas used shall be stated in the report ontesting. Post-weld heat treatment of the test pieces is allowedonly if such treatment shall be carried out in the regular pro-duction of welded components. After being subjected to ra-diographic examination of test pieces, the test specimensshall be cut from each test piece in accordance with Fig.1.5.8.3.

The required properties of the welded jointwhich shall be complied with for welding consumable gradesare stated in Table 1.5.8.3.

The position of the fracture shall be stated inthe test report.

Table 1.5.8.1Welding consumables for aluminium alloys

Base material for the test1) Base materials also "covered" by the approvalGradeNumerical Chemical symbol Numerical Chemical symbol

RA/WA 5754 AlMg 3 - -RB/WB 5086 AlMg 4 5754 AlMg 3

RC/WC 5083 AlMg 4,5 Mn W 0,7

57545086

6005 (A)60616082

AlMg 3AlMg 4AlSiMg

AlMg 1 SiCuAlSi 1 MgMn

RD/WD

6082 AlSi 1 MgMn

575450865083

6005 (A)60616082

AlMg 3AlMg 4

AlMg 4,5 Mn 0,7AlSiMg (A)

AlMg 1 SiCuAlSi 1 MgMn

Note:1) In respect to the bend test, it is recommended to carry out the test with base material in "soft" conditions.

Table 1.5.8.1-1Chemical compositions of the shielding gases and mixtures

Gas composition (vol. %)1)Group

Argon HeliumI - 1I - 2I - 3I - 4I - 5

100-

RestRestRest

-100

> 0 do 33> 33 do 66> 66 do 95

S Special gas, composition to be specified.Note:1) Gases of other chemical composition (mixed gases) may be considered as

"special gases" and covered by a separate test.


2009

Figure 1.5.8.2

Z = Flat tensile test specimenBD = Transverse bend test specimen , cover pass in tensionBW = Transverse bend test specimen , root pass in tensionM = Macro section

Figure 1.5.8.3

Table 1.5.8.3Required properties of welded joints

Grade(chemical symbol)

Minimumtensile

strength[N/mm2]

Mandreldiameter

[mm]

Minimumbendingangle 1)

RA/WA (AlMg3) 190 3 t 180o

RB/WB (AlMg4) 240 6 t 180o

RC/WC (AlMg4,5Mn0,7) 275 6 t 180o

RD/WD AlSi1MgMn) 170 6 t 180o

Note:1) Bending angle before first incipient crack, minor pore exposures up to maximum length of 3 mm are

allowed.

1.5.8.4 Annual repeat tests

The annual repeat tests of the approved weldingconsumables shall cover the preparation and testing of butt-weld test piece (1.5.8.3) welded in the downhand position(PA) with wire of 1,2 mm in diameter. Half of specimensmay be used in the repeat tests as in the initial test.

1.6 OVERWELDABLE SHOP PRIM-ERS

1.6.1 General

1.6.1.1 Overweldable shop primers applied to plates,sections etc. shall not significantly impair the quality ofwelded joints.

Overweldable shop primers for which the Reg-ister has issued Certificate on approval on the basis of a po-rosity test may be used. Even if the Certificate on approvalhas been issued, overweldable shop primers intended for


2009

welding may be approved for automatic double fillet weldingonly after a special welding procedure test in the users work.

1.6.2 Testing and approval of shop primers

1.6.2.1 Application for approval of the shop primershall be submitted by the manufacturer to the Register to-gether with the following information:

− Manufacturer (and licensor, where applica-ble),

− Brand name (and licensors brand name,where applicable) together with the originalbrand name in the case of commercial des-ignations used for marketing.

− Code number/symbol identifying the for-mulation,

− Characteristic pigment base− Characteristic binding agent base− Instructions for use (preparation of surface,

methods of application, dry coat thicknessetc.,

− Documentation relating to previous tests,approvals etc.,

− Place and date of proposed tests.

1.6.2.2 The porosity test shall be performed by neutral,properly equipped testing authorities recognized by the Reg-ister for that purpose. Testing should be performed in accor-dance HRN EN ISO 17652-2.

1.6.2.3 The identity of the sample submitted for testingshall be established and recorded in the test report.

1.6.2.4 The Certificate on approval issued by the Reg-ister, imposes on the manufacturer the responsibility for en-suring that the composition and characteristics of the shopprimer remain constant. Any modifications shall be reportedautomatically to the Register and shall necessitate new testsin compliance with 1.6.2.2.

1.6.2.5 Approval is valid for 3 year. On application bythe manufacturer it may be extended by a further 3 years attime. In the application, the manufacturer shall confirm inwrithing that no changes have been made to the product sincethe initial approval was granted.


2009

2 FABRICATION AND IN-SPECTION OF WELDED JOINTS

2.1 FABRICATION OF WELDEDJOINTS

2.1.1 General

2.1.1.1 This Chapter contains the general guidancesapplicable to the performance of welding work extendingfrom the weld preparation to the completion of the weldedjoint.

2.1.1.2 All workshops wishing to perform weldingworks shall comply with the requirements of this Rules speci-fied in 1.2, 1.3, 1.4 and, where necessary 2.3. Each workshopshall maintain up-to-date records on the compliance with therelevant requirements and shall submit them to the Surveyorto the Register, at his request.

2.1.1.3 Welding may be performed on materials whoseidentity and weldability, under the given production condi-tions, can be uniformly established (by reference to markings,certificates etc.).

2.1.1.4 Welding consumables tested in compliancewith 1.5. of these Rules, approved by the Register and of aquality grade appropriate to the base material, may be usedfor welding. Welding consumables for the special weldingprocedures, approved on the basis of the welding proceduretest, may be used only for the range of application specifiedin the relevant approval certificate.

2.1.1.5 Overweldable shop primers applied to plates,sections, etc. which are not removed prior to welding shall betested and approved by the Register in compliance with 1.6of these Rules.

2.1.1.6 Welded joints shall be performed in accordancewith approved drawings, welding practice or company stan-dards approved by the Register. Exceptions to these Rules aresubject to the Registers agreement in each particular case.

2.1.2 Weld preparation

2.1.2.1 Weld preparation may be carried out by thermalcutting or machining. Groove edges shall be free from impu-rities and defects which may impair the quality of the weldedjoint.

2.1.2.2 When preparing and assembling components,care shall be taken to ensure compliance with the weld shapesand root openings specified in the approved documentation.For single- and double-bevel butt welds, provision shall bemade for adequate root openings to enable sufficient rootpenetration.

The root opening shall not exceed twice thespecified gap. The size of the gap may be reduced locally bythe build-up welding of the side walls in agreement with thesurveyor to the Register.

2.1.2.3 Components which are butt welded shall bealigned as accurately as possible. Therefore sections weldedto plating shall be left unwelded at the ends for this purpose.

2.1.2.4 Tack welds shall be performed as much as pos-sible, by trained personnel. The places where their qualitydoes not meet the requirements applicable to the weldedjoint, shall be carefully removed before permanent welding.Clamping plates, temporary ties and aligning pins shall bemade from the same or similar material as base material andshall not be used more than necessary. Any damage causedduring their removal shall be competently repaired.

2.1.3 Weather protection, preheating

2.1.3.1 The areas which shall be welded shall be ade-quately protected against climatic influences such as wind,damp and cold and shall be preheated where necessary. Theneed for preheating and the preheating temperature shall bedetermined by various factors such as chemical composition,plate thickness, heat dissipation and ambient temperature.Details regarding this requirement are given in 2.2. Preheat-ing shall be applied uniformly throughout the thickness of theplate over width of four times the plate thickness, but not lessthan 100 mm.

2.1.4 Welding positions and welding sequence

2.1.4.1 Welding shall be performed, as a rule, in theoptimum welding position.

The welding sequence shall ensure minimumrelieving stresses and deformations in welded structures. Inparticular cases, the Register may require the welding sched-ule to be submitted.

2.1.5 Performance of welding work

2.1.5.1 The welding shop shall ensure that the specifiedwelding parameters are adhered to and that the welding workis expertly performed. Components which have not beenfully welded and which shall be handled or turned shall havewelded joints of adequate strength. Cracked tack welds shallnot be welded over, but they shall be machined out prior towelding. Welds shall have sufficient penetration and shalldisplay a clean, regular surface with smooth transition to thebase material. Excessive weld metal, undercuts or notcheswhich may affect the weld quality shall be avoided.

2.1.6 Straightening and tolerances

2.1.6.1 Straightening operations (thermal or mechani-cal) shall not impair the quality of the materials and weldedjoints. Register may require verification of the suitability ofthe straightening method (e.g. by means of a welding proce-dure test). Tolerances for welded structures are stated in themanufacturing documentation and shall be in accordancewith one of the recognized standards (e.g. HRN EN ISO13920).


2009

2.1.7 Post-weld treatment

2.1.7.1 When the post-weld treatment is intended to becarried out to improve the surface finishing in case of dy-namic loading, such treatment shall not impair the character-istics of the welded joints.

For post-weld heat treatment, see 2.2 and forthe surface treatment for non-destructive testing see 2.3.

2.2 HEAT TREATMENT

2.2.1 General

2.2.1.1 This Chapter apply to the preheating prior toand during the welding as well as to heat treatment of weldedjoints.

2.2.2 Equipment and appliances for heattreatment

2.2.2.1 When heat treatment is carried out in furnaces,the furnaces shall be equipped with calibrated devices fortemperature control, monitoring and temperature recorders.The furnace dimensions and heating system shall enable thecomponent to be evenly heated to the required temperature.The furnace shall be properly serviced and examined atregular intervals.

2.2.2.2 If no furnaces of sufficient size are available,heat treatment may be carried out in specially designedequipment. Such equipment shall comply with the require-ments of 2.2.2.1. regarding control, monitoring and tempera-ture recording.

2.2.2.3 If no heat treatment units of sufficient size areavailable, heat treatment may be carried out in sections inagreement with the Register. Requirements regarding control,monitoring and temperature recording, specified in 2.2.2.1,shall be complied with also in this case and for this equip-ment.

2.2.2.4 Preheating may be carried out in furnaces or bymeans of heating appliances such as gas burners or resistancemats. Their use imposes the method of pre-heating tempera-ture monitoring as well as interpass temperature throughoutthe welding operation. Temperature may be monitored bymeans of suitable appliances such as contact thermometers,temperature sensitive crayons or similar.

2.2.3 Weather protection, preheating

2.2.3.1 The area in which welding work is performedshall be sheltered from wind, damp and cold. Where gas-shielded arc welding is carried out, special attention shall bepaid to adequate draught protection.

At ambient temperature below +5oC, additionalmeasures shall be taken, such as shielding of components,preliminary heating and preheating, especially when weldingwith a rather low heat input (laying down of thin fillet weldsor welding of thick-walled components).

Wherever possible, no welding shall be per-formed at ambient temperatures below -10oC.

2.2.3.2 The need for preheating and the preheatingtemperature depend on a number of factors. The most consid-erable are:

− chemical composition of the base material,− the workpiece thickness and the type of

weld joint,− the welding process and welding parame-

ters,− temperature dependence on mechanical

properties of the weld metal and the heat-affected zone,

− diffusible hydrogen content of the weldmetal.

The operating temperature to be maintained(minimum preheating temperature and maximum interpasstemperature) for (hull) structural steels may be determined inaccordance with HRN EN 1011-2. Guide values for the pre-heating temperature are contained in Figures 2.2.3-a and2.2.3-b shown below for two different energy inputs per unitlength of weld1) and hydrogen contents H2) of the weld metaltogether with the various carbon equivalents Ceq3).

1) Energy input per unit length of weld:

U [volts] ⋅ I [amps] ⋅ welding time [min] ⋅ 6E =length of weld [mm] ⋅ 100

mmkJ

2) Hydrogen content:H 5 = max. 5 ml diffusible hydrogen per 100 g of weldmetalH 15 = max 15 ml difusible hydrogen per 100 g of weldmetal

3) Carbon equivalent:

402010NiCuCrMoMnCCeq +

++

++=

When the temperature of a component beingwelded is lower than the preheating temperature (calculatedon the basis of above data) preheating is necessary.

Various methods of preheating may be applied:− continuous heating prior to and during the

welding,− alternate heating and welding,− heating only prior to start of welding. When

the heat input during welding is sufficientto maintain the minimum preheating andinterpass temperatures.

The heating method may be chosen at ones dis-cretion, provided that it does not affect material by localoverheating or cause nuisance by making the welding areadirty.

Irrespective of the data referred to in Figures2.2.3-a and b, at the area where auxiliary erection welds arecarried out (e.g. handling lugs) shall be preheated as well asall unalloyed steels with thickness of 20 mm and over and allalloyed steels.

For austenite steels, drying of the areas to bewelded by heating shall be sufficient.

Preheating shall be applied uniformly through-out the thickness of material over the width of 4 x the mate-rial thickness, but not less than 100 mm on both sides of theweld. Local overheating shall not be permitted.


2009

The preheating temperatures specified in Fig-ures 2.2.3-a and b may be applied to tack welds.

Ceq = 0,25 / H5

Ceq = 0,30 / H5

Ceq = 0,35 / H5

Ceq = 0,40 / H5

Ceq = 0,25 / H15

Ceq = 0,30 / H15

Ceq = 0,35 / H15

Ceq = 0,40 / H15

Wall thickness (mm)

Figure 2.2.3-aMinimum preheating temperatures (operating temperatures) applicable to welding processes with a relatively low heat input

(energy input per unit length1) E ≈ 0,5 kJ/mm) as a function of the carbon equivalent Ceq on the base material and hydrogen contentof the weld metal

Ceq = 0,25 / H5

Ceq = 0,30 / H5

Ceq = 0,35 / H5

Ceq = 0,40 / H5

Ceq = 0,25 / H15

Ceq = 0,30 / H15

Ceq = 0,35 / H15

Ceq = 0,40 / H15

Wall thickness (mm)

Figure 2.2.3-bMinimum preheating temperatures (operating temperatures) applicable to welding processes with a relatively high input

(energy input per unit length1) E ≈ 3,5 kJ/mm) as a function of the carbon equivalent Ceq on the base material and the hydrogencontent of the weld metal

Min

imum

tem

pera

ture

pre

heat

ing

(o C)

Min

imum

tem

pera

ture

pre

heat

ing

(o C)


2009

Table 2.2.3 gives guide values for the carbonequivalent Ceq of some of the grades of hull structural steels(based on the information of steel manufacturer).

Table 2.2.3

Ceq [% in weight]Hull steel grades

Average value1) Maximum value1)AE

D36E36TM

D40E40TM

0,270,260,330,270,270,24

0,280,270,340,280,280,25

1) For product thickness up to 50 mm.

2.2.4 Post weld heat treatment

2.2.4.1 Post weld heat treatment shall be carried out onwelded joints in accordance with 3.1 to 3.4.

Stress relief heat treatment at temperaturesspecified in Table 2.2.4.1, is generally sufficient.

The stress relief heat treatment shall be carriedout by means of slow, even heating of the components to theprescribed temperature ranges, holding in these ranges fortwo minutes per mm of wall thickness (but not less than 30minutes), slow cooling down to 400o and after that completecooling in still air. For thick-walled components, the holdingtime need not be longer than 150 minutes.

Table 2.2.4.1Heat treatment temperatures for stress-relief heat treatment,

of welded joints using similar filler metals

Category in accordancewith

DIN V 1738 (CR 12187)Steel grades

Examples of appropriatesteels in accordance with So-

ciety's Rules or theStandards1)

Heat treatmenttemperature

[oC]

1.1Normal-strength hull structural steels andcomparable structural steels, grade of steelforgings and castings

Grades A - E 550-600

1.2Higher-strength hull structural steels andcomparable structural steels, grades of steelforgings and castings

Grades A36- E36 530-580

1.2 High-temperature, low Mo alloy steels 16 Mo 3 550-620

2Normalised or thermo-mechanically proc-essed fine-grained steels with yieldstrengths > 360 N/mm2

Grades A39- E39S 460 tm 550-600

3Quenched and tempered fine-grainedstructural steels with yield strengths> 360 N/mm2

S 690 QL 530-580

55.15.2

Steels with a max. Cr content of 10%, max.Mo content of 1,2%

13 Cr Mo 4-510 Cr Mo 9-10,10 Cr Mo 9-10

630-680670-720

77.17.27.37.37.3

Nickel steels with a max. Ni content of 10%

13 Mn Ni 6-3 (0,5% Ni)12 Ni 14 (3,5% Ni)12 Ni 19 (5% Ni)X 8 Ni 9 (9% Ni)X 7 Ni 9 (9% Ni)

530-560530-560550-560

2)2)

Note:1) Steel grades not listed here are to be classed with comparable grades.2) Heat treatment should be avoided.

2.3 NON-DESTRUCTIVE TESTING OFWELDS

2.3.1 General

This Chapter apply to the performance of non-destructive tests of welded joints according to the methodsand scopes prescribed in the individual sections of Chapter 3for various fields of application. The present part shall alsoapply to the non-destructive tests of welded joints specified

in other Parts of the Rules for which no specific details aregiven therein. The standards specified in the following para-graphs of this Chapter are integral part of these Rules andshall be complied with when performing the non-destructiveweld tests. When the standards differ from the Rules, the lat-ter shall take precedence.

The works inspection department shall be inde-pendent and free from the fabrication department what isnecessary to ensure that the testing and evaluation of the re-sults are carried out objectively. This applies to outside in-spection bodies in analogous manner.


2009

2.3.2 Test methods, appliances and testequipment

The choice of the test method to be applied ineach particular case shall be determined, among other things,by the weld shape, the material and the defects to be expected(type and position). The following basic requirements shallbe mostly complied with:

a) For wall and weld thickness up to 30 mm,radiographic inspection shall be prefer-able method; for larger thickness, ultra-sonic inspection shall be used as the basictest method.

b) For wall or weld thickness of 10 mm andabove, either radiographic or ultrasonicexaminations shall be applied in agree-ment with the Register.

c) For radiographic examination, x-raysources shall be used wherever possible.Gamma-ray sources may be used only inagreement with the Register on the basisof examination and approval of the testmethod.

d) For magnetic materials, testing for sur-face cracks shall be carried out by themagnetic particle method; the use ofpenetrants for magnetic materials shall bein agreement with the Register.The test method shall be such as to enabledetecting of possible external or internaldefects. Where necessary, two or moretest methods may be used in combination.The particular test method to be usedshall be stated in the inspection schedule.The test appliances as well as media usedshall comply with the requirements of therelevant standards and shall be properlyused and serviced.

2.3.3 Inspection personnel, supervisors

The non-destructive weld testing may beperformed only by persons trained in the use of the relevanttest method and appliances as well as having the practicalexperience. The Register may require the appropriatedocumentary proof of such training and experience of thepersonnel for the particular non-destructive weld testmethods.

2.3.4 Inspection schedule, inspection reports

Inspection schedule for the non-destructiveweld test shall cover the following information:

− components of welded joints to be tested;− scope and method of testing;− areas to be inspected (location of sections,

product);− criteria to be complied with;− test method and/or standard, if the different

standards from those specified in theseRules, shall be applied.

The inspection schedule shall be submitted tothe Register for approval.

The reports on testing shall be prepared on thebasis of all testing results and shall be submitted to the sur-veyor to the Register with other relevant documentation.

2.3.5 Timing of testing

Non-destructive tests of welds shall, as a gen-eral rule, be carried out after all welding operations are com-pleted on the components concerned. Prior to these tests,welded joints shall be visually inspected and all surface de-fects which may cause misinterpretation of test results orconclusion shall be removed. Components subjected to thepost-weld heat treatment shall be, as a general rule, inspectedafter heat treatment. In case of higher strength, speciallyhigh-strength structural steels and similar where the delayedcracking are likely to occur (due to the presence of hydrogenin the weld metal) the tests shall not be carried out earlierthan 48 hours after completion of the welding work. TheRegister may require longer waiting time (e.g. 72 hours up toa maximum of 7 days) or repeated tests (on a random sam-pling basis) after appropriate waiting time.

2.3.6 Preparation and performance of tests

The areas to be tested shall be sufficiently cleanand smooth for the respective test method. Irregularities inthe welded joint remains of auxiliary welds, welding spatter,slag remains etc. and any protective coatings shall be re-moved before the tests, if they are liable to prevent them frombeing performed properly. In special cases (e.g. ultrasonictesting for transverse defects), machining of the weld and theassociated edge surface may be required. Non-destructivetests are specified in 2.3.11. to 2.3.14.

2.3.7 Evaluation of test results

In the case of radiographic testing and individ-ual methods of surface testing, the symbols specified in Table2.3.7-a shall be used to identify test defects(HRN EN ISO 6520).

For evaluation of particular sections of steelwelded structures, the evaluation categories in compliancewith HRN EN ISO 5817, shall be used, and for evaluation ofparticular sections of aluminium alloys welded structures theevaluation categories in compliance with HRN EN ISO10042 shall be used.

The test results shall be evaluated by the qualitycontrol department, while the ultimate evaluation shall bemade by a surveyor to the Register.

In the case of radiographic examination, theresults shall be rated in accordance with Table 2.3.7-c and forultrasonic examination the results shall be rated in twocategories: "acceptable" and "not acceptable" (repaired orrejected).

Acceptability of welded joints (radiographicallytested) may be evaluated by applying the evaluation categorywith three or five grades.

Evaluation of quality, according to the evalua-tion category with five grades, shall be performed under theTable 2.3.7-c or under the standard recognized by the Regis-ter.


2009

Evaluation of quality, according to the evalua-tion category with three grades, shall be performed in accor-dance with HRN EN ISO 5817 or HRN EN ISO 10042 re-spectively of base material.

The quality of welded joints shall comply withthe requirements set forth in Table 2.3.7.-b.

Table 2.3.7-aSymbols denoting defects (taken from HRN EN ISO 6520)

Symbol No. / symbol ac-cording to MIZ Description 1)

100 E Cracks101 Ea Longitudinal cracks102 Eb Transverse cracks104 Ec End crater cracks2011 Aa Pore2015 Ab Elongated cavity2016 Ab Worm hole2024 K End crater cavity301 Ba Slog inclusion304 H Metallic inclusion4011 - Lack of side-wall fusion4012 - Lack of inter-run fusion4013 D Lack of root fusion402 D Incomplete penetration5011 F Undercut, continuos5012 F Undercut, intermittent5013 - Root notch502 - Excessive weld reinforcement

(butt weld)503 - Excessive convexity (fillet weld)504 - Excessive root reinforcement507 - Misalignment of edges510 - Burn-through511 - Incompletely filled groove515 - Root concavity517 - Poor restart

Table 2.3.7-bQuality of Welded Joints

Minimum permissible grade

Structure CategoryAccording toTable 2.3.7-b

According to HRNEN ISO 5817 orHRN EN ISO

10042Hull 3* CHeatexchangersand pressurevessels

IIIIII

233

BCC

Pipings IIIIII

233

BCC

Machineryand gears

On agreement with the Register

*) Depending on the loads applied to welded joints, theRegister may increase or decrease the required grade,stated in the Table.

Table 2.3.7-cEvaluation ratings

Findings Rating Remark

Weld free from detectable defects 1 = excellent -

Minor defects such as isolated pores andsmall slag inclusions which do not reducethe strength of the welded joints

2 = serviceable -

Acceptable defects such as small rows orclusters of pores, small slag lines, shortroot defects and minor lack of fusion

3 = leave as isRepair not recommended for componentssubject to normal stresses. Short rootdefects and minor lack of fusion may beleft only at non-critical points.

Defects to be avoided, e.g. coarse slag in-clusions, pore accumulations, root defects,lack of fusion, small isolated cracks

4 = to be repaired Repair required

Extensive major defects and cracks 5 = to be replaced Replacement of the sections of weld or ofthe entire welded joints required


2009

2.3.8 Extension of the scope of inspection

If the percentage of defects exceeds that of theprescribed, the Register may extend the scope of inspection.

2.3.9 Repairs, re-inspection

Welded joints shall be repaired in agreementwith the Register. Repaired welds shall be re-inspected andshall be specially indicated in the inspection report and on theradiographs ( R= repair).

2.3.10 Visual examination

Visual examination shall cover ( using the opti-cal appliances, where necessary ) as follows:

− completeness; (if welded all required)− dimensional accuracy;− compliance with the specified weld shape;− presence of inadmissible external defects.The dimensional accuracy shall be checked by

means of suitable measuring instruments, on a random sam-pling basis.

When checking the shape and external defects,special attention shall be paid to:

− weld reinforcement or depression;− weld edge angle;− misalignment of edges,− undercuts;− visible porosity and slag inclusions;− fused weld spatter;− arc strikes on the base material;− concave root surface and incomplete root

fusion;− cracks;− unequal side lengths (with fillet welds).

Tolerances are referred to in 2.3.7.Repair of visible cracks is mandatory.

2.3.11 Radiographic examination

X-ray sources shall be used for the radiographicinspection. In particular cases, in agreement with theRegister, gamma-ray sources may be used. Radiographicparameters prescribed in the HRN EN 1435 for the testcategory A shall be preferably used in shipbuilding and fortest category B, in steam boiler, pressure vessel and pipelinemanufacture. In applying several films to inspect the welds(e.g. for circumferential radiographs) they shall overlap at theends. When pipes are inspected having an outside diameter≤ 90 mm, elliptical radiograph may be made.

Each radiograph shall include one imagequality indicator in accordance with HRN EN 462-1 (wireindicator). Each radiograph shall also include the appropriatesymbols (marks) to uniformly indicate its relation to thestructure as well as to the test report. The inspection reportshall cover the following information together withexplanatory sketches (where necessary):

− work number, component, inspectionschedule number, inspection position;

− material, welding process;− workpiece or weld thickness;− date and time of test;− radiation source;− tube voltage during inspection;− radiographic parameters (to HRN EN 1435)

position of wire indicator;− type of film;− test category, image quality index;− symbol denoting defect, to Table 2.3.7-a.The initial evaluation shall be usually carried

out by the quality control department and the ultimateevaluation on the basis of the radiographs and relevant re-ports shall be carried out by the Surveyor to the Register.

2.3.12 Ultrasonic examination

The test appliances, probes and other accesso-ries shall be in accordance with relevant standards (e.g. HRNEN 27963 or HRN EN 1714). Calibration of the instrumentsprior to inspection shall be performed on the calibrationblocks to HRN EN 27963.

Depending on the required echo sensitivity(height) setting of sensitivity shall be done to DIN 54127,Part 1.

The weld test surface shall be smooth and freefrom impurities, rust and spatter on both sides. Paint andprotection coatings which are not likely to affect the test re-sults need not be removed prior to testing. The testing proc-ess shall depend on the weld geometry and the possible ori-entation of defects. The Table 2.3.12 shows the limit values(number and length of defects) of the longitudinal and trans-versal defects above which the repair shall be carried out.

Continuous echo indication which point at thesystematic weld defects (e.g. root defects due to incompletepenetration or rows of pores), requires the repair even if therepair limit values are not attained (to Table 2.3.12). Echo in-dications which point at the presence of cracks necessitaterepairs anyway. Echo indication due to transverse defects callfor the repair in any case unless they are below the repairlimit values stated in Table 2.3.12. If the evaluation of echoindications gives rise to doubt regarding the need for repairs,the evaluation may be complemented with radiographic in-spection as to obtain accurate assessment.

Inspection report (prescribed in HRN EN 1714)shall be prepared for all testing and shall contain essential in-formation. Where echo indications below repair limit valuesreferred to in Table 2.3.12. are also stated in the report, eachdefect thus identified shall be marked (e.g. leave as it is or tobe repaired: a - acceptable, or b - not acceptable).


2009

Table 2.3.12Repair limit values (number and length of defects)

Longitudinal defects Transverse defectsCategory to

HRN EN ISO5817 and HRNEN ISO 10042

Wall thicknessof the weld

[mm]

Number ofdefects per

meterof the weld

Registrationlength

[mm]

Max. permissibleexcess of echo

high[dB]

Number ofdefects per mof the weld

Registrationlength

[mm]

Max. permissibleexcess of echo

high[dB]

10...1510 and3 and

1

102010

6612

3 10 6

> 15...2010 and3 and

1

102010

6612

3 10 6

> 20...4010 and3 and

1

102510

6612

3 10 6

B

> 4010 and3 and

1

103010

6612

3 10 6

10...2010 and3 and

1

153010

6612

3 10 6

> 20...4010 and3 and

1

154010

6612

3 10 6C

> 4010 and3 and

1

155010

6612

3 10 6

10...2010 i3 i1

155010

6612

5 10 6

> 20...4010 and3 and

1

150010

6612

5 10 6D

> 4010 and3 and

1

205010

6612

5 10 6

2.3.13 Magnetic particle testing

The test appliances and media shall complywith the requirements of the relevant standards (e.g. HRN EN1290; HRN EN 1291). The magnetising equipment shall beprovided with measuring devices which indicate the magnet-ising current strength. Magnetic particles (black or fluores-cent) in a suitable suspension under influence of magneticcurrent, shall accumulate at the limits of defects. The choiceof the magnetisation method depend on the geometry of thecomponent and shall be agreed with the Register. The testingsurface shall be free from loose scale, rust, weld spatter andother impurities. Notches, indentations, scratches and edgeswhich may cause false indications shall be removed prior toinspection. Thin, dry layers (e.g. coat thickness up to 20 µ

mm) shall not be removed if they do not impede the inspec-tion. Every spot of accumulation of magnetic particles whichis not due to false indication shall be stated in testing-reportand shall be repaired. In the case of small cracks, this may bedone by grinding. Larger cracks shall be machined out andrepair-welded.

Inspection report shall cover the following de-tails:

− details on the component, or a weld tested;− data on magnetisation ;− magnetizing equipment data;− test media;− test results;− place and time of testing, testing body and

person performing the test.


2009

2.3.14 Penetrant testing

Coloured or fluorescent penetrants may be usedas penetrant media. Penetrant removers and developers shallbe compatible with the penetrant used. The testing surfaceshall be completely free from scale, rust, greases, oils andpaints before the penetrant is applied as to enable penetrationinto any surface defect. Also care shall be taken to ensure thatdefects are not mechanically sealed by preliminary cleaning.The testing surface shall be dry and the temperature of theworkpiece shall be between 5o and 50oC. The penetrationtime shall be chosen in accordance with the manufacturersinstructions but shall not be less than 15 minutes for work-piece temperatures of 15oC and over, or less than 30 minuteswhere the temperature is below 15oC. After this procedurethe surplus penetrant shall be completely wiped off. The de-veloper shall be applied evenly and thinly as possible on thedried surface. The developing time shall be the same as thatof penetration.

Visual inspection shall be carried out upon theexpiry of application time of the developer. The test resultsshall be assessed analogously as those in 2.3.13.

Test report shall cover the following:− details on the component or a weld joint;− test media (type, brand name);− description of the test procedure;− test results;− place and time of testing, testing body and

person performing the test.

2.4 MECHANICAL AND TECHNO-LOGICAL TESTS

2.4.1 General

This Chapter shall prescribe the usual shapes oftest specimens as well as the mechanical and technologicaltesting of welds.

2.4.2 Preparation of specimens and testing

All tests shall be carried out by trained person-nel using calibrated testing machines. The testing machinesshall be kept in good working condition and shall be calibrateat regular intervals by an independent inspection authority.

Before being cut out of test piece, specimensshall be marked by a Surveyor. They shall be, as a rule , me-chanically cut and machined to the required dimensions.When cut by a thermal process, test specimens shall be wideenough to ensure that the heat-affected zone can be com-pletely machined off.

All mechanical and technological tests shall beperformed in the presence of the Surveyor, unless otherwisestipulated or agreed.

Specimen thickness a≤ 5 > 5

to≤ 10

> 10to≤ 20

> 20to≤ 30

Specimen thickness b 15 20 25 30Gauge length Lc Weld width

bs + 80 mm1)

Head width B ≥ 25 ≥ 30 ≥ 35 ≥ 40Total length Lt Lc + 180Radius r ≥ 35

Note:1) bs measured on the side of the weld with the greater

seam width.

Figure 2.4.2-1Flat tensile specimen (welded joint)

2.4.3 Tensile tests

a) Flat tensile specimen (HRN EN 895)This test is carried out to determine thetensile strength, position and type offracture and elongation of specimen(where required). The dimensions of flatspecimen are shown in Fig. 2.4.2-1. Thethickness "a" of the specimen is usuallythe wall thickness. If the thickness isgrater than 30 mm and less than 50 mm,the specimen may be machined down to athickness of 30 mm. With thickness of≥ 50 mm, two or more specimens shall beprepared.

b) Round tensile specimens (HRN EN 876)This test is carried out to determine thetensile strength, yield strength σ02, reduc-tion in area and elongation of the weldmetal. Where necessary, in the case ofhigh-temperature steels, yield strength σ02at elevated temperatures shall also be de-termined. Wherever possible, the testshall be performed on a 10 mm roundtensile specimen with longitudinal axis isin the direction of the seam.


2009

Figure 2.4.2-2Round tensile specimen (weld metal)

Figure 2.4.2-3Location of specimen in weld metal

If the dimensions of weld do not permit thepreparation of a 10 mm diameter tensile specimen, specimenswith a smaller diameter may be used provided that the gaugelength is 5 times and the parallel length at least 6 times thediameter of the specimen.

2.4.4 Bend testa) Transverse bend test (HRN EN 910)

This test is carried out to determine theductility of the welded joint across theseam. For this purpose the specimen isbent over a mandrel or prescribed diame-ter and the angle achieved, with the modi-fication of the bending elongation on thetension side of the specimen. The speci-men dimensions are shown inFig. 2.4.4-1.

The thickness of the specimen is normally thewall thickness. If the thickness is greater than 30 mm, thespecimen may be machined down on one side to thickness of30 mm. On the tension side during the test, the edges may berounded to the specified radius r. Depending on the test pro-cedure, the specimens shall be mounted in the testing deviceso that either the upper and lower side of the weld is in ten-sion during the test. The test rig for bend test is shown in Fig.2.4.4.-2.

Specimen thickness aDimensions≤ 11 > 11 ≤ 14 > 14 ≤ 17 > 17 ≤ 22 > 22 ≤ 27 > 27 ≤ 35

Specimen width b 20 30 30 ≥ 1,5 a ≥ 1,5 a ≥ 1,5 a

3ad≤ 250 250 250 250 300 380

4ad= 250 250 250 290 350 430

Specimenlength Lt

where

6ad= 250 250 290 350 430 530

Radius r, side in tension ≤ 2 ≤ 2 ≤ 2 ≤ 3 ≤ 3 ≤ 3

Figure 2.4.4-1Dimensions of the transverse bend test specimen

Section A - B


2009

Figure 2.4.4-2Test rig

If the elongation values of the base material andthe weld metal differ greatly (e.g. in the case of welded alu-minium test pieces), the test rig shown in Fig. 2.4.4-3 may beused in order to prevent premature incipient cracking of thespecimen.

Figure 2.4.4-3Special test rig ("wrap round")

b) Side bend test (HRN EN 910)This test is carried out to determine theductility of the welded joint in the cross-sectional plane. For this purpose thespecimen is bent over a mandrel of speci-fied diameter and the bending angle at-tained is measured. The shape and dimen-sions of the specimen is shown in Fig.2.4.4.-4 and Table 2.4.4-4.

Figure 2.4.4-4Side bend test specimen

Table 2.4.4-4Dimensions for side bend test

Ratio d/aDimensions≤ 3 4 6

Specimen thickness a 10

Specimen width b Product thickness

Radius r, tension side ≤ 1 ( ≤ 3)1)

Specimen length, Lt 150 170 200

Notes:1) The radius in brackets applies to specimens where the

weld reinforcements are not machined off.

Testing specimen are to be mounted in thetesting device shown in Fig. 2.4.4-3 in such a way that thetesting load acts in the direction of the original longitudinalaxis of the seam. On the side of in tension during the test, thelong edges of the specimen may be rounded to the specifiedradius.

If the welded clad plates are subjected to sidebend testing, the form of specimen shown in Fig. 2.4.4.-5shall be used. The dimensions are stated in the Table 2.4.4.-4.

Figure 2.4.4-5Form of clad side bend test specimen


2009

c) Bend test specimen from pipe jointsIf the bend test specimens are taken fromthe circumferential pipe welds, the sidefaces shall be parallel. If necessary, theside of the specimen which is in compres-sion shall be machined in accordancewith Fig. 2.4.4-6

side in compression

Figure 2.4.4-6Cross section of bend test specimen (cut out from a pipe)

2.4.5 Impact test

(HRN EN 875)The purpose of this test is to determine impact

energy in joules ( J ). ISO V-notched specimens shall beused; their location in the test piece shall be such that thelongitudinal axis of the specimen is perpendicular to the di-rection of the seam while the notch axis is at right angles tothe surface of the product (Fig. 2.4.5-1).

Depending on the test specification, the notchshall be located either at the centre of the weld metal, on thefusion line or in the heat-affected zone of the base metal at aspecified distance from the fusion line (Fig. 2.4.5-1). The testshall be carried out at the specified test temperature. Wherethe product thickness is < 10 mm, specimens measuring 7,5 x10 mm and 5 x 10 mm shall be used wherever possible. Forthese specimens the required impact energy in relation to thestandard 10 x 10 mm test specimen shall be as indicated inthe Table below 2.4.5-1.

Notch located on fusion line(Ks)

Notch located at centre ofweld metal (KM)

Notch located in heat-affected zone (Ku)

Figure 2.4.5-1Locations of specimens for notched bar impact testing

Table 2.4.5-1Impact energy for the specimen of reduced section

Cross section of specimen(mm)

Mean impact energy value re-quired, E

Standard specimen10 x 10

E

Specimen of reducedsection10 x 7,510 x 5

5/6 E2/3 E

Where specimens are taken from only one sideof a double V-welds, they shall be taken from the side of theseam which was welded last. The specimens shall be ma-chined down to the dimensions shown in Fig. 2.4.5-2, and thecompliance with the specified tolerances shall be verified.

Dimensions Nominal size Tolerance

Length 55 mm ± 0,60 mm

Width 10 mm ± 0,11 mm

Height 10 mm ± 0,06 mm

Notch angle 45o ± 2o

Height from the notch bottom 8 mm ± 0,06 mm

Notch radius 0,25 mm ± 0,025 mm

Distance between centre ofnotch and ends of specimen 27,5 mm ± 0,42 mm

Angle between plane ofsymmetry of notch and lon-gitudinal axis of specimen

90o ± 2o

Angle between adjacent lon-gitudinal specimen surfaces 90o ± 2o

Figure 2.4.5-2ISO V-notch specimen dimensions

2.4.6 Hardness tests of welds

(HRN EN 1043-1)The hardness of welded joints shall be meas-

ured by Vickers hardness tester using the load of 49 or 98 N(HV 5 or HV 10) on polished or etched specimens whose testface is perpendicular to the weld axis. The choice of test loaddepends on the test material grade. Positions of impressionsmade by hardness tester are shown in Fig. 2.4.6-1.


2009

hO = distance from the surfacehG = distance from the bottomhW = distance of the impression location from root to

surfaceFigure 2.4.6-1

Hardness testing - impression locationThe impressions made by the hardness tester

shall be close enough to give an accurate hardness curve(Fig. 2.4.6-2)

Vickers hardness sym-bol

Distance between hardness testimpressions l (mm)

HV 5 0.7

HV 10 1

Figure 2.4.6-2Location of hardness test impressions in the

heat-affected zone

2.4.7 Metallographic examinations

The macro and micro -structure shall be evalu-ated by reference to polished sections.

Unless otherwise agreed, the polished surfaceof the sections shall be perpendicular to the weld axis(Fig. 2.4.6-1). The metallographic specimens shall be of suchdimensions (sizes) and so ground and etched that they revealnature and structure of the crystallisation of the weld metaland the heat-affected zone as well as the structure of the basematerial and in case of micrographs, the grain boundaries inthe area under examination. The report on testing shall con-tain one photo of a macro metallographic specimen and three

photos of micro metallographic specimens ( weld metal, fu-sion lines and heat-affected zone ), magnified at least 100:1.

2.4.8 Inspection report

Inspection report shall cover the following:− Type of inspection or test (e.g. welding

procedure test);− Dimensions and numbers of test pieces;− Base material;− Weld preparation;− Welding processes and positions;− Welding (and auxiliary) consumables/ ma-

terials (dimensions, quality);− Welding current source;− Welding current strength and voltage;− Post-weld heat treatment;− Test methods and shapes of specimens;− Test results.The report shall be submitted to the Surveyor to

the Register (at least two copies).The Surveyor shall confirm the correctness of

the results obtained by his stamp and signature.


2009

3 WELDING IN THE VARIOUSFIELDS OF APPLICATION

3.1 WELDING OF HULL STRUC-TURES

3.1.1 General

The requirements of this Chapter apply to allwelding works carried out on the ships hull, superstructureand deckhouses including the components forming part of theships structure (e.g. hatch covers, masts, deck cranes etc.) re-ferred to in the Chapter 1.1.1 of these Rules.

3.1.2 Approval of shipyards and weldingshops

All shipyards and welding shops intended toperform works on structures covered by these Rules undersupervision of the Register, shall comply with the require-ments referred to in the Chapter 1.2 of these Rules and shallbe approved by the Register. Application for approval shallbe submitted to the Register before starting the welding andshall contain information and documentation prescribed inthe Chapter 1.2 of these Rules.

3.1.3 Quality control

Shipyards and welding shops shall ensureregular quality control during the manufacture. The weldingworks shall be in compliance with these Rules, approvedworkshop documentation and good welding practice.

3.1.4 Materials, weldability

Welded structures shall be fabricated only us-ing base materials of proven weldability.

The welding of hull structural steels of qualitygrades A, B, D and E tested by the Register may be per-formed without preliminary verification. Welding of hullstructural steels of quality grades A32, A36, A40, D32, D36,D40, E36, E40, F32, F36 and F40, tested by the Registershall be verified before welding procedure. High-strengthsteels, fine-grained structural steels, steels for low tempera-tures and stainless steels shall be verified in combination withwelding process and welding consumables.

3.1.5 Welding consumables

All the welding consumables used for weldingthe structures referred to in 3.1.1 shall be approved by theRegister in compliance with 1.5 of these Rules. Choice andgrades of welding consumables for hull structural steels shallbe in compliance with the Table 3.1.5.

The welding consumables may only be used inthe approved welding positions and in accordance with therequirements and recommendations of the manufacturer.

Table 3.1.5Choice of welding consumables for hull structural steels

Hull structural steel gradesGrade of weldingconsumables A B D E A32/36 D32/36 E32/36 F32/36 A40 D40 E40 F40

1, 1S, 1T, 1M, 1TM, 1V X1YS, 1YT, 1YM, 1YTM,1YV

X 1) X2)3)

2, 2S, 2T, 2M, 2TM, 2V X X X2Y, 2YS, 2YT, 2YM,2YTM, 2YV X X X X3) X3)

2Y40, 2Y40S, 2Y40T,2Y40M, 2Y40TM, 2Y40V

1) 1) 1) X3) X3) X3) X3)

3, 3S, 3T, 3M, 3TM, 3V X X X X3Y, 3S, 3YT, 3YM, 3YTM,3YV X X X X X3) X3) X3)

3Y40, 3Y40S, 3Y40T,3Y40M, 3Y40TM, 3Y40V

1) 1) 1) 1) X3) X3) X3) X3) X3) X3)

4Y, 4YS, 4YT, 4YM,4YTM, 4YV X X X X X3) X3) X3) X3)

4Y40, 4Y40S, 4Y40T,4Y40M, 4Y40TM, 4Y40V

1) 1) 1) 1) X3) X3) X3) X3) X3) X3) X3) X3)

Notes:1) Not to be used, if possible. Otherwise, only with the approval of the Register.2) For A32/36 welding consumables of quality grade 1Y may be used only when welding thinner plates (up to 25 mm).3) For plates over 50 to 70 mm thick, welding consumables and materials with one quality grade higher shall be used and for those

over 70 and up to 100 mm thick those with two quality grades higher shall be used in each case in compliance with the higherbase material requirements.


2009

Table 3.1.6Requirements applicable to hull structural steels

Impact energy1)

(J)Grade(base material)

Yield strength(yield metal)

[N/mm2]

Tensilestrength

[N/mm2]

Elongation(weld metalLo = 5 do)

[%]manual andsemi-autom.

automatic Temp.[oC]

Bending angle(D = 4t)

A/B + 20D 0E

305 400 22 47 34- 20

180o

A32 + 20D32 0E32 - 20F32

335 440 22 47 34

- 40

180o

A36 + 20D36 0E36 - 20F36

375 490 22 47 34

- 40

180o

A40 + 20D40 0E40 - 20F40

400 510 22 47 34

- 40

180o

Note:1) Notch on ISO-V notch test piece is in the middle of the weld metal. Average value of three test pieces as well as individual

value shall not be less than 33J i.e. 24 J.

3.1.6 Welding processes and welding proce-dure tests

Welding processes shall, regularly, be tested bythe Register in compliance with 1.4.

The requirements to which the welded joints ofthe hull structural steels shall be complied with are shown inthe Table 3.1.6.

3.1.7 Welding of clad steels

Edge preparation of the welded joint shall be inaccordance with the standards or drawings approved by theRegister. Edges shall be machined or ground. The edges ofparts to be assembled shall fit each other closely and shall notbe out of alignment on the clad surface. Corrosion resistanceand the thickness of the clad side shall be equal to that of theclad material. The chemical composition of weld metal, ex-cept of that in the root size, shall correspond to that of cladmaterial.

As a rule, the plate surface opposite to the cladsurface shall be welded first and than on the clad side. Thenon clad side shall be welded so that no melting of the clad-ding layer is likely to occur. Prior to welding on the clad side,the root of the unalloyed weld shall be cleaned to soundmetal by machining or grinding and given a concave shape.For a back sealing run the same welding consumables shallbe used as for welding the cladding layer. The cladding layershall be welded so as to reduce the interpenetration of alloyedand unalloyed materials to a minimum. For welding the clad-ding layer, welding electrodes and wires of the smallest pos-sible diameter shall be used.

The welding shall be carried out at the lowestpossible rate of energy input. The weld on the clad face shallbe made at least two layers. Transverse weawing of the elec-trode in welding the cladding layer shall not be permitted.Where the top layer width is such that it should be depositedin several runs, the last run shall be made along the middle ofthe weld. When the two-side welding of clad steel pipes isnot possible, the entire joint shall be welded by welding con-sumables appropriate for the cladding material.

Thin steel plates shall be welded by weldingconsumables appropriate for the cladding material.

3.1.8 Welding of castings and forgings

Steel castings and forgings regardless of theambient temperature, shall be pre-heated or subjected to othertechnological measures prior to welding, to ensure the re-quired quality of welding. The defects in the new steel forg-ings and castings may be rectified by welding only in casethe weldability of the steel concerned has been previouslychecked with due regard to the special conditions of the castor forged element.

The repair shall be carried out prior to the finalheat treatment. Welding after the final heat treatment shall bepermitted only exceptionally. The repair of castings andforgings by welding shall not be permitted if the same defectsappear repeatedly. The welding of defects in castings shall becarried out after sprues and heads have been removed and thecastings thoroughly cleaned of sand, scale and inclusions.The surfaces to be repaired shall be ground to sound metal soas to ensure the full penetration throughout the welded area.The surfaces to be welded shall be horizontal and shall bewithout sharp corners.


2009

The normal strength hull structural steels do notrequire preheating. However, with large cross sections (e.g.steel castings or forgings where unfavourable conditions re-garding design or welding technology apply, uniform pre-liminary heating of the areas surrounding the welded joints isadvisable. Higher strength hull structural steels shall gener-ally be preheated if the temperature of the workpiece is lessthan 5oC.

If it is higher than this, preheating shall be car-ried out upwards of a specific threshold wall thickness withrespect to other factors referred to in Table 3.1.9.

For an average carbon equivalent and an aver-age heat input (energy applied per unit length of weld) thewall thickness t and preheating temperature T shown in Fig.3.1.9 may be used as a guide.

Table 3.1.9Influence of various factors on the preheating temperature

Lower preheating temperature Factors influencing preheating Raised preheating temperatureLow-alloyed steels Chemical composition (hardening properties) of the base

material, e.g. expressed by the carbon equivalent.higher-alloyed steels

small Thickness of workpiece (heat dissipation, rigidity,state of residual stresses)

large

Butt welded joints (uniting twoplates) thick (multiplepass) seam

Type of joint, shape and dimensions of weld, heat input,heat dissipation

T-joints(uniting three plates), thin(single-pass) seams

high Ambient temperature, temperature of workpiece (heatdissipation)

low

high Heat input during welding (energy applied per unitlength of weld)

low

low Hydrogen content of weld metal (type and re-baking ofwelding consumables and auxiliary materials)

high

3.1.9 Preheating

Necessity and degree of preheating shall be inaccordance with Table 3.1.9.

Figure 3.1.9Wall thickness and preheating temperatures for higher-

strength hull structural steels (guide values)

Preheating shall be applied uniformly through-out the thickness of the plate and to a distance four times theplate thickness, but not more than 100 mm on both sides ofthe weld. Localized preheating shall not be permitted. Thepreheating temperature shall be kept constant throughout theduration of the welding work.

3.1.10 Welding of aluminium and its alloys

The welding operations on aluminium and onits alloys referred to in 1.1.1. shall be performed by certifiedwelders approved by the Register.

Welding consumables and the welding proce-dure applied shall be approved by the Register and the weld-ers shall be qualified. The welding operations shall be so per-formed as to ensure a good quality joint, its maximumstrength, chemical composition similar to that of the basemetal and the sufficient corrosion resistance. Edge prepara-tion prior to welding shall be carried out in compliance withthe standards or technical documentation approved by theRegister. The joints shall be arranged so as to make it possi-ble to weld them in the most convenient position. Intermittentfillet welds shall not be permitted. Where scalloped con-structions are concerned, the welding shall be performedround the ends of all lugs.

The reinforcement of edges shall be removedonly if stated in the drawings. Just before welding, the jointedges of aluminium and aluminium shall be degreased andcleaned from dirt by steel wire brush. In case of multirunwelding, each run of deposit shall be brushed before the nextrun is applied. The welding of wires and rods of aluminiumand its alloys shall be degreased, cleaned from dirt and oxidefilm. The welding of aluminium alloys by means of remain-ing or removable backing shall be permitted. The removablebackings may be made of structural steel, copper or stainlesssteel. The backings that are not removed shall be made of al-loy of the same kind as that used for the parts to be welded.

In case of the double-sided welding prior towelding of the reverse side, the root of the weld shall becleaned to the sound metal. In way of riveted structures madeof aluminium alloys, all major welding operations shall becompleted before riveting.

non-hydrogen controlled weld metal

low-hydrogen weld metal

TM steel, low-hydrogen weld metal


2009

Welded joints shall have no machining orpainting whatsoever when submitted for acceptance. Appli-cation of non-destructive methods other than radiographyshall be specially considered by the Register.

The requirements to which the welded joints ofaluminium alloys shall be complied with are shown in Table3.1.10.

Table 3.1.10Requirements applicable to aluminium alloys

Base material Welded joints1)

Numerical Chemical symbol Tensile strength[N/mm2]

Bending angle2)

5754 Al Mg 3 1905086 Al Mg 4 2405083 Al Mg 4,5 Mn 0,7 2755383 Al Mg 4,5 Mn 0,7 mod 290

6005A Al Si Mg (A) 1656061 Al Mg Si 1 Cu 155

180o

6082 Al Si 1 Mg Mn 1701) Using a weld consumable of a quality grade in accordance with 1.5.8.12) Bending mandrel diameter to be selected in accordance with 1.5.8.3

3.1.11 Inspection of welding and welded joints

3.1.11.1 Inspection of welding operations and weldedjoints during manufacture and repairs of structures and com-ponents shall be performed through the inspection authoritiesof the working organizations. The inspection results shall beregistered by the working organization and filed until thecommissioning of the item and shall be submitted to the Sur-veyor to the Register on his request, for supervision. Whennecessary, the working organization shall perform the fol-lowing tests of welded joints:

1. tightness test;2. strength test;3. non-destructive testing.The method of these testing shall comply with

the requirements of the relevant Parts of the Rules, or withstandards approved by the Register. The welds shall be ex-amined by the following non-destructive methods:

− visual inspection;− radiographic examination;− ultrasonic examination;− magnetic particle examination;− liquid penetrant examination.

Other methods may be applied on agreementwith the Register. Personnel performing the non-destructivetesting methods shall be specially qualified and their qualifi-cations shall be confirmed by the competent authorities (inaccordance with the recommendations of the Croatian Asso-ciation for Non-destructive testing).

At request of the Surveyor, the additional num-ber of welded joints may be examined.

3.1.11.2 The number of radiographs at radiographic ex-amination or controlled weld lengths at the ultrasonic exami-nation of welded joints in hull structures referred to in3.1.11.3 shall be determined by the formula:

,,

Ln50100 ⋅

⋅=

η

where:n = number of the controlled weld

lengths,L = total length of welded joints, m;0,5 = controlled weld length, m;η = ratio of the controlled weld lengths

and total weld lengths in percentage(in accordance with Fig. 3.1.11.3).

Where the controlled weld length is less than0,5 m, the real value of controlled weld length shall be sub-stituted in the formula. The working organization shall de-termine the percentage of weld defects, once every sixmonths at least, on the basis of the examination results andshall report these data to the Register. The percentage of de-fects K shall be determined by the formula:

LK 100⋅=l

,

where:l = total length of welds found defective

during the examination, m.L = total weld length controlled, mIf the percentage of defects is more than 5 per-

cent, Register reserves the right to require, for every percentof rejected welds exceeding 5 percent, an increase in thenumber of the controlled weld lengths by 10 percent. Thenumber of controlled weld lengths may be reduced if theRegister finds the general standard of welding operationssatisfactory. The sections of welded joints where the majordefects are found shall be cut and re-welded. Rectified sec-tions shall be re-tested and the testing results reported to theRegister.

3.1.11.3 Number of welded joints to be subjected to anon-destructive examination shall comply with the approvedscheme and their positions on the relevant object shall be de-termined by the manufacturers quality control in agreementwith the Register after welding operations are complied with.In addition to the number of controlled weld lengths in ac-cordance with the diagram 3.1.11.3 and Table 3.1.11.3, thefollowing welded joints shall be controlled:


2009

Table 3.1.11.3

Location of weldedjoints to be examined

Percentage of the totalnumber of controlled

weld lengths

Note

Strength deck(deck plating) 20 See note

Bottom plating,including bilge strake 20 See note

Side plating 10 See noteHatch coamings andsecond deck girders 20

Hatch coamings andstrength deck girders 10

Watertight bulkheadplating 10

Stern frame 5 See3.1.11.3.5

Double bottom platingand other parts of hullstructure subjected tohigh loads

5

Note:2/3 of the total number of controlled weld lengths shallbe of butt transverse welds and 1/3 of butt longitudinalwelds.

.1 those lying amidship (according to theRules, Part 2 - Hull) but not closer than0,4 L on the longitudinal and transversalseams of the strength and second deckplating at hatchway corners at points ad-joining the coaming, but not less than onecontrolled weld length per seam;

.2 butts on thickened stringer plates of theupper deck at the ends of superstructures,

but not less than one controlled weldlength per butt,

.3 butts of the sheerstrake lying amidship,but not less than one controlled weldlength per butt,

.4 mounted butt weld joints of hull memberslying amidships at least;− one controlled weld length for every 5

butts of longitudinal framing mem-bers,

− one controlled weld length for 10butts of transverse framing members.

5. joints of stern, sternframe and ice belt ofship with 1 AS, 1 A, 1 B, 1C and 1D icecategory and icebreakers, the number ofweld length shall be agreed with the Reg-ister.

6. T-joints between deck stringer plate andsheerstrake, examination is required for20 percent of the length of welds,

.7 when welding into a rigid contour is car-ried out, the welded joints shall be con-trolled along whole length.

Besides, the welded joints of all structures ex-posed to heavy loads such as cargo masts and posts, cantile-ver beams etc. shall be also subject to control. When thequality grade of weld is not achieved, two additional lengthsof the same weld shall be controlled at another two places.Should these lengths reveal any defects, further control shallbe undertaken along the same weld in both directions untilsatisfactory results are obtained.

Where conversion or repair is concerned, thenumber of controlled weld lengths shall be determined by theRegister depending on the extent of the welding operations aswell as on the class of structure.

3.1.11.4 The evaluation category of welded joints ofships hull is specified in 2.3.7 of the Rules.

Diagram of the part of welded joints to be controlled

The total length of welded joints, L, mFigure 3.1.11.3


2009

3.2 WELDING OF STEAM BOILERSAND PRESSURE VESSELS

3.2.1 General

The requirements of this Chapter apply to thewelding of steam boilers and pressure vessels manufacturedfrom base metal and welding consumables which complywith the requirements of the present part of the Rules as wellas with those of the Part 25 - Metallic Materials.

3.2.2 Execution of welded joints

Welded joints of boilers shall be so marked asto make it possible to identify the operator (welder) who hasperformed the welding. Longitudinal and transversal welds ofboiler shells shall be performed by full penetration welding,except where the welding coefficient of the welded joint inaccordance with the Rules, Part 10 - Boilers, Heat Exchang-ers and Pressure Vessels, paragraph 2.1.5.1, is adopted to be≤ 0,8. Longitudinal and transversal joints of boiler shells aswell as those of pressure vessels shall be butt welded. If buttwelding cannot be applied, the type of weld and the weldingprocedure shall be specially considered by the Register ineach particular case. Any welding of fastenings, catches andsimilar components for erecting purposes on the boiler shell,shall be considered by the Register in each particular case.When the openings in boilers are closed up by means ofplugs fixed by welding the requirements of standards ap-proved by the Register shall be complied with.

Worn-out shell plates of boilers and pressurevessels can be repaired by building-up only on agreementwith the Register.

The built-up area shall not exceed 500 cm2 andits depth shall not be over 30 per cent of the plate thickness.If these conditions cannot be fulfilled, the defect area shall berepaired by inserting a new plate.

3.2.3 Heat treatment

Heat treatment of boilers and pressure vesselsshall be carried out in compliance with the standards or in-formation of the base material manufacturer. Welded jointswhich are oversized or which are of special design and can-not be subjected to stress relief heat treatment as a whole ,shall be heat treated partly in agreement with the Register.Such heat treatment shall be performed by uniform heatingalong the welded joint (see 2.2.3.2). Oxyacetylene heattreatment shall not be permitted to be applied locally.

3.2.4 Inspection of welded joints

The mechanical properties and macrostructureof the welded joints when manufacturing boilers, heat ex-changers and pressure vessels classified in accordance withthe Rules, Part 10 - Boilers, Heat Exchangers and PressureVessels, paragraph 1.3.1.2., shall be examined within thefollowing extent:

1. Boilers and pressure vessels of class IIn case of the individual and serial pro-duction, each longitudinal joint for each

plate thickness shall be tested. Transver-sal joint shall be tested only in case thewelding procedure is substantially differ-ent from that applied to the longitudinaljoint or when a pressure vessel is manu-factured with a transverse joint only.In case of serial production of pressurevessels which are welded solely applyinga transverse joint, one test assembly shallbe prepared for each 30 m of joint length.Welded joint on a separately prepared testassembly shall be as equivalent as possi-ble to the transverse joint on the vessel.

2. Boilers and pressure vessels of class IIIn case of the individual production, eachlongitudinal joint for each plate thicknessshall be tested.In case of serial production, one test as-sembly shall be prepared for each 40 m ofthe longitudinal and transverse jointlength.

3. Pressure vessels of class IIIIn case of individual production, one testassembly shall be prepared and in serialproduction for each 40 m of the longitu-dinal and transversal joint length, one testassembly shall be prepared.

Test assemblies shall be attached to the longi-tudinal joint of a boiler or pressure vessel so that the test platejoint to be welded is a continuation of the joint of the relevantpart. The test assembly shall be manufactured from the sameplate as that of the boiler shell or the relevant pressure vessel,and the welding procedure shall be the same as employed inthe welding of the boiler or pressure vessel joint. Dimensionsof test assembly shall be sufficient to enable the preparing oftest pieces as well as the re-tests. Prior to heat treatment, testassembly shall be straightened. For that purpose, it may beheated to the temperature which is lower than that for heattreatment. Test assemblies shall be heat treated simultane-ously in the same furnace integral with the items to whichthey belong. They are separated from the boiler shell afterbeing marked by the Register. A test assembly thus preparedshall provide:

Class I− one transverse tensile test specimen;− two transverse bend test specimens (one

with the face of the weld in tension, theother with the root of the weld in tension);

− three impact test specimens.The longitudinal axis of the test specimen shall

be perpendicular to the weld and shall run through the middleof the plate parallel with its surface. The notch in the testspecimen shall be perpendicular to the plate surface nearly tothe middle of the weld.

Class II− one transverse tensile test specimen,− one transverse bend test specimen (the root

of the weld in tension)Class III

− one transverse tensile test specimen.But welded joints of boilers, heat exchangers

and pressure vessels shall be examined by one of the non-destructive methods to the extent referred to in the Table


2009

3.2.4, depending on the class of construction (see 1.3.1.2,Part 10 , Boilers, Heat Exchangers and Pressure Vessels).

Table 3.2.4

Length of tested welds, in per cent,compared to total weld length

ClassLongitudinal

weldsTransverse

weldsI 100 50II 25III On agreement with the Register

The evaluation category of welded joints ofboilers and pressure vessels is specified in 2.3.7 of the Rules.

3.3 WELDING OF PIPELINES

3.3.1 General

The type of welded joints in pipes shall be incompliance with the standards.


The butt welded joints of pipes shall be carriedout with full root penetration. Welding with the removablebacking rings shall be permitted. The use of remaining back-ing rings in butt welds of pipelines shall be permitted onlywhere these rings do not adversely affect the performance.Butt joints of flanges with pipes shall not be carried out withthe remaining backing rings.

Welded joints of pipes shall be heat treated inthe following cases:

1. in pipes of low-alloy steel;2. in case of welding of main steam pipe-

lines at temperature above 350oCThe welded joints of piping depending on the

class indicated in Table 1.2.2, Part 8, Piping, shall be ra-diographed to the extent as stated below:

− Class I piping with the outer diameter ofpipe ≥ 75 mm-100% butt joints;

− Class I piping with the outer diameter ofpipe < 75 mm-10% of butt joints;

− Class II piping with the outer diameter ofpipe ≥ 100 mm -10% of butt joints;

− Class II piping with the outer diameter ofpipe < 100 mm -random check of buttjoints.

When 10% of the butt joints are radiographed,not less than one joint from the total number made by a par-ticular welder shall be controlled.

If required by the Register, the scope of testingmay be extended depending on the type of material or weld-ing procedure.

The Class III piping shall be examined visuallybut the Register may require a random check of welds by ra-diography.

Where, for technical reasons, the Class I and IIpiping cannot be radiographed, the Register may permit othermethods of examination.

In some cases, the ultrasonic examination maybe applied instead of radiography.

For controlling fillet welds of Class I and IIpiping, magnetic particle method may be applied on agree-ment with the Register, depending on the type of material,thickness, outer diameter and on the composition of theworking medium.

In the case of automatic and semi-automaticwelding of pipes, or in the case of serial production of pipes,the scope of radiographic examination may be reduced onagreement with the Register.

The acceptance criteria of welded piping arespecified in 2.3.7 of these Rules.

The repair of pipeline damaged areas by weld-ing in each case shall be subject to special consideration ofthe Register.

3.4 WELDING OF MACHINERYCOMPONENTS

3.4.1 General

The requirements of this Chapter apply to thewelding of the ship machinery structures manufactured frombase materials and welding consumables which comply withthe requirements of the present Part of the Rules as well aswith the Part 25 - Metallic Materials. The structures mayalso be manufactured from the equivalent material if agreedwith the Register.


The welded joints in structures exposed to dy-namic loads shall be welded with full penetration. The transi-tion from the base metal to the weld shall be smooth. Wherethe structure is intended to operate at high temperature or in achemically aggressive medium, these conditions shall betaken into account when selecting the welding consumables.

The application of welding to shafting andcrank shafts shall be specially considered by the Register ineach particular case. Conditions to be fulfilled shall be asfollows:

− 100 per cent of testing shall be carried outby one of non-destructive methods;

− the fatigue strength of welded joint adoptedin calculation shall be guaranteed.

Scope of test welding as well as the test pro-gram prior to welding procedure shall be agreed with theRegister. The application of welding, building-up, metal pul-verisation and other similar methods, when manufacturing orrepairing ship machinery items, may be permitted in case thetesting results are satisfactory in accordance with the methodapproved by the Register and provided that such a methodproves that it may be applied successfully with a particularworkshop.

Ships shafts of carbon steel, up to 0,45 per centcarbon content, which have been worn out or have surface


2009

cracks may be repaired by building-up provided that the ex-tent of wear or the depth of a cracking does not exceed 5 percent of shaft diameter, but not over 15 mm. The building-upshall be performed according to the procedure agreed withthe Register. Welding may be performed in areas of compo-nents where cold forming has been carried out, including theadjoining surfaces over width of 5 times the plate thickness t,provided that the requirements specified in Table 3.4.2 arecomplied with.

The evaluation category of welded piping isspecified in 2.3.7 of the Rules.

Scope of examination of constructions whichare not listed in 3.1 up to 3.4 with non destructive methods,shall be agreed with the Register.

Table 3.4.2Requirements for welding in areas subjected to cold forming

Ratio r/t Elongation, ε[%]

Acceptable plate thickness, t[mm]

≥ 10 < 5 any≥ 3,0 ≤ 14 ≤ 24≥ 2 ≤ 20 ≤ 12≥ 1,5 ≤ 25 ≤ 8≥ 1,0 ≤ 33 ≤8

RULES FOR THE CLASSIFICATION OF SHIPS 73PART 26 - APPENDIX I

2009


APPLICATION FOR APPROVALOF SHIPYARD / WELDING SHOP TO

PERFORM WELDING WORKS IN SHIPBUILDING AND THE MACHINERYCOMPONENTS THEREOF

In accordance with the Rules of the Croatian Register of Shipping, Part 26-Welding,

we Company:

Address:

hereby make application to the CRS for approval together with following documents:

Nature of the approval sought Approval forshipyard/welding shop Extension

1. Application from shipyard/welding shop

2. Description of shipyard/welding shop in accordance with Appendix II 1)

3. "Range of application" appendix(es) to description of shipyard/weldingshop

1)

4. Proof of qualifications for welding supervisor(s) 1)

5. List of qualified welders 1)

6. Descriptions of welding procedures (WPS) 1)

7. List of qualified welding procedures 1)

8. List of inspection (supervising) personnel 1)

9. Other proofs, approvals (e.g. proof of compliance with the quality re-quirements:

1)

- in accordance with HRN EN ISO 3834-2, or 1)

- in accordance with HRN EN ISO 3834-3 or 1)

- in accordance with HRN EN ISO 3834-4 1)

Note:1) Only if changes have been made since first approval.

Place, Date Applicant

RULES FOR THE CLASSIFICATION OF SHIPS 75PART 26 - APPENDIX II

2009


DESCRIPTION OF SHIPYARD/WORKSHOP FOR APPROVALTO PERFORM WELDING WORKS IN

SHIPBUILDING AND THE MACHINERY COMPONENTS THEREOF

SHIPYARD/WORKSHOP

Address:

Telephone: Fax: e-mail:

Responsible person:

Range of welding work:

1. WELDING PERSONNEL

1.1 Supervisor(s)(welding engineer, welding technician, foreman)

1.2 qualified welders

a) Certificates and records, renewal, withdrawalb) Welders filec) Intervals and shop control of weldersd) Welders activities to Certificatee) Welders marksf) Promotion of welders, new weldersg) Supervision of the welders performanceh) Existing number of welders

2. WELDING CONSUMABLES

2.1 Warehouse

a) Records (input-output)b) Dryingc) Dispatch

2.2 Type of welding consumables

3. BASE MATERIALS, (PLATES, PROFILES, PIPES)

3.1 Warehouse

a) Recordsb) Marking

3.2 Grade of material

76 RULES FOR THE CLASSIFICATION OF SHIPSPART 26 - APPENDIX II

2009

4. WELDING EQUIPMENT

4.1 Electric sources

a) Types (prospectus)b) Records (file of sources)c) Maintenance (with respect to the Protection at Work Requirements and technological performance properties)d) Number of existing electrical sources

4.2 Welding equipment

a) Control units for MIG/MAG, TIG, plasma, SMAW

4.3 Welding jigs

a) Positionersb) Turnoversc) Other

5. PERFORMED WELDING PROCEDURES AND WELDERS QUALIFICATION TESTS

5.1 Performed welding procedure qualification tests

5.2 Performed welders qualification tests

6. SUPERVISION AND CONTROL

6.1 Organisational scheme and control position

6.2 Non-destructive examination of welds (internal)

6.3 Qualifications of supervising personnel

6.4 Non-destructive examination of welds (external)

7. DOCUMENTATION

7.1 Workshop documentation and its review from the technological point of view

7.2 Technological instructions (instruction sheets) for integral welding

7.3 Scope and method of welded joints examination

8. MISCELLANEOUS

8.1 Heat treatment (equipment)

8.2 Protection at work with respect to welding

9. REFERENCES

Welding supervisor:

Place, date, Name

Rules for the classification of ships, Part 26, 2009 - crs.hr for the... · RULES FOR THE CLASSIFICATION OF SHIPS Part 26 ... No. 20(1988), No. 47(2008), No. 70(2006) International

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