RULES

PUBLICATION NO. 3/P

PRINCIPLES FOR EXAMINATION OF WELDERS

2010

Publications P (Additional Rule Requirements) issued by Polski Rejestr Statkw complete or extend the Rules and are mandatory where applicable.

GDASK

RULES

PUBLICATION NO. 3/P

PRINCIPLES FOR EXAMINATION OF WELDERS

2010

GDASK

Publication No. 3/P Principles for Examination of Welders 2010 is an extension of the requirements contained in Part IX Materials and Welding of the Rules for the Classification and Construction of Sea-going Ships. This Publication was approved by the PRS Board on 21 December 2010 and enters into force on 1 January 2011. The present Publication replaces Publication No. 3/P Principles for Examination of Welders 2006.

Copyright by Polski Rejestr Statkw, 2011

PRS/AW, 11/2011

CONTENTS Page
1 General ..................................................................................................................... 1.1 Application ........................................................................................................ 1.2 Qualification Certificate Validity ...................................................................... 1.3 Definitions ......................................................................................................... 1.4 Symbols and Abbreviations............................................................................... 1.5 Normative References ...................................................................................... 5 5 6 7 8 9

2 General Provisions on Holding Qualification Test of Welders ........................... 10 3 Welders Qualification Test ................................................................................... 3.1 Admission to Qualification Test ....................................................................... 3.2 Job Knowledge Test ......................................................................................... 3.3 Practical Test .................................................................................................... 3.4 Test Piece Examination .................................................................................... 3.4.1 General Requirements ........................................................................ 3.4.2 Non-destructive Examination ............................................................. 3.4.3 Destructive Examination .................................................................... 3.5 Assessment of Qualification Test Results ........................................................ 3.6 Welders Qualification Test Certificate Issue ................................................... 3.7 Re-tests ............................................................................................................. 11 11 12 13 14 14 16 17 19 19 19

4 Prolongation of Welders Qualification ................................................................ 20 5 Range of Welders Qualification ........................................................................... 20 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 Designation of Welders Qualification ............................................................. Welding Processes ............................................................................................ Product Type .................................................................................................... Weld Type ........................................................................................................ Material Groups ................................................................................................ Welding Consumables ...................................................................................... Dimensions ....................................................................................................... Welding Positions ............................................................................................. Weld Details ..................................................................................................... 20 22 24 25 25 33 35 37 39

Annex 1 ................................................................................................................... 41 Annex 2 ................................................................................................................... 43

1 1.1

GENERAL Application

1.1.1 The present Publication specifies the principles for examining welders and the issue of welder qualification certificate by PRS. 1.1.2 According to PRS requirements, welded structures or equipment which are subject to PRS survey shall be performed by welders holding valid PRS qualification certificates. 1.1.3 Welders who have successfully passed qualification tests and have obtained PRS qualification certificates are entitled to perform welding operations, during construction or repair, of the following structures, ship equipment and other equipment surveyed by PRS: hulls of ships and other floating objects, machinery and machinery installations, steam boilers and pressure vessels, hull equipment, piping systems, freight containers, cargo handling and hoisting devices, other essential machinery installations and structures. 1.1.4 Welders are allowed to perform only those welding operations which are specified in their current welder qualification certificates issued by PRS. 1.1.5 Welder qualification certificates for welding steels intended for welded structures, weldable steel forgings and steel castings, as well as wrought aluminium alloys which comply with the requirements specified in the Rules for the Classification and Construction of Sea-going Ships, Part IX Materials and Welding are issued by PRS after examining the welders skills and knowledge in accordance with the principles set out in the present Publication. 1.1.6 In the case of examination of welders for welding copper or copper alloys, it is recommended that PN-EN ISO 9606-03 standard should be used. 1.1.7 The principles for examination of welders within the scope of welding processes and materials not covered by the present Publication shall be agreed with PRS in each particular case. These principles shall be developed, having due regard to specific properties of these welding operations and materials, as well as the applicable requirements of the current EN, ISO or other standards. 1.1.8 The present Publication refers to the provisions of other documents (e.g. standards). These provisions, through reference to this text, constitute the requirements of the present Publication. Standards, current at the time of the present

Publication issue, are specified in sub-chapter 1.5. It is recommended that current editions of the reference documents should be used. 1.2 Qualification Certificate Validity

1.2.1 The qualification test certificate is issued to a welder for a period of two years commencing with the date of the practical test, i.e. the date of welding the test piece. In the case of prolongation of qualification in accordance with 4.1, i.e. without passing the practical test, the qualification test certificate will be valid from the day following the date of qualification prolongation. 1.2.2 The Welders Qualification Test Certificate is valid for a period of two years, provided that the person duly authorised by the employer to supervise welding operations confirms, every six months, that the welder has been working within the initial range of qualification. 1.2.3 The welders qualification expires where he has not performed any welding operations for a period longer than six months. 1.2.4 The welders qualification may be withdrawn at the request of PRS Surveyor who supervises the welding operations if the welder has failed to comply with the good welding practice or where the quality of the welds has decreased significantly. 1.2.5 A welder, whose qualification certificate is no longer valid is not authorised to perform the welding operations which are subject to PRS survey. 1.2.6 Welders qualification can be prolonged for further two years after he has passed the practical test, within the scope of the granted qualification. The welders qualification can be prolonged without the necessity to pass the practical test, subject to compliance with the conditions, specified in paragraph 4.1. 1.2.7 A shipyard or a manufacturer is responsible for control of welders qualification, the training of welders and their continuous work to allow them to maintain their skills. The control of the validity of welders qualification at a given manufacturer rests with the persons, authorised by the manufacturer, to supervise the welding operations. 1.2.8 The manufacturer employing welders is obliged to keep a record of the welders qualified by PRS. The record shall include: the welders full name, national personal identity number, the welders code used for marking the welds that he performed, designation of welders qualification, welders qualification expiry date, welders qualification test certificate number. 6

1.3

Definitions

C a p p i n g r u n in multi-run welding, the run visible on the weld face after completion of welding. C e r a m i c b a c k i n g ( t e m p o r a r y ) individually shaped ceramic material for the purpose of supporting molten weld metal and forming a face root run. F i l l i n g r u n in multi-run welding, the run deposited after the root run and before the capping run. H e a t a f f e c t e d z o n e ( H A Z ) metal area in the welded joint adjacent to the weld, undergoing changes of structural, physical, mechanical and other properties under the effect of welding heat. M a n u f a c t u r e r shipyard or other works employing welders, manufacturing or repairing steel structures. M e t a l b a c k i n g ( p e r m a n e n t ) a plate made of metal having a melting point equal or almost equal to the melting point of the welded material, placed at the reverse side of the joint to be welded for supporting molten weld metal; the plate undergoes partial melting. Metal backing (temporary) a plate made of metal having a melting point significantly different from the melting point of the welded material, placed at the reverse side of the joint to be welded for supporting molten weld metal; the plate does not undergo partial melting. Multi-run weld weld made by depositing more than one run. One-side welding welding process where the whole weld is made from one side of a welded joint only. One-side weld weld made using one-side welding process. P a r e n t m a t e r i a l material from which the element to be welded is made. Q u a l i f i c a t i o n t e s t test carried out to issue PRS qualification certificate to a welder for the first time or to extend the range of qualification already granted by PRS. R e v i s i o n t e s t test carried out at the request of PRS Surveyor, e.g. where the quality of the welds performed by welder has decreased significantly, to check the welders current skills. R o o t r u n in multi-run welding, the run of the first layer deposited in the root. Single-run weld weld made by depositing a single run only. T e s t p i e c e welded joint made during the welders test. Weld part of a welded joint made of material melted during the welding process. W e l d e r s q u a l i f i c a t i o n p r o l o n g a t i o n t e s t test carried out to prolong the validity of the welders qualification, granted by PRS, for further two years. Weld run metal melted or deposited under one heat source passage. 7

W e l d i n g c o n s u m a b l e material constituting the weld or which allows making the weld; it may be, e.g. covered electrode, welding rod, wire, flux, gas. Welding Procedure Specification (WPS) a document stating details of variable parameters required for a specified welding process and ensuring that welded joints made in accordance with this document satisfy quality uniformity criteria. W e l d t h i c k n e s s thickness of weld, excluding any reinforcement; for butt welds it is equal to the welded material thickness, whereas for fillet welds it is equal to the minimum height of the triangle inscribed into the weld cross-section. 1.4 Symbols and Abbreviations The symbols and abbreviations, used in the present Publication, are given below. 1.4.1 a b BW D FW l P ReH s1 s2 t t1 t2 T 1.4.2 nm A B C M P R RA RB RC RR S V 8 Test Piece design throat thickness, gap, butt weld, outside pipe diameter, fillet weld, length of test piece, plate, yield strength, weld metal thickness for welding process 1, weld metal thickness for welding process 2, material thickness of test piece (plate or wall thickness), material thickness of test piece for welding process 1, material thickness of test piece for welding process 2, pipe. Welding Consumables no filler metal, acid covering, basic covering or electrode core basic, cellulosic covering, electrode core metal powder, electrode core rutile, fast freezing slag, rutile covering or electrode core rutile, slow freezing slag, rutile-acid covering, rutile-basic covering, rutile-cellulosic covering, rutile-thick covering, solid wire/rod, electrode core rutile or basic / fluoride,

W Y Z 1.4.3 bs lw mb ml nb rw sl ss

electrode core basic/fluoride, slow freezing slag, electrode core basic/fluoride, fast freezing slag, electrode core other types. Weld Details

welding from both sides (butt welds), leftward welding (process 311), welding with backing (butt welds), mutli-run (fillet welds), welding without backing (butt welds), rightward welding (process 311), single-run (fillet welds), single-side welding (butt welds). Bend Tests

1.4.4 A d ts 1.5

minimum tensile elongation required by the material specification, diameter of the former or the inner roller, thickness of the bend test specimen. Normative References Qualification test of welders. Fusion welding. Part 1: Steels. Non-destructive testing. Qualification and certification of NDT personnel General principles. Destructive tests on welds in metallic materials. Bend tests. Non-destructive examination of fusion welds. Visual examination. Destructive tests on welds in metallic materials. Fracture test. Destructive tests on welds in metallic materials. Macroscopic and microscopic examination of welds. Welding Personnel Approval testing of welding operations for fusion welding and resistance weld setters for fully mechanized and automatic welding of metallic materials. Non-destructive examination of welds. Radiographic examination of welded joints. Non-destructive examination of welds. Ultrasonic examination of welded joints. Acceptance levels. Non-destructive examination of welds. Ultrasonic examination of welded joints. 9

PN-EN 287-1:2007 PN-EN 473:2008 PN-EN ISO 5173:2010 PN-EN 970:1999 PN-EN 1320:1999 PN-EN 1321:2000 PN-EN 1418: 2000

PN-EN 1435:2001 PN-EN 1712:2001 PN-EN 1714:2002

PN-EN ISO 4063:2009 PN-EN ISO 5817:2009

PN-EN ISO 6520-1:2009

PN-EN ISO 6947:1999 PN-EN ISO 9606-2:2007 PN-EN ISO 9606-3:2001 PN-EN 10042:2008 PN-EN ISO 17635:2010 PN-EN 12517-1:2008

PN-EN 12517-2:2008

PN-EN ISO 14175:2008 CEN TR ISO 15608:2005

Welding and allied processes. Nomenclature of processes and reference numbers. Welding. Fusion-welded joints in steel, nickel, titanium and their alloys (beam welding excluded). Quality levels for imperfections. Welding and allied processes. Classification of geometric imperfections in metallic materials. Part 1: Fusion welding. Welds. Working positions. Definitions of angles of slope and rotation. Qualification test of welders. Fusion welding. Part 2: Aluminium and aluminium alloys. Approval testing of welders. Fusion welding. Part 3. Copper and copper alloys. Welding Arc-welded joints in aluminium and its alloys. Quality levels for imperfections. Non-destructive testing of welds. General rules for metallic materials. Non destructive testing of welds Part 1. Evaluation of welded joints is steel, nickel, titanium, and their alloys. Acceptance levels. Non-destructive testing of welds Part 2: Evaluation of welded joints in aluminium and its alloys by radiography. Acceptance levels. Welding Consumables Gases and gas mixtures for fusion welding and allied processes. Welding. Guidelines for a metallic materials grouping system.

GENERAL PROVISIONS ON HOLDING QUALIFICATION TEST OF WELDERS

2.1 The testing of welders to be qualified by PRS shall be carried out in the presence of PRS Surveyor conducting the direct supervision of the test. 2.2 The Examining Body shall consist of a welding operations supervisor of the manufacturer or the firm holding the test and a person duly qualified to perform visual testing of fusion welds. PRS Surveyor is the chairman of the examining body. 2.3 The firm holding the test shall request its direct supervision from the relevant PRS Branch Office or Survey Station. The list of welders, together with their application forms as shown in Annex 2, shall be enclosed with the request. 10

2.4 Training courses which the welder has underwent, as well as the hand-on experience in welding shall be documented, e.g. confirmed by appropriate entries in the Welders Book. 2.5 The manufacturer or the firm holding the test is responsible for providing such practical test conditions, which will allow PRS Surveyor to monitor the test welding processes carried out by particular welders. 2.6 The welding of test pieces may be carried out in places specially designated for that purpose or directly on the welding site. The welding site shall be provided with appropriate welding and other additional equipment so as to allow the welder to control both the welding process and to satisfy all requirements specified in the Welding Procedure Specification (WPS) for the test piece. 2.7 The practical test welding stand shall be provided with the Welding Procedure Specification (WPS). The WPS shall contain basic data relating to the welding process of the test piece to be welded during the qualification test. Recommendations given in the WPS shall be consistent with the welding procedure for the given material group or sub-group and shall take into account the welded material thickness. 2.8 PRS Surveyor participates in the job knowledge test and directly supervises the practical test. 2.9 Examination of the test pieces shall be performed by laboratories approved by PRS. 2.10 The welders test for PRS qualification certificate neither constitutes an examination in occupational safety and fire protection nor substitutes such examination. 3 WELDERS QUALIFICATION TEST

Welders qualification test is carried out to issue PRS qualification certificate to a welder for the first time or to extend the range of qualification already granted by PRS. 3.1 Admission to Qualification Test

3.1.1 A welder may be admitted to the qualification test in metal-arc welding, provided that the two conditions, given below, are satisfied: .1 completion of theoretical training course in the welding process, type of product, groups of parent materials, type of weld and welding position which will be the subject of the qualification test, and .2 appropriate a minimum six months is recommended hand-on experience in using this process for welding a group or sub-group of parent materials to be welded during the qualification test. 11

3.1.2 Only a welder who has completed the training course in single-side butt welding on temporary backing strips, which form the weld root (e.g. ceramic backing), shall be admitted to the qualification test within the scope of single-side butt welding on temporary backing strips. 3.1.3 The condition for admission of a welder to the qualification test in submerged arc welding with one wire electrode (process 121, 125) using self-propelled welding tractors which require permanent control of the welding parameters by the operator is: completion of the training course in the welding process, which is the subject of the qualification test, appropriate hand-on experience at least one months experience is recommended in using this process for welding a particular group or sub-group of parent materials. 3.1.4 The condition for admission of a welder to the qualification test in oxyacetylene welding (process 311), only for steel pipes of the maximum outside diameter of 100 mm made from sub-group 1.1 materials, is: completion of the training course in welding process 311, a minimum half-year hand-on experience in using this process for welding pipes. 3.1.5 Completion of the training courses shall be confirmed by appropriate entries in the Welders Book, whereas the hand-on experience in welding shall be certified. 3.1.6 Upon PRS Head Office consent, the requirement concerning the recommended period of the welders hand-on experience may be dispensed with to allow admission to the qualification test in fillet welding of the given material group or sub-group, provided that the welder has received the relevant theoretical training in such welding process and has undergone practical training comprising a minimum of 200 hours in the case of fillet welding and a minimum of 300 hours in the case of butt welding. 3.1.7 The condition for admission of a welder to the qualification test intended to extend the range of the possessed qualification is completion of the qualification training course within the scope of welding process, product type and material groups subject to the intended extension of the range of qualification. 3.2 Job Knowledge Test

3.2.1 Job knowledge test is required within each qualification test, regardless of its type. 3.2.2 Job knowledge test shall be limited to the check of the welders knowledge of the essential problems related to the welding process used during the test to allow the use of correct welding procedure and skilful operation of the welding equipment. 12

3.2.3 Job knowledge test shall comprise: identification of the range of qualification based on the current qualification test, properties and identification of parent materials within the material groups or sub-groups of the test pieces, properties and identification of parent materials within the material groups or sub-groups covered by the range of the qualification certificate to be issued, characteristic features of the welding process being the subject of the qualification test, properties and identification of welding consumables used for the particular welding process, the principles of edge preparation for welding and pre-welding assembly, the principles of selecting proper welding parameters, the principles of pre-heating and pre-heating control, proper interpass temperatures and their control, weld imperfections and their causes, method of repair of the welds below the acceptance level. 3.2.4 The form of job knowledge test is subject to acceptance by PRS Surveyor supervising the test. The job knowledge test result shall be stated as accepted or not accepted. 3.2.5 The results of the test shall be documented. Where there is a written job knowledge test, the welders test sheets shall be enclosed with the test records. 3.3 Practical Test

3.3.1 During the practical test, the welder shall perform the test weld to prove the skill necessary to obtain a relevant qualification certificate. 3.3.2 Parent materials and welding consumables used during the test shall be properly selected for the applied examination programme and their grade and quality shall be certified. Welding consumables having valid PRS Approval Certificate shall be used. 3.3.3 In qualification tests for welders of sea-going ship hulls, the plates of higher-strength hull steel (ReH 355 MPa) of minimum 8 mm in thickness are recommended for the test pieces. 3.3.4 The dimensions of typical test pieces are given in Annex 1. The length of submerged-arc welded test pieces shall be not less than 600 mm. 3.3.5 Tack welding of the test piece shall be performed by a welder. Welding consumables used for tack welding shall be the same as those used for actual welding. The use of other welding consumables is permitted if such provision has been made in the WPS for the test piece welding process. The preparation of edges and gap shall comply with the WPS; the prestrain of the tack-welded parts may be left at the discretion of welder. 13

3.3.6 Each test piece shall be identified with a durable mark, e.g. in the top right corner. The mark shall allow an unambiguous identification of the welder performing the test piece, the welding process and the welding position. 3.3.7 After compliance of the tack-welded piece with the scope of the test has been checked, the test piece is marked by PRS Surveyor in two places with PRS stamp. In at least one of the places marked with PRS stamp, the examined welder shall stop and restart welding to perform the root run and weld face layer. 3.3.8 The welding of the test piece shall be performed in the presence of PRS Surveyor supervising the test. 3.3.9 The procedure of welding the test piece shall comply with the Welding Procedure Specification (WPS), which shall be available at the practical test welding stand. The welding time for the test piece shall correspond to the working time under usual production conditions. Any post-weld heat treatment required in the WPS may be omitted unless bend tests are required. 3.3.10 The test piece with the butt weld applied on both sides shall be performed entirely in the same welding position. 3.3.11 Replacement of the initiated test piece by a new one is possible only in the case where, according to PRS Surveyor supervising the test, difficulties, not associated with the welders qualifications, have occurred and the consequential defects cannot be removed without worsening the quality of the test piece. 3.3.12 The welder shall be allowed to remove minor imperfections by grinding, only when permitted by PRS Surveyor supervising the test. No corrections are allowed on the surfaces after finishing the weld; this applies to both the weld face and root. 3.3.13 PRS Surveyor may stop the test if the welding conditions are not correct or if it appears that the welder does not have the skill to fulfil the requirements. 3.4 3.4.1 Test Piece Examination General Requirements

3.4.1.1 Prior to any examination, all slag and spatters shall be removed carefully and the weld profile and dimensions shall be checked. No grinding on the root and the face side of the weld is permitted. Stop and restart location of the welding process to make the weld root and face shall be explicitly identified and marked with PRS stamp. 3.4.1.2 Each test piece shall be so marked as to unambiguously identify: the welder, the welding process and the welding position. The same marking and PRS stamp shall be placed on each test specimen taken from the examination test piece for destructive testing. 14

3.4.1.3 Examination of the test pieces shall be carried out by laboratories possessing a valid PRS Approval Certificate authorising to conduct such tests. 3.4.1.4 The results of all examinations shall be documented. The reports of the test piece examination shall contain identification marks of such test piece. 3.4.1.5 The test methods to be used for examination of the test piece consisting of either plates or pipes, as well as the scope of such examination depending on the weld type of the test piece are specified in Table 3.4.1.5. Table 3.4.1.5 Examination of the test pieces
Examination method Visual testing (VT) in accordance with PN-EN 970 Radiographic testing (RT) in accordance with PN-EN 1435 Butt weld BW 100% of weld length 100% of weld length 1) Fillet weld FW 100% of weld length not required

Bend test in accordance with PN-EN 910

Fracture test in accordance with PN-EN 1320 Macroscopic examination in accordance with PN-EN 1321
1)

Transverse bend test2),3),4): 2 specimens from test piece of steel plates; 4 specimens from test piece of plates of Al and Al alloy; 2 specimens from pipe test pieces welded only in not required position PA or PC; 4 specimens from pipe test pieces welded in positions other than PA or PC 100% of weld not required length 5) not required 2 specimens 5)

2)

3)

4)

5)

For material thickness t t 8 mm, the radiographic testing may be replaced by ultrasonic testing in accordance with PN-EN 1714. In each case the same number of specimens for weld root tensile test and weld face tensile test. For material thickness t t 12, the transverse bend test may be replaced by the side bend test. For outside pipe diameter D d 25 mm, the bend or fracture tests may be replaced by a notched tensile test of the complete test piece with 4 holes of 4.5 mm in diameter made in the weld (every 90) for pipe wall thickness t t 1.8 mm and with 3.5 mm hole diameter for thinner materials. Where radiographic testing was carried out, the bend test is required only for welding processes 131, 135, 138 and the welding process 311. The fracture test may be replaced by macroscopic examination in accordance with PN-EN 1321 using minimum 2 test specimens.

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3.4.2 3.4.2.1

Non-destructive Examination Visual Testing

3.4.2.1.1 Each test piece shall be subjected to visual testing (VT): after the root run of the butt weld has been performed in the test piece, after completion of the test piece. 3.4.2.1.2 Visual testing and its recording shall comply with the guidelines contained in PN-EN 970. 3.4.2.1.3 The quality level of the test pieces, based on type and size of imperfections, shall be assessed in accordance with PN-EN ISO 5817 for steel test pieces and PN-EN 10042 for the test pieces of aluminium or its alloys. 3.4.2.1.4 Surface imperfections of the test piece shall be within quality level B. In the case of undercuts, their height cannot exceed 0.5 mm. Angular misalignment (508) is not considered in the assessment of a welded joint. Only the following types of imperfections in quality level C are permitted: excess butt weld metal (502), excess fillet weld metal (503), excess throat of the fillet weld (5214), excessive penetration (504), incorrect weld toe (505). The reference numbers given in brackets are in accordance with PN-EN ISO 6520-1. 3.4.2.1.5 In the assessment of the root run of the butt weld test piece welded from both sides, weld root removed, surface imperfections shall not exceed limits for imperfections within quality level D. 3.4.2.2 Radiographic and Ultrasonic Testing

3.4.2.2.1 If the butt weld is accepted by visual examination, radiographic testing (RT) shall be carried out. Radiographic testing may be replaced by ultrasonic testing (UT) where the test piece material thickness is 8 mm or more. 3.4.2.2.2 Radiographic testing shall be performed in accordance with PN-EN 1435. The level of imperfections detected in the test pieces shall correspond to acceptance level 1 in accordance with PN-EN 12517. 3.4.2.2.3 Ultrasonic testing shall be performed in accordance with PN-EN 1714. The acceptance level for imperfections detected in the test pieces during the ultrasonic testing shall correspond to acceptance level 2 in accordance with PN-EN 1712.

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3.4.2.2.4 The reports on radiographic or ultrasonic testing shall contain acceptance levels for imperfections indicated using those methods. 3.4.2.2.5 The correlation between the acceptance levels of the different nondestructive testing techniques used for the test pieces and the quality levels are specified in PN-EN ISO 17635. 3.4.3 3.4.3.1 Destructive Examination Bend Test

3.4.3.1.1 For butt weld test piece accepted by visual examination and radiographic testing, the bend test shall be carried out only for welding processes 131, 135, 138 and the welding process 311. 3.4.3.1.2 From a test piece for butt welds, specimens for transverse bend test shall be taken as follows: two specimens from a test piece for butt weld in steel plates and two specimens from pipes, performed in position PA or PC, four specimens from other test pieces. Before the bend test, the weld shape and location shall be determined by slightly etching the surface of the specimens. The root bend test and the face bend test shall be performed on the same number of specimens. For a test piece made of material t > 12 mm in thickness, the transverse bend test may be replaced by the side bend test on the same number of specimens. In that case test specimens shall be taken from evenly spaced places, one specimen being taken from the place where the welding process was stopped and restarted. 3.4.3.1.3 The preparation of all specimens and the records of test results shall comply with the requirements specified in PN-EN ISO 5173:2010. 3.4.3.1.4 Diameter d of the bending mandrel used for the bend test depends on the relative elongation A of the test piece parent material and on the bend test specimen thickness ts. Where A 20%, the mandrel of d = 4t in diameter shall be used; where A < 20%, the mandrel diameter shall be calculated using the following formula: 100 K ts d
ts A The bending angle is 180 for all specimens. 3.4.3.1.5 The bend test result is accepted where no cracks of the length 3 mm are found on the stretched side after bending the specimen by 180. Cracks near the specimen edges may be neglected unless they are due to the test piece defect. 3.4.3.1.6 Each specimen which failed the test shall be replaced by the double number of additional specimens. The result obtained from the bend test of additional specimens is considered final. 17

3.4.3.2

Fracture Test

3.4.3.2.1 Each fillet weld test piece shall be subjected to fracture test. Where the fracture test conditions do not allow to break the test piece over its whole length, then the specimens for the fracture test shall be taken from the test piece in such a way as to cover the whole length of the test piece. 3.4.3.2.2 Where radiographic testing or ultrasonic testing of butt weld test piece is not feasible, then, in exceptional case, the fracture test of such test piece is permitted. The specimens for the fracture test shall be taken from the test piece in such a way as to cover the whole length of the test piece. 3.4.3.2.3 Performance and reports of fracture test shall comply with the requirements specified in PN-EN 1320. Fracture over the entire length of the test piece weld shall be visually tested. The fracture shall be assessed by a person qualified to perform visual testing of welded joints. 3.4.3.2.4 Fracture test of fillet weld test piece may be replaced by macroscopic examination. At least two test specimens shall be taken; one specimen shall be taken from the place where the welding process was stopped and continued. 3.4.3.2.5 The results of these two tests are considered satisfactory where the internal imperfections of the fracture or macrosections of the test piece are within quality level B in accordance with PN-EN ISO 5817 for steel test pieces and PN-EN 10042 for test pieces of Al or Al alloys. 3.4.3.3 Macroscopic Examination

3.4.3.3.1 Where the fracture test of fillet weld test piece is replaced by macroscopic examination, one of the test specimens shall be taken in such a way as to cover the welding process stop/start location. 3.4.3.3.2 Macroscopic test specimens shall cover the weld, heat affected zones on both sides of the weld, as well as minimum 10 mm area of the parent material beyond the heat affected zone. The etching of one surface of the specimen shall reveal: the weld, fusion lines, heat affected zones and the parent material. 3.4.3.3.3 Test specimens taking and preparation, as well as recording the results of macroscopic examination shall be in accordance with the requirements specified in PN-EN 1321. 3.4.3.3.4 The result of macroscopic examination is considered satisfactory if the internal imperfections of the test piece are within quality level B in accordance with PN-EN ISO 5817 for steel test pieces and PN-EN 10042 for Al or Al alloys test pieces.

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3.5

Assessment of Qualification Test Results

3.5.1 The overall result of the qualification test is considered satisfactory if the results of the job knowledge test and the results of all examinations of the test piece performed during the test are satisfactory. 3.5.2 The results of the qualification test and other decisions shall be documented in a collective record. 3.5.3 A set of documents of the qualification test carried out shall include: application forms, welding procedure specifications (WPS) for the test pieces, copies of certificates for both parent materials and welding consumables used for the qualification test, records of all examinations of the test pieces, a collective record. 3.6 Welders Qualification Test Certificate Issue

3.6.1 Welders qualification test certificate may be issued by PRS only when the examined welders skills and job knowledge within the scope of the qualification test are considered satisfactory. 3.6.2 In general, for each test piece a separate Welders qualification test certificate shall be issued. If more than one piece is welded, a single Welders qualification test certificate can be issued that combines the ranges of qualification of the individual pieces. Only one of the following essential variables is permitted to be changed: type of weld, welding position, dimensions material thickness for plates, wall thickness and outside diameter for pipes. 3.7 Re-tests

3.7.1 If the practical test or the job knowledge test fails to comply with the requirements of the present Publication, the welder shall be given an opportunity to repeat the qualification test, however, no earlier than 14 days and no later than six months after the failed test. 3.7.2 Where the welder fails both the job knowledge test and the practical test, he may be given an opportunity to repeat the test after completion of another qualification training course confirmed by the training unit.

19

PROLONGATION OF WELDERS QUALIFICATION

4.1 Prolongation of welders qualification for further two years without the necessity to weld the test pieces can be made at the request of the manufacturers welding supervisor. All records and evidence which constitute the basis for the request shall allow to identify the welder and the welding procedure (the WPS) used in the production. The request shall be accompanied by: reports confirming good quality of the test pieces made by the welder during the period of the qualification validity the percentage of imperfections in the test pieces made by the welder shall not exceed 10 %, records of non-destructive tests (radiographic or ultrasonic), as well as destructive testing (fracture tests, bend tests, etc.), if applied, of minimum two test pieces made by the particular welder during the recent 6 months of the qualification validity. Only the test pieces which were made in the conditions corresponding to those of the qualification test for prolongation of the welders qualification (welding process, intermediate product type, weld type, material group, filler metal, welding position, weld details) shall be taken into account. As regards the welded material thickness (t) or pipe diameter (D), it will be sufficient if they are within the range of the qualification to be prolonged. 4.2 The request shall be submitted to PRS before the expiry date of the welders qualification to enable verification of the submitted documents regarding welders qualification prolongation in due time. The documents related to welders qualification prolongation shall be retained for a minimum of two years. 4.3 If conditions, referred to in 4.1, are not satisfied, in order to prolong the welders qualification, the welder shall take and pass a test which should be held in accordance with the general principles applicable to welders qualification tests, specified in Chapter 3. 4.4 Where the welder taking the test for prolongation of qualification has been previously qualified by PRS to make joints with both butt and fillet welds and the majority of welds carried out in production are butt welds, the test piece with only butt weld is permitted to be made. 5 5.1 RANGE OF WELDERS QUALIFICATION Designation of Welders Qualification

5.1.1 The designation of a welders qualification in Welders qualification test certificate is a conventional record of the practical test held. It constitutes a set of symbols (items) which define the conditions of the test piece performance. The designation is consistent with the standard, referred to at the beginning of the record. The designation items are arranged in one row; the order of particular items of the designation and information which the items provide are given in Table 5.1.1-1. The designation examples are given in Table 5.1.1-2. 20

Table 5.1.1-1 Designation of welders qualification

The order of a particular item in qualification designation 1 1 Successive items of qualification designation and information they contain 2 Number of reference standard for the welders qualification test: EN 287-1 for steel, and EN ISO 9606-2 for aluminium and its alloys Three numbers they indicate numerical designation of the welding process used for the test piece in accordance with Table 5.2.1, e.g. 111; however, where two welding processes were used for the butt weld of the test piece, e.g. for the root run: 141 and for the filling run: 111, the designation of both processes is indicated as 141/111 see Table 5.2.3. Capital letter indicates the test piece type: P plate, T pipe. Two capital letters indicate the test piece weld type: BW butt weld, FW fillet weld. Numerical designation indicates the group or sub-group of the parent material used for the test piece in accordance with CEN-TR ISO 15608, as shown in Table 5.5.1-1 for steel, and in Table 5.5.2-1 for aluminium and its alloys. Letter designation indicates a welding consumable used for the test piece: nm test piece made without a consumable, S solid wire/rod, one or two capital letters indicate the type of electrode coating of a covered electrode or powder type for flux-cored wires see Table 5.6.1. If two different welding processes, e.g. 141/111 were used for the test piece with butt weld, then the designation of the consumables for both processes shall be S/B where electrodes with basic covering were used. Designation of the parent material thickness. It consists of a small letter t and the number indicating the parent material thickness in accordance with the material approval certificate. If two different welding processes were used for the test piece with butt welds, then the parent material thickness designation is followed by the thicknesses (given in brackets) of the welds made using the particular processes, e.g. t 20 (5/15) see Table 5.2.3. Where pipe T was used for the test piece, the designation of the pipe outside diameter consists of capital letter D and the number indicating the magnitude of outside diameter of the welded pipe in accordance with the approval certificate. Designation of the test piece welding position in accordance with PN-EN ISO 6947, specified in Table 5.8.1. This usually consists of two capital letters, the first of which is P, indicating the test piece welding position. If a welder makes two identical test pieces which differ in welding positions only, then both positions are indicated: e.g. PF PC. Letter designation indicates the test piece welding details; the weld details are given in Tables 5.9.1, 5.9.2, and 5.9.3; for butt welds BW, one of the following: ss nb, ss mb, bs, bs mb; for fillet welds FW, one of the following: sl, ml; for oxy-acetylene welding (311), additionally: lw, rw.

3 4 5

10

21

Table 5.1.1-2 Qualification designation examples

Standard Welding process Product type Weld type Material group Welding consumable(s) Material thickness Pipe Welding outside Weld details position diameter

EN 287-1 EN 287-1 EN 287-1 EN 287-1 EN 287-1 EN 287-1 EN ISO 9606-2

111 141/111 141 111 136 136 131

T T T T P P P

BW BW BW BW FW BW FW

1.2 1.1 1.1 1.1 1.2 1.1 22

B S/B S B B R S

t10 t20(5/15) t5 t15 t12 t10 t6

D60 D60 D60 D60

PA H-L045 H-L045 H-L045 PE PC PF

ss nb ss nb/ss mb ss nb ss mb ml ss mb ml

5.1.2 The order in which the items of welders qualification designation are arranged is the same for all types of qualification test. Detailed information concerning particular items of the designation is given in the appropriate paragraphs of the present Chapter. 5.1.3 As a rule, a welder is qualified not only for welding the test pieces in the conditions used in the test, indicated in the designation, but also for the joints which are considered to be easier to weld. 5.1.4 The principles of defining the range of qualification resulting from particular items of welders qualification designation are specified in the relevant paragraphs of the present Chapter. 5.2 Welding Processes

5.2.1 Numerical designation of the most common welding processes is given in Table 5.2.1. Table 5.2.1 Welding processes
Welding process 1 Metal-arc welding with covered electrode Flux-cored wire metal-arc welding without gas shield Metal-arc inert gas welding (MIG) Metal-arc active gas welding (MAG) Flux-cored wire metal-arc welding with active gas shield (MAG) Flux-cored wire metal-arc welding with inert gas shield (MIG) Metal-cored wire metal-arc welding with active gas shield (MAG) Tungsten inert gas arc welding (TIG) Process designation according to PN-EN ISO 4063 2 111 114 131 135 136 137 138 141

22

1 Submerged arc welding, single wire Submerged arc welding, flux-cored wire Plasma-arc welding Gas welding (oxy-acetylene welding)1)
1)

2 121 125 15 311

Only pipes with diameter D 100 mm of the material of sub-group 1.1 according to Table 5.5.1-1 are permitted by PRS to be welded.

5.2.2 Each qualification test normally qualifies only one welding process. A change to the welding process requires a new qualification test. The qualification test held for process 138, i.e. metal-cored wire (M) metal arc welding with active gas shield qualifies the welder for this process and also for welding process 135, i.e. with solid wire (S). 5.2.3 It is permitted for a welder to be qualified for two or more welding processes by welding a single test piece (multi process joint) or by two or more separate qualification tests. Thus, if qualification for single-side butt welding, where the weld root is made using tungsten inert gas arc welding (process 141) and the weld is filled by metal-arc welding with covered electrode (process 111), is required, the welder may be qualified in accordance with either pattern. Table 5.2.3 contains an example of a multi process joint. Table 5.2.3 Multi process joints for butt welds BW
Material thickness and weld thicknesses for determining joint thickness t given in Table 5.7.1 Multi process joint Single process joint

Multi process test piece for butt welds BW

for welding process 1/2: t = s1 + s2 Key s1 thickness of butt weld BW made using welding process 1, e.g. 141, for single-side welding without backing is described: ss nb, s2 thickness of butt weld BW made using welding process 2, e.g. 111, the weld made using welding process 1 constitutes a steel backing for the weld made using process 2. The weld made using welding process 2 is a single-side weld made with steel backing described: ss mb. t material thickness Exemplary designation of qualification test scope: welding process 141/111 weld thickness t 20 (5/15)

for welding process 1 e.g. 141: t = s1 for welding process 2 e.g. 111: t = s2 Qualification range for each welding process used shall be based on the thickness of the test piece made using the welding process concerned

23

5.3

Product Type

5.3.1 The qualification test shall be carried out on plate or pipe, designated: P plate, T pipe. The range of qualification based on the test piece product type is given in Table 5.3.1. Table 5.3.1 Range of qualification for test piece product type
Test piece product type Range of qualification for product types pipe T D 50 mm X from D up to 2 D D 150 mm X only for welding positions PA, PB, PC D > 500 mm X

plate P

plate P

D 25 mm pipe T D > 25 mm

X 25mm or 0.5D whichever is the greater

5.3.2 A test piece in plates qualifies the welder for welding pipes of outside diameter D: D J 150 mm only in welding positions PA, PB, PC, provided they result from the test piece welding position, D J 500 mm in welding positions resulting from the test piece welding position, but only the plate test piece made in welding position PE qualifies the welder for welding pipes in position PF. 5.3.3 A test piece in pipes of D 25 mm in outside diameter qualifies the welder for welding pipes of outside diameters ranging from D to 2D only. A test piece in pipes of D  25 mm qualifies the welder for welding pipes with outside diameters J 0.5D, but not less than 25 mm. 5.3.4 Test pieces with single-side (ss) butt welds (BW) without backing (nb), qualify the welder for branch connections with an angle J 60 at the range of qualification based on the outside pipe diameter and wall thickness. A specific test piece shall be used to qualify the welder for branch connections with an angle < 60. 5.3.5 In cases where the majority of work is welding of branch connections or the form of such connections is complicated, customized training for welders is recommended. 24

5.4

Weld Type

5.4.1 Conventional letter designation of the test piece weld type is as follows: BW butt weld, FW fillet weld. The range of qualification based on the type of qualification test and the type of weld is specified in Table 5.4.1. Table 5.4.1 Range of qualification for weld type
Test piece weld type BW BW
1) 2)

Range of qualification for welds BW x x FW x x

FW
1)

BW FW x x In production, the majority of work is fillet welding 2) In production, the majority of work is butt welding Key X indicates the welds for which the welder is qualified. indicates the welds for which the welder is not qualified.

5.4.2 Qualification test usually qualifies the welder only for the weld type used in the test piece. This principle applies to welders engaged at works in which the majority of work is fillet welding, e.g. in works constructing or repairing the hulls of ships or other floating objects. 5.4.3 During qualification prolongation test of welders engaged at works in which the majority of work is fillet welding, the principle, set out in 5.4.2, shall be applied. In the case of welders engaged at works where the majority of work is butt welding, butt welds BW used in the test piece during the test extend the validity of qualification for fillet welds FW also, provided that the welders have already been qualified for fillet welds. 5.5 Material Groups

5.5.1 The division of steels into groups and sub-groups according to CEN TR ISO 15608 is given in Table 5.5.1-1. The range of qualification for groups and sub-groups of steel based on the parent material of the test piece is given in Table 5.5.1-2. 5.5.2 The division of aluminium and its alloys into groups and sub-groups according to CEN TR ISO 15608 is given in Table 5.5.2-1. The range of qualification for groups and sub-groups of aluminium and its alloys based on the parent material of the test piece is given in Table 5.5.2-2. 25

5.5.3 Where parent material is outside the grouping system according to Table 5.5.1-1 and Table 5.5.2-1, a separate qualification test is required, and the material shall be designated in accordance with the relevant standard defining such a material. 5.5.4 A qualification test made on steel groups qualifies for cast material and mixture of cast and wrought material in the same group or sub-group. Table 5.5.1-1 Grouping system for steels according to CEN TR ISO 15608
SubGroup group numnumber ber
1 2

Examples of steel designation Grade

3

Reference standard
4

Steels with a specified minimum yield point Re 460 MPa 1) and with analysis in %: C 0.25%; Si 0.60%; Mn 1.70%; Mo 0.70% 2); S 0.045%; P 0.045%; Cu 0.40% 2); Ni 0.5% 2); Cr 0.3% 2); Nb 0.05%; V 0.12% 2); Ti 0.05% Steels with a specified minimum yield strength Re 275 MPa S235JR, S235J0, S235J2, S275JR, S275J0, S26575J2 PN-EN 10025-2 S275N, S275NL PN-EN 10025-3 P235GH, P265GH, 16Mo3 PN-EN 10028-2 P275NH, P275NL1, P275NL2 PN-EN 10028-3 L210GA, L235GA, L245GA PN-EN 10208-1 L245NB, L245MB PN-EN 10208-2 P195TR1, P195TR2, P235TR1, P235TR2, P265TR1, P265TR2 PN-EN 10216-1 P195GH, P235GH, P265GH PN-EN 10216-2 1.1 P275NLX PN-EN 10216-3 P215NL, P255QL, P265NLX PN-EN 10216-4 P245GHX PN-EN 10222-2 E235, E275, E275K2 PN-EN 10297-1 Part IX of PRS 1 A, B, D, E Rules R35, R45 PN-89/H-84023/07 K10, K18 PN-75/H-84024 Steels with a specified minimum yield strength 275 MPa < Re 360 MPa S355JR, S355J0, S355J2, S355K2 PN-EN 10025-2 S355N, S355NL PN-EN 10025-3 P295GH, P355GH, 18MnMo4-5 PN-EN 10028-2 P355N, P355NH, P355NL1, P355NL2 PN-EN 10028-3 P355M, P355ML1, P355ML2 PN-EN 10028-5 1.2 P355Q, P355QH, P355QL1, P355QL2 PN-EN 10028-6 L290GA, L360GA PN-EN 10208-1 L290NB, L290MB, L360NB, L360MB, L360QB PN-EN 10208-2 20MnNb6, 16Mo3 PN-EN 10216-2 P285NH, P355NH, P285QH, P355QH PN-EN 10222-4

26

4 PN-EN 10225 PN-EN 10297-1 PN-75/H-84024 Part IX of PRS AH32, DH32, EH32, AH36, DH36, EH36 Rules Normalized fine-grain steels with a specified minimum yield strength Re > 360 MPa S420N, S420NL, S460N, S460NL PN-EN 10025-3 1.3 P460N, P460NL1, P460NL2 PN-EN 10028-3 L415NB PN-EN 10208-2 8MoB5-4 PN-EN 10216-2 P460NH PN-EN 10216-3 P420NH PN-EN 10222-4 Part IX of PRS AH40, DH40, EH40 Rules Steels with improved atmospheric corrosion resistance S235J0W, S235J2W, S355J0WP, S355J2WP, S355J2W, PN-EN 10025-5 1.4 S355K2W P285NH, P285QH, P355NH, P355QH PN-EN 10222 Thermomechanically treated fine grain steels with a specified minimum yield strength Re > 360 MPa Thermomechanically treated fine grain steels with a specified minimum yield strength 360 MPa < Re 460 MPa S420N, S420NL, S460N, S460NL PN-EN 10025-3 P460N, P460NH, P460NL1, P460NL2 PN-EN 10028-3 2.1 P420M, P420ML1, P420ML2, P460M, P460ML1, P460ML2 PN-EN 10028-5 2 L415MB, L450MB PN-EN 10208-2 S390GP, S430GP PN-EN 10248-1 Thermomechanically treated fine grain steels with a specified minimum yield strength Re > 460 MPa L485MB, L555MB PN-EN 10208-2 2.2 P420NH PN-EN 10222 Quenched and tempered steels and precipitation hardened steels with a specified minimum yield strength Re > 360 MPa, except stainless steels Quenched and tempered steels with a specified minimum yield strength 360 MPa < Re 690 MPa S460Q, S460QL, S460QL1, S500Q, S500QL, S500QL1, S550Q, S550QL, S550QL1, S620Q, S620QL, S620QL1, PN-EN 10025-6 S690QH, S690QL, S690QL1 P460Q, P460QH, P460QL1, P460QL2, P500Q, P500QH, PN-EN 10028-6 P500QL1, P500QL2, P690Q, P690H, P690QL1, P690QL2 3 3.1 C35E, C35R, C40E, C40R, C45E, C45R, C50E, C50R, C55E, PN-EN 10083-2 C55R, C60E, C60R, 28Mn6, L415QB, L450QB, L485QB, L555QB PN-EN 10208-2 38Cr2, 46Cr2, PN-EN 10208-3 P620Q, P620QH, P620QL PN-EN 10216-3 P420QH PN-EN 10222-4

3 S355G2, S355G3, S355G5, S355G6, S355G7, S355G8 E315, E355 16M

27

3 4 A420, D420, E420, F420, A460, D460, E460, F460, A500, Part IX of PRS D500, E500, F500, A550, D550, E550, F550, A620, D620, Rules E620, F620, A690, D690, E690, F690, Quenched and tempered steels with a specified minimum yield strength Re > 690 MPa 34Cr4, 34CrS4, 37Cr4, 37CrS4, 41Cr4, 41CrS4, 25CrMo4, 3.2 25CrMoS4, 34CrMo4, 34CrMoS4, 42CrMo4, 42CrMoS4, PN-EN 10083-3 50CrMo4, 34CrNiMo6, 30CrNiMo8, 36CrNiMo16, 51CrV4 Precipitation hardened steels, except stainless steels S890Q, S890QL, S890QL1, S960Q, S960QL PN-EN 10025-6 PN-EN 10137-3 3.3

S500A, S500AL, S550A, S550AL, S620A, S620AL, S690A, S690AL Low-vanadium alloyed Cr-Mo-(Ni) steels with Mo 0.7% and V 0.1% Steels with a content of Cr 0.3% and Ni 0.7% 4.1 4.2 P215NL, P255QL, P265NL 15NiCuMoNb5-6-4

PN-EN 10216-4 PN-EN 10216-2

Steels with Cr 0.7% and Ni 1.5%

Cr-Mo steels 3) free of vanadium with C 0.35% Steels with 0.75% Cr 1.5%; Mo 0.7% 13CrMo4-5, 13CrMoSi5-5 34CrMoS4, 25CrMoS4 5.1 10CrMo5-5, 13CrMo4-5, 25CrMo4 26CrMo4-2 15HM Steels with 1.5% < Cr 3.5%; 0.7% < Mo 1.2% PN-EN 10028-2 PN-EN 10208-2 PN-EN 10216-2 PN-EN 10216-4 PN-75/H-84024 PN-EN 10028-2 PN-EN 10216-2 PN-75/H-84024 PN-EN 10222-2 PN-EN 10028-2 PN-EN 10216-2 PN-EN 10216-2

10CrMo9-10, 12CrMo9-10 11CrMo9-10 10H2M Steels with 3.5% < Cr 7.0%; 0.4% < Mo 0.7% X16CrMo5-1 X12CrMo5 X11CrMo5+I, X11CrMo5+NT1, X11CrMo5+NT2 Steels with 7.0% < Cr 10.0%; 0.7% < Mo 1.2% 5.4 X11CrMo9-1+I , X11CrMo9-1+NT 5.3 5.2

High vanadium alloyed Cr-Mo-(Ni) steels Steels with 0.3% Cr 0.75%; Mo 0.7%; V 0.35% 14MoV6-3 6.1 13HMF Steels with 0.75% < Cr 3.5%; 0.7% < Mo 1.2%; V 0.35% 6.2 6.3 13CrMoV9-10, 12CrMoV12-10 20CrMoV13-5-5 Steels with 3.5% < Cr 7.0%; Mo 0.7%; 0.45% V 0.55% PN-EN 10216-2 PN-EN 10216-2 PN-75/H-84024 PN-EN 10028-2

28

2 3 Steels with 7.0%<Cr12.5%; 0.7% < Mo 1.2%; V 0.35% 6.4 X10CrMoVNb9-1

4 PN-EN 10028-2

X20CrMoV11-1 PN-EN 10216-2 Ferritic, martensitic or precipitation hardened stainless steels with C 0.35%; 10.5% Cr 30% Ferritic stainless steels X2CrNi12, X2CrTi12, X6CrNiTi12, X6Cr13, X6CrAl13, X2CrTi17, X6CrTi17, X6Cr17, X3CrTi17, X3CrNb17, X6CrMo17-1, X6CrMoS17, X2CrMoTi17-1, X2CrMoTi18-2, PN-EN 10088-1 X2CrMoTiS18-2, X6CrNi17-1, X6CrMoNb17-1, X2CrNbZr17, X2CrAlTi18-2, X2CrTiNb18, X2CrMoTi29-4 X12Cr13, X12CrS13, X20Cr13, X30Cr13, X29CrS13, X39Cr13, X46Cr13, X50CrMoV15, X70CrMo15, X14CrMoS17, X39CrMo17-1, X105CrMo17, X90CrMoV18, X17CrNi16-2, X3CrNiMo13-4, X4CrNiMo16-5-1 X5CrNiCuNb16-4, X7CrNiAl17-7, X5CrNiMoCuNb14-5,

7.1

Martensitic stainless steels 7.2 PN-EN 10088-1

Precipitation hardened stainless steels 7.3 PN-EN 10088-1 Austenitic stainless steels Austenitic stainless steels with Cr 19% X2CrNiN18-7, X2CrNi18-9, X2CrNi19-11, X5CrNi18-10, X6CrNi18-10, X6CrNiTi18-10, X2CrNiMo17-12-2, X6CrNiMoTi17-12-2, X2CrNiMo17-12-3, X2CrNiMo18-14-3, PN-EN 10028-7 X2CrNiMoN17-13-5, X6CrNiNb18-10, X2CrNiMoN17-13-3, X3CrNiMo17-13-3, X2CrNiMoN18-12-4 X10CrNi18-8, X8CrNiS18-9, X4CrNi18-12, X1CrNiSi18-15-4, X3CrNiCu19-9-2, X6CrNiCuS18-9-2, X3CrNiCu18-9-4, X3CrNiCuMo17-11-3-2 X7CrNiNb18-10, X3CrNiMo18-12-3 X7CrNiTi18-10, X7CrNiTiB18-10, X6CrNiMo17-13-2, X8CrNiMoNb16-16, X10CrNiMoMnNbVB15-10-1 1H18N9, 1H18N10T, 0H18N12Nb Austenitic stainless steels with Cr > 19% 8.1 X6CrNi23-13, X6CrNi25-20, X1NiCrMoCu25-20-5, X5NiCrAlTi31-20, X8NiCrAlTi32-21, X1CrNi25-21, X1CrNiMoN25-22-2, PN-EN 10088-1 PN-EN 10222-5 PN-EN 10216-5 PN-71/H-86020

PN-EN 10028-7

8.2

X2CrNi18-9, X2CrNiN18-10, X5CrNi18-10, X2CrNiCu19-10 PN-EN 10222-5 X5NiCrAlTi31-20, X8NiCrAlTi32-21 PN-EN 10216-5 Manganese austenitic stainless steels with 4.0% < Mn 12.0% 8.3 X12CrMnNiN17-7-5, X2CrMnNi17-7-5, X12CrMnNiN18-9-5, PN-EN 10088-1 Nickel alloy steels with Ni 10.0% Nickel alloy steels with Ni 3.0%

9.1

11MnNi5-3, 13MnNi6-3, 15NiMn6 13MnNi6-3, 15NiMn6

PN-EN 10028-4 PN-EN 10222-3

29

2 3 Nickel alloy steels with 3.0% < Ni 8.0% 9.2 12Ni14, X12Ni5 X8Ni9, X7Ni9 Nickel alloy steels with 8.0% < Ni 10.0%

4 PN-EN 10028-4 PN-EN 10028-4 PN-EN 10216-4

X10Ni9 Austenitic-ferritic stainless steels (duplex) Austenitic-ferritic steels with Cr 24.0% X2CrNiMoN22-5-3, X2CrNiN23-4 10.1 X2CrNiMo22-5-3 X2CrNiMoSi18-5-3 Austenitic-ferritic steels with Cr > 24.0% 10.2 X2CrNiMoN25-7-4, X3CrNiMoN27-5-2, X2CrNiMoCuN25-6-3, X2CrNiMoCuWN25-7-4

9.3

PN-EN 10088-1 PN-EN 10222-5 PN-EN 10216-5

10

PN-EN 10088-1

Steels with a specified minimum yield strength Re 460 MPa with 0.25% < C 0.50%; Si 0.60%; Mn 1.70%; Mo 0.70% 4); S 0.045%; P 0.045%; Cu 0.40% 4); Ni 0.5% 4); Cr 0.3% 4); Nb 0.05%; V 0.12% 4); Ti 0.05% Steels with 0.25% < C 0.35% 11.1 11.2
1) 2) 3) 4)

11

C35 C40, C45,

PN-EN 10083-2 PN-EN 10083-2

Steels with 0.35% < C 0.50%

In accordance with the specification of the steel product standards, Re may be replaced by R0.2 Higher content is permitted, provided that Cr + Mo + Ni + Cu + V 0.75%. Free of vanadium means that vanadium has not been added deliberately. Higher content is permitted, provided that Cr + Mo + Ni + Cu + V 1%.

Table 5.5.1-2 Range of qualification for steel parent material group or sub-group of the test piece
Material subgroup or group 1) of the test piece 1 1.1, 1.2, 1.4 1.3 2 3 4 5 6 7 82) 9.1 Range of qualification 1.1 1.2 1.4 2 X X X X X X X X X 1.3 3 X X X X X X X X 2 4 X X X X X X X X 3 5 X X X X X X X X 4 6 X X X X 5 7 X X X X 6 8 X X X X 7 9 X X X X 8 10 X 9.1 11 X X X X X X X X 9.2 9.3 12 X 10 13 X 11 14 X X X X X X X X

30

1 9.2, 9.3 102) 11

1) 2)

2 X X

3 X

10 X

11

12 X X

13 X

14 X

Material group according to CEN TR ISO 15608. Qualifies for welding steel material group 8 or 10 with other steels, provided that welding consumables used are suitable for welding steel group 8 or 10. Key X indicates the material groups for which the welder is qualified. indicates the material groups for which the welder is not qualified.

Table 5.5.2-1 Grouping system for aluminium and aluminium alloys according to CEN TR ISO 15608
Group number
1

Subgroup number
2

Examples of alloy designation 1) Grade

3

Reference standard
4

Pure aluminium with 1% of impurities or alloy content 21

EN AW-1199, EN AW-1098, EN AW-1198, EN AW-1090, PN-EN 573-3 EN AW-1085, EN AW-1070 Aluminium-manganese alloys 22.1 EN AW-3103 (EN AW-AlMn1) EN AW-5005 (EN AW-AlMg1(B)); EN AW-5005A (EN AW-AlMg1(C)) EN AW-5051A (EN AW-AlMg2(B)); EN AW-5754 (EN AW-AlMg3) PN-EN 573-3 Aluminium-magnesium alloys with Mg 1.5% 22.2 PN-EN 573-3

Not heat-treated alloys

Aluminium-magnesium alloys with 1.5% < Mg 3.5%

22

22.3

PN-EN 573-3

Aluminium-magnesium alloys with Mg > 3.5% EN AW-5086 (EN AW-AlMg4); EN AW-5083 (EN AW-AlMg4.5Mn0.7); EN AW-5056A PN-EN 573-3 (EN AW-AlMg5); EN AW-5383 (EN AW-AlMg4.5Mn0.9) 22.4 EN AC-51400 (EN AC-AlMg5(Si)); EN AC-51200 (EN AC-AlMg9) 5059 PN-EN 1706 Part IX of PRS Rules

Heat-treated alloys
Aluminium-magnesium-silicon alloys EN AW-6005A (EN AW-AlSiMg(A)); EN AW-6061 (EN AW-AlMg1SiCu); EN AW-6082 (EN AW-AlSi1MgMn) Aluminium-magnesium-zinc alloys 23.2 EN AW 7108 (EN AW-AlZn5Mg1Zr) 23.1

23

PN-EN 573-3

PN-EN 573-3

31

Aluminium-silicon alloys with Cu 1%

Aluminium-silicon alloys with Cu 1% and 5% < Si 15% EN AC-44000 (EN AC-AlSi11); EN AC-44400 24.1 PN-EN 1706 (EN AC-AlSi9); EN AC-44100 (EN AC-AlSi12(b)) Aluminium-silicon-magnesium alloys with Cu 1%; 5% < Si 15% and 0.1% < Mg 0.80% EN AC-43300 (EN AC-AlSi9Mg); EN AC-42000 24.2 (EN AC-AlSi7Mg); EN AC-42100 (EN AC-AlSi7Mg0.3); PN-EN 1706 EN AC-42200 (EN AC-AlSi7Mg0.6)

24

Aluminium-silicon-copper alloys with 5.0% < Si 15.0%; 1.0% < Cu 5.0% and Mg 0.8% 25
EN AC-45000 (EN AC-AlSi6Cu4); EN AC-45100 (EN AC-AlSi5Cu3Mg); EN AC-45400 (EN AC-AlSi5Cu3); EN AC-46200 (EN AC-AlSi8Cu3); EN AC-46300 (EN AC-AlSi7Cu3Mg) EN AC-21000 (EN AC-AlCu4MgTi); EN AC-21100 (EN AC-AlCu4Ti) PN-EN 1706

Aluminium-copper alloys with 2% < Cu 6% 26

PN-EN 1706

Groups 21y23 are for wrought materials and groups 24y26 are generally for cast materials.
1)

Numerical designation of the alloys intended for plastic working is in accordance with PN-EN 573-1. The designation of cast alloys is in accordance with PN-EN 1780-1. Designation of those alloys using chemical symbols according to PN-EN 573-2 or PN-EN 1780-2, respectively is given in brackets.

Table 5.5.2-2 Range of qualification for aluminium and aluminium alloy parent material group
Material group1) of the test piece Range of qualification 21 22 23 24 25 26

1 22 X X 23 X X X2) 24 X X 25 X X 26 X X X 1) Material group according to CEN TR ISO 15608. 2) The test piece made with AlMg welding consumable qualifies the welder for welding those material groups with AlSi consumable, but not vice versa. Key X indicates the material groups for which the welder is qualified. indicates the material groups for which the welder is not qualified.

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5.6

Welding Consumables

5.6.1 Designation of welding consumables used for the particular welding processes is given in Table 5.6.1-1. The designation of shielding gases is given in Table 5.6.1-2. Only Argon and Helium and the mixtures of these two gases are inert gases. 5.6.2 The ranges of qualification based on the welding consumables used for the test piece are given in Table 5.6.2. 5.6.3 A qualification test made using shielded-arc welding gives qualification only for the shielding gas used for the test piece. Table 5.6.1-1 Designation of welding consumables
Welding process Welding consumWelding consumable name able designation Covered electrodes type of covering A acid B basic C cellulose R rutile RA rutile-acid RB rutile-basic RC rutile-cellulose RR rutile thick Flux-cored wires core type B 136, 137, 125 basic P rutile fast-freezing slag R rutile slow-freezing slag Z others Flux-cored wires core type V 114 W Y Z S nm rutile or basic/fluorides basic/fluorides slow-freezing slag basic/fluorides fast-freezing slag others solid wire/rod no filler metal

111

121, 135, 131, 141, 311 141, 311

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Table 5.6.1-2 Examples of shielding gas composition according to PN-EN ISO 14175
Welding Gas process designation C1 C2 M11 M12 M13 M14 M20 135, 136, 138 M21 M22 M 23 M24 M25 M26 M27 M31 M32 M33 131, 137,141 I1 I2 I3 Composition, volume percentage CO2 100 the remainder 0.5 CO25 0.5 CO25 0.5CO25 5<CO215 15<CO225 0.5 CO25 5<CO215 5<CO215 15<CO225 15<CO225 25<CO250 25<CO250 O2 0.5O230 0.5O23 0.5O23 3<O210 3<O210 0.5O23 3<O210 0.5O23 3<O210 10<O215 2<O210 H2 0.5 H25 Ar the remainder the remainder the remainder the remainder the remainder the remainder the remainder the remainder the remainder the remainder the remainder the remainder the remainder the remainder the remainder 100 the remainder He 100 0.5He95

Table 5.6.2 Range of qualification for welding consumables used for test piece
Welding process 1) used for test piece 1 111 Welding consumables 2) 2 A, RA, RB, RC, RR, R B C solid S Range of qualification Covered electrodes A, RA, RB, RC, RR, R 3 X X B 4 X Wires flux-cored B M C 5 X

R, P, Z

V, W, Y, Z

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1 121, 131, 135 136, 137, 125 114 141, 311

2 solid S flux-cored R, P, Z flux-cored B flux-cored M flux-cored V, W, Y, Z X X

3 X X

4 X X

5 X

no filler metal nm solid wire / rod S no filler metal nm X solid wire / rod S X X 1) For designation of welding processes, see Table 5.2.1; for designation of welding consumables, see Table 5.6.1-1. 2) The type of welding consumable used for the test piece root run without backing (ss nb) is the type of welding consumable qualified for root runs in production. Key: X indicates the consumables for which the welder is qualified indicates the consumables for which the welder is not qualified.

5.7

Dimensions

5.7.1 The welder qualification test of butt welds is based on the material thickness t, i.e. the plate thickness or pipe wall thickness specified in the material approval certificate. For butt welds (BW), the range of qualification for material thickness is specified in Table 5.7.1-1 for steel and in Table 5.7.1-2 for aluminium and its alloys. Table 5.7.1-1 Range of qualification of steel parent material thickness and weld metal thickness for butt welds (BW)
Material thickness or weld metal thickness t [mm] td3 3  t d 12 t ! 12 For oxy-acetylene welding (311): from t to 1.5t. For oxy-acetylene welding (311): from 3 mm to 1.5t. Range of qualification from t to 2t1) from 3 mm to 2t2) t 5 mm

1) 2)

Table 5.7.1-2 Range of qualification of aluminium or aluminium alloy parent material thickness and weld metal thickness for butt welds (BW)
Material thickness or weld metal thickness t [mm] td6 t!6 Range of qualification from 0.5t to 2t t 6 mm

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5.7.2 In the case of butt weld test pieces with multi process joints (Table 5.2.3), the total thickness of the joint shall be: t = s1 + s2 t joint thickness, i.e. parent material thickness, s1 thickness of the weld made with the first welding process; this is usually a root run, s2 thickness of the weld made with the other welding process. For such a test piece, the welder is qualified for the weld thickness ranges separately for each welding process used, and they result from the butt weld thickness obtained using the particular process. 5.7.3 For more than one test piece made during the qualification test which differ only in thickness of the parent material, the thinnest and the thickest material thickness of the test pieces shall be taken into account to define the welders qualification. 5.7.4 For fillet welds (FW), the range of qualification based on the thickness of parent material used for the test piece is specified in Table 5.7.4. The test pieces shall comply with the following weld thickness requirement: 0.5t @ a @ 0.7t. Table 5.7.4 Range of qualification of material thickness of test piece for fillet welds (FW)
Material thickness or weld metal thickness t [mm] t3 tt3 Range of qualification from t to 3 mm t 3 mm

5.7.5 The range of qualification based on the outside diameter of the pipe used for the test piece is specified in Table 5.7.5. Table 5.7.5 Range of qualification for outside diameter of pipe test piece
Outside pipe diameter of test piece D [mm] De d 25 De ! 25
1)
1)

Range of qualification from D to 2D 25mm or 0.5D the greater value shall apply

For hollow sections, D is the dimension of the smaller side

5.7.6 If, during the qualification test, several test pieces are made of pipes with different outside diameters and wall thicknesses which differ only in dimensions the welders qualification is based on the thinnest and the thickest material thickness and the smallest and the largest outside pipe diameter.

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5.7.7 The range of welders qualification resulting from the test pieces with branch welding depends on the branch type, taking into account the following: for set on branches the material thickness and outside pipe diameter of the branch, for set in or set through branches the material thickness of the main pipe or shell and the outside diameter of the branch. 5.8 Welding Positions

5.8.1 Designation of welding positions for test pieces with butt welds BW or fillet welds FW in/on plates and pipes is given in Table 5.8.1. The welding positions: horizontal vertical position (PB) and horizontal overhead position (PD) are only used for fillet welds; the remaining welding positions are used for both butt welds and fillet welds. 5.8.2 The range of qualification resulting from the test piece welding position is specified in Table 5.8.2. 5.8.3 Welding, during qualification test, two pipes with the same outside pipe diameter, one in welding position PC and the other in welding position PF also qualifies the range of qualification of a pipe welded in welding position H-L045. 5.8.4 Welding, during qualification test, two pipes with the same outside pipe diameter, one in welding position PC and the other in welding position PG also qualifies the range of qualification of steel pipe welded in welding position J-L045. 5.8.5 During qualification test, the butt weld of pipe test piece with outside pipe diameter D J 150 mm can be welded in two welding positions: 1/3 of circumference PC, 2/3 of circumference PF (for each type of pipes) or PG (for steel pipes only). Table 5.8.1 Test piece welding positions
Test piece Product type 1 Plate welding P Weld type 2 Flat Horizontal Vertical upward Vertical downward Overhead Welding position according to PN-EN ISO 6947 Test piece welding position 3 PA PC PF PG PE Designation 4

Butt weld BW

37

2 Flat Horizontal vertical Vertical upward Vertical downward Horizontal overhead

3 PA PB PF PG PD

Fillet weld FW

Butt weld BW Pipe welding T

Flat, horizontal pipe axis, pipe rotating Horizontal , vertical pipe axis, pipe fixed Vertical upward, horizontal pipe axis, pipe fixed Vertical downward, horizontal pipe axis, pipe fixed Upward welding, pipe axis inclined at an angle of 45q, pipe fixed Downward welding, pipe axis inclined at an angle of 45q, pipe fixed Horizontal vertical, horizontal pipe axis, pipe rotating or vertical pipe axis, pipe fixed Vertical upward, horizontal pipe axis, pipe fixed Vertical downward, horizontal pipe axis, pipe fixed Horizontal overhead, horizontal pipe axis, pipe fixed

PA PC PF PG H-L045 J-L045

PB PF PG PD

Fillet weld FW

Table 5.8.2 Range of qualification for welding positions

Test piece Weld type 12 Welding position (product type) 1) 2 PA PC PE(P) PE(T) PF(P) PF(T) BW PG(P) PG(T) H-L045(T) J-L045(T)
3)

Range of qualification Product type: plate (P) 3 PA PA PC PA PC PE PF PA PC PE PF PA PF PA PE PF PG PA PE PG PA PC PE PF PA PC PE PG PA PC PF PA PC PE PF PA PC PE PG Product type: pipe (T) 4 PA PA PC PA PC PE PF2) PA PC PE PF PA PA PE PF PA PE PG PA PC PE PF H-L045 PA PC PE PG J-L0453) PA PC PA PC PE PF H-L045 PA PC PE PG J-L0453)

PC PF(P) PC PF(T) PC PG (T)

38

2 PA PB4) PC PD4) PE PF(P) PF(T) PG(P) PG(T) H-L045(T) J-L045(T)

3)

3 PA PA PB PA PB PC PA PB PC PD PE PF PA PB PC PD PE PF PA PB PF PA PB PD PE PF PG PA PB PD PE PG PA PB PC PD PE PF PA PB PC PD PE PG

4 PA PA PB PA PB PC PA PB PC PD PE PF2) PA PB PC PD PE PF2) PA PB PA PB PD PE PF PA PB PD PE PG PA PB PC PD PE PF H-L045 PA PB PC PD PE PG J-L0453)

FW5)

1)

2) 3) 4) 5)

If product type is not specified, the indicated ranges of qualification do not depend on type of product. Only for pipes with outside diameter D t 500 mm. Only for steel pipes. Welding positions PB and PD apply to fillet welds only. According to 5.4.3.

5.9

Weld Details

5.9.1 The range of qualification based on the weld details of butt weld test pieces is specified in Table 5.9.1. Table 5.9.1 Range of qualification for weld details on butt welds (BW)
Range of qualification Butt weld (BW) details of test piece single-side welding without backing (ss nb) single-side welding with backing ceramic (ss mb) metal (ss mb) welding from both sides with ceramic backing (bs mb) X weld root removed (bs) X X X X

single-side welding X X without backing (ss nb) single-side welding with X X ceramic backing (ss mb) single-side welding with X metal backing (ss mb) welding from both sides, X weld root removed (bs) Key X indicates the butt welds for which the welder is qualified. indicates the butt welds for which the welder is not qualified.

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5.9.2 The range of qualification based on the weld details of fillet weld test pieces is specified in Table 5.9.2. Table 5.9.2 Range of qualification for weld details on fillet welds (FW)
Test piece fillet weld (FW) 1) single run (sl) multi run (ml)
1)

Range of qualification single run (sl) X X multi run (ml) X

Throat thickness shall be in the range of 0.5t d a d 0.7t. Key X indicates the fillet welds for which the welder is qualified. indicates the fillet welds for which the welder is not qualified.

5.9.3 The range of qualification based on the weld details of butt weld test pieces for oxy-acetylene welding process is specified in Table 5.9.3. Table 5.9.3 Range of qualification for welding direction for process 311
Test piece welding direction leftward welding (lw) rightward welding (rw) Range of qualification leftward welding (lw) X rightward welding (rw) X

Key X indicates the welding type (i.e. welding run direction) for which the welder is qualified. indicates the welding type (i.e. welding run direction) for which the welder is not qualified.

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Annex 1 a)

b)

Fig.1. Dimensions of plate test piece (P); S PRS stamp. a) butt weld (BW) b) fillet weld (FW)), 0.5 t a 0.7 t

41

a)

b)

Fig. 2

Dimensions of pipe test piece (T). a) butt weld (BW); b) fillet weld (FW), 0.5 t a 0.7 t

42

Annex 2

Application to Polski Rejestr Statkw for welder?s qualification test

WELDER?S FULL NAME: ......................................................................................................................................... WELDER?S NATIONAL PERSONAL IDENTITY NUMBER: ................................................................................ DATE AND PLACE OF BIRTH: ................................................................................................................................ WELDER?S BOOK NO.: ............................................................................................................................................. EMPLOYER: ............................................................................................................................................................... TESTING STANDARD/RULES: ................................................................................................................................ TYPE OF QUALFICATION TEST: INITIAL, PROLONGATION, REVISION 1) DESIGNATION OF PREVIOUS QUALIFICATION TEST: .................................................................................... WELDING PROCEDURE SPECIFICATION (WPS): ............................................................................................... Scope of qualification test Qualification test details Welding process number Product type Weld type Parent material grade Group of parent material Thickness of parent material/welds Outside diameter of pipes Welding consumable designation Shielding gas Welding position Backing type Weld details
1) 2)

Welders qualification test Report No./Welders qualification No. Carried out2) Date of test piece welding

Proposed

Test piece designation

Welding consumable grade

Visual examination results root: face: Theoretical job knowledge test result Initials and signature of Surveyor

Delete as appropriate. To be completed by PRS Surveyor.

.................................. Date ........................

Signature and stamp of the firm

43