STEEL KONNECT (INDIA) PVT. LTD.

SKIPL /QC/P - 08
PROCEDURE MANUAL PAGE : 1 OF 4

PROCEDURE FOR PRODUCTION TEST REVISION : 00

COUPEN DATE : 01.02.2013

1.0 PURPOSE
The purpose of this procedure is to establish and maintain documented
procedure to ensure that the product analysis is carried out as per the
applicable specifications / standards.

2.0 SCOPE
This procedure covers the methodology for verification of weld joint soundness
for process control, acceptance norms and clearance of machine welded fillet
welds for main columns & Ceiling Girders only.

3.0 REFERENCE
ASME SEC IX: 2010 & 2011a addenda
AWS D1.1:2010
MPS

4.0 RESPONSIBILITY
Lab Assistance / Lab In charge or Engineer In charge shall be responsible for
carrying out & evaluation of testing.

5.0 SAFETY
Before testing, an Engineer/Supervisor shall be familiar with relevant
regulations covering health safety and hazardous substances, both local and
statutory, appropriate test method.

6.0 PREPARATION OF TEST SAMPLE

6.1 For Butt Joint – Thickness of the production test coupon shall be of
maximum of the joint being welded. The size of the coupon shall be:
Length: 150 mm
Plate Size: 150 x 300 x Thickness

The test coupon shall be subjected to the following mechanical tests.

a) One tensile test – shall meet the minimum requirements of parent
material.
b) Radiography or Ultrasonic Examination – shall meet the minimum
requirements of fusion in parent metal. (If ultrasonic test
equipment used, shall be of recordable type.)
c) The weld will be cleared based on test coupon acceptance

Prepared By Reviewed By Approved By

 Engineer QC Head QA&C Management Representative

STEEL KONNECT (INDIA) PVT. LTD. SKIPL /QC/P - 08

PROCEDURE MANUAL PAGE : 2 OF 4

PROCEDURE FOR PRODUCTION TEST REVISION : 00

COUPEN DATE : 01.02.2013

6.2 For Fillet joint – The production test coupon shall be attached to one
end of the maximum thick Column. The size of the coupon shall be:
Flange Width: 300 mm
Flange Length: 200mm
Web Length: 200mm
Web Height: 150mm
Thickness: Same of the column
The test coupon shall be subjected to the following mechanical tests
6.2.1 Macro Examination – shall meet the requirements of fusion as
specified in AWS D 1.1
The number of passes as determined by the minimum fillet weld
size and maximum fillet weld size for a single pass shall be
verified.

7.0 EQUIPMENT USED

Universal Testing Machine
Make : BLUE STAR
Capacity : 100 MT
Calibration Frequency : Once in the Year

8.0 METOD
8.1 Measure the thickness & width of test specimen, calculate the effective
area in (mm2) & note down in testing log register/system.
8.2 Load the sample on the machine with proper gripping of the end strips.
8.3 Start to apply load to the sample.
8.4 Note down the Ultimate Load (N) at the breaking of the sample.
8.5 Find out the results by placing the values in following formulas:

Ultimate Load (N)

 Tensile Strength (Mpa) = -----------------------------
Area (mm2)

8.6 For fillet weld, cut two samples from the coupon plate & check macro test
by using suitable etching solution.

9.0 INVALIDATION OF THE TESTS

Specimen showing material defects or defective preparation, whether observed
before or after breaking, may be discarded and replacements shall be
considered as original specimen. The replacement test piece can be taken from
the balance sample which is already preserved with punching.
10.0 ACCEPTANCE CRITERIA
As per ASME SEC IX / AWS D 1.1 & Client’s Technical specification.

Prepared By Reviewed By Approved By

Engineer QC Head QA&C Management Representative

STEEL KONNECT (INDIA) PVT. LTD. SKIPL /QC/P - 08

PROCEDURE MANUAL PAGE : 3 OF 4

PROCEDURE FOR PRODUCTION TEST REVISION : 00

COUPEN DATE : 01.02.2013

11.0 RETEST
In case of any failure, the following will be the disposition:
11.1 The cause of the failure shall be clearly established & agreed
between SKIPL & Client.
11.2 100% RT in case of columns, at location wherever not done
earlier as called for in approved QAP
11.3 Cut all the representing welds and re weld if called for in the
agreed Conclusion / actions as per clause no. 11.1 above.
11.4 in case of re - welding, re – test coupon will be approved and all
other procedure requirements shall be applicable.

12.0 RECORDS
Each production test coupon & spliced portions shall be traceable to the column
& joint.
Column number & joint number shall be punched.
Following Results of testing shall be recorded in format.
12.1 Identification of test pieces (e.g. sample ID no.).
12.2 Size of test pieces.
12.3 Test Results.
12.4 Name & designation of testing & approving personnel.

Material Sampling & Test Plan – Test Plates

Balance to be preserved with punching

30mm Transverse Tensile

15mm Discard
 Thick T Weld 150 mm

300 mm

Figure 1

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Engineer QC Head QA&C Management Representative

STEEL KONNECT (INDIA) PVT. LTD. SKIPL /QC/P - 08

PROCEDURE MANUAL PAGE : 4 OF 4

PROCEDURE FOR PRODUCTION TEST REVISION : 00

COUPEN DATE : 01.02.2013

Web Thick T2

150 mm Balance to preserve with punching

Macro Sample 100 mm

Discard 15 mm 200
mm

Flange Thick T1

300 mm

Note: Figure 2

1. The sketch does not indicate the cutting allowance which is about 5 mm for each cut.
2. If the thickness is 30mm & below, Top & Bottom is not required. One tensile specimen
covering the entire thickness is enough
3. In case any weld defects are indicated by NDE, those regions should be point marked so
that it can be avoided in taking specimen. These areas should not be stamped while marking
specimen.
4. Thickness of the slice & the capacity of UTM will be based on NABL approved Laboratory
Prepared By Reviewed By Approved By

Engineer QC Head QA&C Management Representative