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AS/NZS 3992:1998 Pressure equipment - Welding and brazing qualification
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AS/NZS 3992
Licensed to Ms Alison Samuels on 8 September 2011. 1 user personal user licence only. Storage, distribution or use on network prohibited (10239038).
AS/NZS 3992:1998
(Incorporating Amendment No. 1)
Australian/New Zealand Standard™
Pressure equipment—Welding and
brazing qualification
AS/NZS 3992:1998
Licensed to Ms Alison Samuels on 8 September 2011. 1 user personal user licence only. Storage, distribution or use on network prohibited (10239038).
This Joint Australian/New Zealand Standard was prepared by Joint Technical
Committee ME/1, Pressure Equipment. It was approved on behalf of the Council of
Standards Australia on 13 February 1998 and on behalf of the Council of Standards
New Zealand on 16 March 1998. It was published on 5 May 1998.
The following interests are represented on Committee ME/1:
A.C.T. WorkCover
Australasian Corrosion Association
Australasian Institute of Engineering Inspection
Australian Aluminium Council
Australian Building Codes Board
Australian Chamber of Commerce and Industry
Australian Institute of Energy
Australian Institute of Petroleum
Australian Liquefied Petroleum Gas Association
Boiler and Pressure Vessel Manufacturers Association of Australia
Bureau of Steel Manufacturers of Australia
Department for Industrial Affairs, S.A.
Department of Labour, New Zealand
Department of Training and Industrial Relations, Qld
Electricity Corporation of New Zealand
Electricity Supply Association of Australia
Institute of Metals and Materials, Australasia
Institution of Engineers, Australia
Institution of Professional Engineers, New Zealand
Metal Trades Industry Association of Australia
National Association of Testing Authorities, Australia
New Zealand Engineering Federation
New Zealand Heavy Engineering Research Association
New Zealand Institute of Welding
New Zealand Petrochemical Users Group
New Zealand Timber Industry Federation
Victorian WorkCover Authority
Welding Technology Institute of Australia
WorkCover N.S.W.
Work Health Authority, N.T.
Workplace Standards Authority, Tas.
WorkSafe Western Australia
Keeping Standards up-to-date
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the Standard was purchased.
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visiting the Standards Australia web site at www.standards.com.au or Standards
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Please address your comments to the Chief Executive of either Standards Australia
International or Standards New Zealand at the address shown on the back cover.
This Standard was issued in draft form for comment as DR 96090.
AS/NZS 3992:1998
Licensed to Ms Alison Samuels on 8 September 2011. 1 user personal user licence only. Storage, distribution or use on network prohibited (10239038).
(Incorporating Amendment No. 1)
Australian/New Zealand Standard™
Pressure equipment—Welding and
brazing qualification
Originated in Australia as AS 3992 — 1992.
Revised and redesignated AS/NZS 3992:1998.
Reissued incorporating Amendment No. 1 (April 2000).
COPYRIGHT
© Standards Australia/Standards New Zealand
All rights are reserved. No part of this work may be reproduced or copied in any form or by
any means, electronic or mechanical, including photocopying, without the written
permission of the publisher.
Jointly published by Standards Australia International Ltd, PO Box 1055, Strathfield,
NSW 2135 and Standards New Zealand, Private Bag 2439, Wellington 6020
ISBN 0 7337 1876 0
AS/NZS 3992:1998
2
Licensed to Ms Alison Samuels on 8 September 2011. 1 user personal user licence only. Storage, distribution or use on network prohibited (10239038).
PREFACE
This Standard was prepared by the Joint Standards Australia/Standards New Zealand
Committee ME/1, Pressure Equipment to supersede AS 3992 — 1992, Boilers and pressure
vessels — Welding and brazing qualification.
This Standard incorporates Amendment No. 1 (April 2000). The changes required by the
Amendment are indicated in the text by a marginal bar and amendment number against
the clause, note, table, figure, or part thereof affected.
This Standard is the result of a consensus among representative on the Joint Committee to
produce it as a Joint Australian/New Zealand Standard. Consensus means general
agreement by all interested parties. Consensus includes an attempt to remove all
objections and implies much more than the concept of a simple majority, but not
necessarily unanimity. It is consistent with this meaning that a member may be included
in the Committee list and yet not be in full agreement will all clauses of this Standard.
This Standard unifies and revises the requirements for the qualification of welding and
brazing procedures, welding and brazing personnel, and production test plates and welds,
specified in AS 1210, Pressure vessels, AS 1228, Pressure equipment — Boilers and
AS 4041, Pressure piping.
The main changes in this revision are as follows:
(a)
Inclusion of Amendments 1 and 2 to AS 3992 — 1992.
(b)
Inclusion of requirements for hard facing metal overlay.
(c)
Publication as a Joint Australian/New Zealand Standard.
(d)
Clarification and revision of text to current accepted welding and brazing practice.
(e)
Addition of diagrams to define parent material thickness.
(f)
Recognition of the changing role of the Australian regulatory authorities.
The objective of this Standard is to reduce misunderstanding, costs and delays in
qualifying welding; avoid unnecessary duplication of testing; promote greater confidence
in reciprocal acceptance of approved procedures; and improve safety.
This Standard is based on AS 1210, with due allowance for practices or requirements of
AS 1228 and AS 4041. Modifications have been made to utilize current appropriate
requirements of ASME BPV Sec IX ASME Boiler and Pressure Vessel Code,
Section IX: Qualification standard for welding, brazing procedures, welders, brazers and
welding and brazing operators, ISO 9956, Specification and approval of welding
procedures for metallic materials, BS EN 287, Approval testing of welders for fusion
welding, Part 1: Steels, BS EN 288, Specification and approval of welding proceedings
for metallic materials, Part 1: General rules for fusion welding and AS 2885,
Pipelines — Gas and liquid petroleum, Part 2: Welding.
Requirements have been formulated with a view to maximum compatibility with
recognized leading international Standards.
This Standard introduced to the Pressure Equipment Standards the concept of prequalified
welding procedures, i.e. procedures which have been proved by extensive use by many
organizations to meet the quality requirements of the Standards readily and consistently.
Such procedures are limited to materials and thicknesses which are readily welded with
proved processes and consumables by qualified welders.
It is not intended that the publication of this edition will invalidate welding tests that were
accepted in respect of other Standards of AS/NZS 1200, Pressure equipment.
Statements expressed in mandatory terms in notes to tables and figures are deemed to be
requirements of this Standard.
3
AS/NZS 3992:1998
Licensed to Ms Alison Samuels on 8 September 2011. 1 user personal user licence only. Storage, distribution or use on network prohibited (10239038).
The terms ‘normative’ and ‘informative’ have been used in this Standard to define the
application of the appendix to which they apply. A ‘normative’ appendix is an integral
part of a Standard, whereas an ‘informative’ appendix is only for information and
guidance.
AS/NZS 3992:1998
4
CONTENTS
Licensed to Ms Alison Samuels on 8 September 2011. 1 user personal user licence only. Storage, distribution or use on network prohibited (10239038).
Page
SECTION 1 SCOPE AND GENERAL
1.1 SCOPE . . . . . . . . . . . . . . . . .
1.2 APPLICATION . . . . . . . . . . .
1.3 REFERENCED DOCUMENTS
1.4 DEFINITIONS . . . . . . . . . . . .
1.5 OTHER PROCESSES . . . . . . .
1.6 OTHER MATERIALS . . . . . .
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7
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SECTION 2 PREQUALIFIED WELDING PROCEDURES
2.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.2 PREQUALIFIED GASES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.3 ALUMINOTHERMIC WELDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
SECTION 3 QUALIFICATION OF WELDING PROCEDURES FOR BUTT,
BRANCH AND FILLET WELDS
3.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2 METHODS OF QUALIFICATION OF WELDING PROCEDURE . .
3.3 RECORDING OF WELDING PROCEDURE DATA . . . . . . . . . . .
3.4 TESTING OF WELDING PROCEDURE TEST WELDS . . . . . . . .
3.5 REQUALIFICATION OF A WELDING PROCEDURE . . . . . . . . .
3.6 PORTABILITY OF QUALIFIED WELDING PROCEDURES . . . . .
3.7 RECIPROCITY OF QUALIFIED WELDING PROCEDURES . . . . .
3.8 WELDING PROCEDURE SPECIFICATION . . . . . . . . . . . . . . . .
3.9 WELDING PROCEDURES FOR REPAIR WELDING . . . . . . . . . .
3.10 REPAIRS, REPLACEMENT OR ALTERATION TO
IN-SERVICE PRESSURE EQUIPMENT . . . . . . . . . . . . . . . . . . .
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13
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. . . . . . 15
SECTION 4 ITEMS TO BE RECORDED FOR WELDING PROCEDURE
TEST WELDS
4.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.2 ITEMS SPECIFIC TO NOMINATED WELDING PROCESSES . . . . . . . . . 16
4.3 RECORDING OF WELDING PROCEDURE TEST WELDS . . . . . . . . . . . 16
SECTION 5 ESSENTIAL VARIABLES FOR WELDING PROCEDURE
QUALIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
SECTION 6 WELD TEST PIECES
6.1 TEST PIECES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2 VISUAL EXAMINATION . . . . . . . . . . . . . . . . . . . . . . .
6.3 NON-DESTRUCTIVE EXAMINATION OF TEST PIECES
6.4 POSTWELD HEAT TREATMENT . . . . . . . . . . . . . . . . .
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32
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5
AS/NZS 3992:1998
Licensed to Ms Alison Samuels on 8 September 2011. 1 user personal user licence only. Storage, distribution or use on network prohibited (10239038).
Page
SECTION 7 MECHANICAL TESTING OF WELDS FOR PROCEDURE
QUALIFICATION
7.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2 RESPONSIBILITY FOR TESTING . . . . . . . . . . . . . . . . . . . .
7.3 TEST SPECIMENS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.4 TRANSVERSE TENSILE TEST . . . . . . . . . . . . . . . . . . . . . .
7.5 ALL-WELD-METAL TENSILE TEST . . . . . . . . . . . . . . . . . .
7.6 BEND TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.7 CHARPY V-NOTCH IMPACT TEST . . . . . . . . . . . . . . . . . . .
7.8 MACRO EXAMINATION . . . . . . . . . . . . . . . . . . . . . . . . . .
7.9 WELD JOINT HARDNESS TEST . . . . . . . . . . . . . . . . . . . . .
7.10 FILLET BREAK TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.11 NICK-BREAK TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.12 ADDITIONAL TESTS BEFORE REJECTION . . . . . . . . . . . .
7.13 REPORTING OF RESULTS . . . . . . . . . . . . . . . . . . . . . . . . .
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SECTION 8 WELD OVERLAY QUALIFICATION TESTING
8.1 CLAD PLATE CONSTRUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
8.2 CORROSION-RESISTANT WELD METAL OVERLAY . . . . . . . . . . . . . . 49
8.3 HARDFACING WELD METAL OVERLAY . . . . . . . . . . . . . . . . . . . . . . . 50
SECTION 9 WELDER QUALIFICATION
9.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.2 METHODS OF QUALIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . .
9.3 EXTENT OF APPROVAL OF WELDER QUALIFICATION . . . . . . . .
9.4 INFORMATION TO BE GIVEN TO WELDER FOR QUALIFICATION
TEST WELDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.5 EXAMINATION AND TESTING OF WELDER QUALIFICATION
TEST WELDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.6 RECORDING OF WELDER QUALIFICATION TESTS . . . . . . . . . . . .
9.7 RETESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.8 RENEWAL OF WELDER QUALIFICATION . . . . . . . . . . . . . . . . . . .
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SECTION 10 WELD PRODUCTION TESTS
10.1 PRODUCTION TEST PLATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
10.2 ADDITIONAL TESTS BEFORE REJECTION . . . . . . . . . . . . . . . . . . . . . 57
10.3 RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
SECTION 11 BRAZING QUALIFICATION
11.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . .
11.2 QUALIFICATION REQUIRED . . . . . . . . . . .
11.3 GROUPING OF MATERIALS FOR BRAZING
11.4 GROUPING OF BRAZING FILLER METALS
11.5 BRAZING FLOW POSITIONS . . . . . . . . . . .
11.6 RECORDS . . . . . . . . . . . . . . . . . . . . . . . . .
..............
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QUALIFICATION
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AS/NZS 3992:1998
6
Licensed to Ms Alison Samuels on 8 September 2011. 1 user personal user licence only. Storage, distribution or use on network prohibited (10239038).
Page
SECTION 12 QUALIFICATION OF BRAZING PROCEDURE
12.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12.2 REQUALIFICATION OF A BRAZING PROCEDURE . . . . . . . .
12.3 PORTABILITY OF QUALIFIED BRAZING PROCEDURE . . . . .
12.4 PREQUALIFIED BRAZING PROCEDURE . . . . . . . . . . . . . . . .
12.5 ITEMS TO BE RECORDED FOR BRAZING PROCEDURE
QUALIFICATION TEST BRAZES . . . . . . . . . . . . . . . . . . . . . .
12.6 ESSENTIAL VARIABLES FOR BRAZING PROCEDURE
QUALIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12.7 TEST PIECES FOR BRAZING PROCEDURE QUALIFICATION
12.8 VISUAL EXAMINATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 13 EXAMINATION AND TESTING OF
13.1 REMOVAL OF TEST SPECIMENS . . . . .
13.2 TRANSVERSE TENSILE TEST . . . . . . .
13.3 BEND TEST . . . . . . . . . . . . . . . . . . . . .
13.4 PEEL TEST . . . . . . . . . . . . . . . . . . . . . .
13.5 SECTIONING TEST . . . . . . . . . . . . . . .
13.6 WORKMANSHIP SPECIMEN TEST . . . .
13.7 RETESTS . . . . . . . . . . . . . . . . . . . . . . .
BRAZED JOINTS
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SECTION 14 BRAZER AND BRAZING OPERATOR QUALIFICATION
14.1 METHODS OF QUALIFICATION . . . . . . . . . . . . . . . . . . . . .
14.2 ESSENTIAL VARIABLES FOR QUALIFICATION OF
BRAZING PERSONNEL . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14.3 EXTENT OF APPROVAL OF BRAZING QUALIFICATION . . .
14.4 INFORMATION TO BE GIVEN TO BRAZER OR BRAZING
OPERATOR FOR QUALIFICATION TEST JOINT . . . . . . . . . .
14.5 QUALIFICATION TEST JOINTS AND TESTING . . . . . . . . . .
14.6 RECORDING OF BRAZER AND BRAZING OPERATOR
QUALIFICATION TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . .
14.7 RETESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14.8 RENEWAL OF BRAZER QUALIFICATION . . . . . . . . . . . . . .
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. . . . . . . . 73
. . . . . . . . 73
. . . . . . . . 74
. . . . . . . . 74
. . . . . . . . 74
SECTION 15 ALUMINOTHERMIC WELDING OF ELECTRICAL CONDUCTORS
APPENDICES
A LIST OF REFERENCED DOCUMENTS . . . . . . . . . . . . . . . . .
B WELDING PROCEDURE SPECIFICATION . . . . . . . . . . . . . .
C RECORD OF QUALIFICATION OF WELDING PROCEDURE
D TYPICAL FERROUS MATERIAL SPECIFICATIONS . . . . . . .
E MACRO-ETCHING OF WELDED JOINTS . . . . . . . . . . . . . . .
F RECORD OF QUALIFIED BRAZING PROCEDURE . . . . . . . .
G BASIS FOR GROUPING OF STEELS . . . . . . . . . . . . . . . . . .
H EXAMPLES OF THE APPLICATION OF THIS STANDARD
TO PRESSURE VESSEL AND PIPING FABRICATION . . . . .
63
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AS/NZS 3992:1998
STANDARDS AUSTRALIA/STANDARDS NEW ZEALAND
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Australian/New Zealand Standard
Pressure equipment — Welding and brazing qualification
S E C T I O N
1
S C O P E
A N D
G E N E R A L
1.1 SCOPE This Standard specifies requirements for the qualification of welding and
brazing procedures, welders and brazers, and requirements for production weld testing
other than non-destructive examination, when used in the construction, alteration and
repair of boilers, pressure vessels, pressure piping and their components as specified in
AS/NZS 1200, AS 1210, AS 1228 and AS 4041.
This Standard may apply to automotive LPG fuel vessels (covered by AS/NZS 3509),
serially produced pressure vessels (covered by AS 2971) or welded gas cylinders (covered
by AS 2030), when specified by these Standards. This Standard does not apply to
pipelines in accordance with AS 2885 except where referenced.
The Standard provides specific details for the following:
(a)
Manual metal-arc welding, flux cored arc welding, gas metal-arc welding, gas
tungsten-arc welding, submerged arc welding, plasma transferred arc welding,
electroslag welding and oxy-acetylene welding.
(b)
Torch brazing, furnace brazing, induction brazing, resistance brazing and dip
brazing.
(c)
The welding and brazing of carbon, carbon-manganese, and low and high alloy
steels; and copper, aluminium, nickel, titanium and alloys of these materials.
The principles established in this Standard may be used in the qualification of processes,
materials and applications not covered by the above (see also Clause 1.5 and Clause 1.6).
For flash butt welding qualification, refer to AS 4413.
Specific details for stud welding, electron-beam welding, plasma arc welding, electro-gas
welding, and friction welding processes are not covered by this Standard.
Where this Standard makes reference to other Standards, these referenced Standards are
not intended to be limiting or exclusive and other equivalent National Standards
acceptable to the parties concerned may be substituted for the referenced Standards.
AS/NZS 1200 provides a list of pressure equipment Standards used in Australia and
New Zealand.
Compliance with ANSI/ASME Section IX, BS EN 287 or BS EN 288 is deemed as an
acceptable alternative to the requirements of this Standard where agreed between the
parties concerned. Where this Standard (AS/NZS 3992) requires tests not already
completed under these overseas Standards then this can be covered by those additional
tests only, rather than repeating the full set of tests, e.g. as part of a production test plate.
1.2 APPLICATION This Standard is intended for use by designers, fabricators,
welders, brazers, inspection bodies, inspectors, testing authorities and all persons
concerned with the welding and brazing of pressure equipment.
Users of this Standard are reminded that it has no legal authority in its own right, but may
acquire legal standing in one or more of the following circumstances:
(a)
Adoption by a government or other authority having jurisdiction.
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AS/NZS 3992:1998
8
(b)
Adoption by a purchaser as the required standard of construction when placing a
contract.
(c)
Adoption where a manufacturer states that pressure equipment is in accordance with
an application Standard which mandates compliance with this Standard.
1.3 REFERENCED DOCUMENTS
to in this Standard.
The documents listed in Appendix A are referred
Where reference is made to a Standard by its number only, the reference applies to the
current edition of the Standard. Where reference is made to a Standard by number, year
and where relevant an amendment number, the reference applies to that specific document.
1.4 DEFINITIONS
those below apply.
1.4.1
For the purpose of this Standard, the definitions in AS 2812 and
Brazer — a person who performs a manual brazing operation.
1.4.2 Brazing operator — a person who operates furnaces or other automatically
controlled or timed brazing equipment.
1.4.3 Essential variables for a welder qualification — those variables in the welding
procedure in which a change outside the limits specified in this Standard is considered to
reduce the ability of a welder to make a weld with the required mechanical properties and
soundness, e.g. change in welding process or technique, or the deletion of a backing strip,
bar or ring.
1.4.4 Essential variables for a welding or brazing procedure — those variables in the
welding or brazing procedure in which a change outside the limits specified in this
Standard is considered to affect the mechanical properties of the weld, e.g. change in
welding process, consumables, or heat treatment.
1.4.5 Fabricator — the person or organization responsible for the welding of the
pressure equipment.
NOTE: In this Standard, ‘fabricator’ includes ‘constructor’, ‘assembler’, ‘installer’, and
‘erector’ and is used to embrace all or some of these terms and is applicable to all locations, on
or off site, where components may be fabricated.
1.4.6 Inspection body — a body corporate or firm responsible for inspection which may
be any one or more of design verification, fabrication inspection and in-service inspection.
NOTE: The manufacturer may be the inspection body when permitted by AS 3920.1.
1.4.7 Inspector — a person employed by, or acceptable to, the inspection body for the
purpose of inspecting pressure components in accordance with this Standard.
1.4.8 Manufacturer — the person or organization responsible for the design, fabrication
and testing of pressure equipment.
1.4.9 Prequalified welding procedure — a documented welding procedure satisfying the
requirements of Section 2. It has the same standing as a qualified welding procedure when
used within the limits specified in Section 2.
1.4.10 Pressure equipment — boilers, pressure vessels, pressure piping and their
components covered by AS/NZS 1200.
1.4.11 Postweld heat treatment (stress relief) — uniform heating of pressure equipment
or portion thereof to a sufficient temperature below the critical range, followed by
uniform cooling, the purpose of which is to relieve the major portion of the residual
stresses.
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AS/NZS 3992:1998
1.4.12 Qualified welding procedure — a qualified welding procedure is a welding
procedure which has been conducted, documented, verified, tested and assessed as
complying with the requirements of this Standard.
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A1


NOTE: This definition is intended to include the use of prequalified welding procedures as
detailed in Section 2.
1.4.13
Shall — indicates a requirement.
1.4.14
Should — indicates a recommendation.
1.4.15 Test piece — components welded together in accordance with a specified welding
procedure, or a portion of a welded joint detached from a structure, for test.
1.4.16 Test specimen — a portion detached from a test piece and prepared, as required,
for testing.
1.4.17 Welder qualification test — a documented test, carried out by a welder, working
to an approved welding procedure, to determine the welder’s ability to deposit sound weld
metal using the fabricator’s available equipment.
1.4.18 Welding procedure — a specified course of action followed in welding including
a list of materials and, where necessary, tools to be used.
1.4.19 Welding procedure specification — a documented qualified welding procedure
prepared to provide direction for making production welds to the requirements of this
Standard.
1.4.20 Welding procedure test — the making and testing of a welded joint
representative of that to be used in production in order to prove the weldment is capable
of providing the required properties for its intended application.
1.4.21 Weld production test — the making and testing of a representative sample of
production welds to check the quality of welds during the manufacture of pressure
equipment.
1.5 OTHER PROCESSES This Standard does not prohibit the use of processes not
specifically listed in Clause 1.1. Where another process is to be used it shall give a result
at least equal to that set by this Standard.
1.6 OTHER MATERIALS Materials not listed in Clause 1.1 may be welded in
accordance with this Standard provided the welding method gives a result at least equal to
this Standard.
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S E C T I O N
2
P R E Q U A L I F I E D
P R O C E D U R E S
W E L D I N G
2.1 GENERAL Welding procedure qualification testing is not required for the
combination of range of materials, welding processes and design conditions given in
Table 2.1.
Welding procedures which comply with Table 2.1 shall be deemed as prequalified and do
not require further qualification in accordance with Sections 3 to 7, provided that —
A1

(a)
each procedure is documented in accordance with the applicable requirements of
Appendix B;
(b)
each procedure has a signed endorsement by the fabricator (see Appendix B);
(c)
each procedure is only applicable within the limits of the essential variables listed in
Table 5.1 but not Table 5.4 which does not apply to prequalified procedures; and
(d)
each procedure has been used by a welder (named) employed by the fabricator and
who has met the requirements of a welder qualification test (date given) in
accordance with Clause 9.2.
The use of prequalified welding procedures does not relieve the fabricator of any
responsibilities, in respect of the provisions of this Standard, for welder qualification and
weld production testing.
TABLE
2.1
CONDITIONS FOR PREQUALIFIED WELDING PROCEDURES
A1

Item
Pipe diameter
Plate or pipe thickness (nominal)
Parent metal group
Carbon equivalent (see Note 1)
Welding processes
Design minimum temperature
Welding consumables
Weld preparation
Welding position
Welding current, voltage and polarity
Preheat temperature
Travel speed
Range of application
All diameters
3 mm to 13 mm thickness
A1, A2
0.45% maximum based on actual cast analysis
Manual metal-arc, submerged arc, gas tungsten-arc welding and
flux cored arc welding or combination of these processes
Equal to and above 0°C
See Table 2.2 and Clause 2.2
In accordance with weld preparations detailed in the Table 2.3
Positions as shown in Figure 5.1
In accordance with consumable supplier’s requirements and
recommendations
Above 0°C
Runout length for manual electrodes ≤1 (see Note 2) Submerged
arc welding between 200 mm/min and 600 mm/min
Free from any materials which may impair the weld quality
In accordance with the pressure equipment Standard and the
consumable supplier’s requirements and recommendations
Initial and interrun cleaning
Storage and handling of welding
consumables
NOTES:
Mn
Cr + Mo + V
Cu + Ni
1 Carbon equivalent = C +
+
+
percent
6
5
15
2
Where heat analysis of all of the above elements is not quoted, the value of
Mn
= 0.42 percent maximum applies.
C +
6
length of weld run
Runout length =
length of electrode consumed
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TABLE
AS/NZS 3992:1998
2.2
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PREQUALIFIED WELDING CONSUMABLES (See Note 1)
GTAW to
AS 1167.2
MMAW to
AS/NZS 1553.1
SAW to
AS 1858.1
FCAW to
ASME Sect II C Spec
SFA-5.20
Classification
R1 to R7
inclusive
Classification
E41XX
E48XX (see Note 2)
Classification
W40XY
W50XY
Classification
E6XT–G
E7XT–G, 1, 4–9, 11, 12
NOTES:
1
The specified minimum tensile strength of the welding consumables shall be not less
than the specified minimum tensile strength of the parent metal unless the actual tensile
strength is proven by a subsequent transverse tensile test.
2
E4810 and E4811 electrodes and alloy electrodes are not permitted.
LEGEND:
GTAW =
MMAW =
SAW
=
FCAW =
gas tungsten-arc welding
manual metal-arc welding
submerged-arc welding
flux cored-arc welding
2.2 PREQUALIFIED GASES For GTAW welding argon gas of ‘welding quality’ only
shall be used for a prequalified welding procedure. The maximum impurity content shall
not exceed 1 part in 2000 by volume (i.e. the gas shall be at least 99.95 percent pure).
For FCAW shielding gases as recommended and qualified by the consumable
manufacturer
2.3 ALUMINOTHERMIC WELDING
aluminothermic welding, see Section 15.
For pre-qualified welding procedures of
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TABLE
2.3
WELDING PREPARATIONS FOR PREQUALIFIED WELD PROCEDURES
(SEE NOTES 1, 2 and 3)
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Dimensions of joint
Thickness
(t), mm
(max.)
Gap
(g), mm
Bevel
angle
(α)
degrees
Root
face
(f), mm
Single-welded
single-V butt joint.
Full penetration
13
1.5–3
60–90
0–3
2
Single-welded
single-V butt joint
with backing strip.
Full penetration
13
5–10
15–45
0–3
3
Single-welded
single-U butt joint.
Full penetration
13
0–3
20–40
0–3
4
Double-welded
single-V joint back
gouged. Full
penetration
13
0–3
60–90
0–3
5
Double-welded
double-V joint.
Full penetration
13
0–3
60–90
0–3
6
Single or double
welded fillet joint
13
0–2
80–120
on each side
—
Item
Joint type
1
Joint form
(sectional view)
NOTES:
1 All welded preparations are applicable to one of the welding processes (or combinations) permitted in Table 2.1.
2 Branch welds are qualified by butt welds using maximum parent metal thickness nominated for t above.
3 The use of minimum angle should be associated with maximum radius or gap and conversely the minimum radius or gap should be
associated with the maximum angle.
4 Indicate in welding procedure specification whether backing strip is intermittent or continuous welded.
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S E C T I O N 3
Q U A L I F I C A T I O N O F W E L D I N G
P R O C E D U R E S F O R B U T T , B R A N C H
A N D F I L L E T W E L D S
3.1 GENERAL With the exception of prequalified welding procedures (see Section 2),
each welding procedure which is used in the fabrication of pressure equipment shall be
qualified by the fabricator in accordance with this Standard in order to —
(a)
prove the suitability of the welding procedure for the material used in the
construction;
(b)
prove that the weld can be laid without unacceptable defects in the weld deposit and
heat affected zone;
(c)
prove that the mechanical properties, such as strength, and if applicable fracture
toughness and hardness, satisfy specified requirements; and
(d)
demonstrate the fabricator’s organization is capable of successfully using this
procedure.
Requirements to satisfy other parameters such as microstructure or corrosion resistance for
specific service requirements may be specified by the purchaser. Such requirements are
outside of the scope of this Standard.
Only qualified welding procedures shall be used in the fabrication of pressure equipment.
NOTE: The welding procedure qualification test may also be used to qualify a welder (see
Section 9).
3.2 METHODS OF QUALIFICATION OF WELDING PROCEDURE Qualification
of a welding procedure shall be carried out by one of the following methods:
(a)
The making and testing of a procedure test weld in accordance with the
requirements of Sections 6 and 7.
(b)
Simultaneously with the welding and testing of a production test plate or pipe
provided that testing is carried out in accordance with Section 7.
(c)
Using a prequalified welding procedure in accordance with Section 2.
Option (b) above is recognized as being the most representative of production welding
and should be endorsed whenever the fabricator prefers such action. However production
welds, carried out in conjunction with the proving of a welding procedure which fails to
meet the requirements of this Standard, shall be rejected.
3.3 RECORDING OF WELDING PROCEDURE DATA Each procedure shall be
recorded in detail, by the fabricator, with the results of qualification tests (see Appendix C
for recommended form of record), and these records shall be accessible to the inspector
(and purchaser where required). The qualification of a welding procedure shall be carried
out to the satisfaction of the inspection body where required by AS 3920.1 (and purchaser
where required) who may require that it witness qualification tests. For all pressure
equipment, the welding procedure test weld should be witnessed by an inspector (see
Clause 3.7 for reciprocity of qualified welding procedures).
3.4 TESTING OF WELDING PROCEDURE TEST WELDS The type, number, and
methods of tests required to prove the suitability of the welding procedure for the welding
of joints in the components shall be in accordance with this Standard. Where necessary,
additional tests may be required to assess corrosion resistance or other properties of a
weld joint.
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3.5 REQUALIFICATION OF A WELDING PROCEDURE Provided that there are
no changes in the essential variables (as listed in Section 5), a qualified welding
procedure shall remain in force indefinitely. Requalification of a welding procedure is
only required where there is any change in the essential variables as specified in
Section 5.
However, this Standard does not invalidate previous welding procedure approvals made to
former national Standards or specifications providing the intent of the technical
requirements is satisfied and the previous procedure approvals are relevant to the
application and production work on which they are to be employed.
Also, where additional tests have to be carried out to make the approval technically
equivalent, it is only necessary to do the additional tests on a test piece which should be
made in accordance with this Standard.
3.6 PORTABILITY OF QUALIFIED WELDING PROCEDURES A welding
procedure qualified by one fabricator shall be valid for use by a second fabricator
provided that —
(a)
the original qualification tests were carried out in accordance with this Standard,
and were fully documented;
(b)
the second fabricator has adequate equipment and facilities and demonstrates
successful welding of welder qualification tests or production tests using the
procedure;
(c)
the application of the welding procedure is acceptable to both fabricators and the
purchaser; and
(d)
the welding procedure identifies the original and second fabricator.
3.7 RECIPROCITY OF QUALIFIED WELDING PROCEDURES Welding
procedure tests carried out in accordance with this Standard and witnessed by an inspector
or inspection body representative shall be accepted by other inspection agencies, provided
that, the inspector witnesses the making of the test piece and signs the procedure
qualification record (PQR) and the procedure has been successfully applied by the
fabricator in production welding and is not otherwise specified by the purchaser.
3.8 WELDING PROCEDURE SPECIFICATION For production welding, a welding
procedure specification shall be prepared listing all necessary information for production
welds to be made to the requirements of this Standard. This specification shall include
essential variables together with any acceptable ranges for such variables, and any other
variables which may affect the soundness of the welded joint.
An example of the requirements for a welding procedure specification is given in
Appendix B. Other methods of presentation of a welding procedure specification are
acceptable provided that they contain all relevant information to satisfy the requirements
of this Clause for production welds.
3.9 WELDING PROCEDURES FOR REPAIR WELDING Visual or non-destructive
examination which reveals non-acceptable imperfections in equipment which has not been
subject to service environment shall be repaired. Such repair welding shall be carried out
to the original welding procedure or where this is not practicable, to a repair procedure
approved to this Standard.
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3.10 REPAIRS, REPLACEMENT OR ALTERATION TO IN-SERVICE PRESSURE
EQUIPMENT Where repairs, replacement, modifications or alterations are made by
welding to pressure equipment that is or has been in service, the welding shall comply
with the requirements of AS/NZS 3788 and AS 2873 (when applicable) and the following:
(a)
For material, which has not been deteriorated by service environment, the welding
procedure shall be qualified in accordance with this Standard.
(b)
For equipment which shows material deterioration by creep, hydrogen
embrittlement, temper embrittlement, fatigue, erosion, or other forms of
deterioration as referenced in AS/NZS 3788, a repair welding procedure shall only
be effected after the cause of the deterioration has been ascertained and taken into
account to ensure a satisfactory repair procedure. Such a welding procedure must be
capable of producing acceptable welds on the deteriorated material.
(c)
For hot tapping repair procedures, a similar approach to Item (b) shall be
undertaken. In addition, all precautions shall be taken during the hot tapping repair
procedures to ensure the safety of the welding personnel and the repair procedures
have been adequately reviewed.
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S E C T I O N 4
I T E M S T O B E R E C O R D E D
F O R W E L D I N G P R O C E D U R E T E S T W E L D S
4.1
GENERAL
The following items shall be recorded for each welding procedure test:
(a)
Welding process, or processes when more than one is used, in making a complete
joint.
(b)
Parent metal specification and group number, thickness; and for pipe, the outside
diameter or outside dimensions.
(c)
Weld joint detail, including sketch.
(d)
Initial and interrun method for cleaning, degreasing, etc.
(e)
Welding position and direction of weld travel.
(f)
Classification of welding consumables (filler metal material specification and size).
(g)
Preheating and interrun temperature ranges, including method and control.
(h)
Approximate number and arrangement of runs and welding sequence, including
sketch and string or weave technique, as applicable.
(i)
Back gouging or reverse side treatment, when applicable.
(j)
Postweld heat treatment, temperature and holding time.
(k)
Special features applicable to a specific welding procedure not covered in Table 4.1.
(l)
Name of fabricator responsible for carrying out the procedure test.
(m)
Name (and number) of welder performing the test weld.
4.2 ITEMS SPECIFIC TO NOMINATED WELDING PROCESSES The items listed
in Table 4.1, in relation to a specific welding process, shall be recorded for each welding
procedure test in addition to those items in Clause 4.1.
4.3 RECORDING OF WELDING PROCEDURE TEST WELDS A record of the
welding procedure test welds shall be retained by the fabricator. A recommended form for
the recording of welding procedure test welds is given in Appendix C.
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TABLE
AS/NZS 3992:1998
4.1
ITEMS SPECIFIC TO NOMINATED WELDING PROCESSES
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Item to be recorded
Welding process (see Note)
MMAW GTAW
GMAW
SAW
ESW
GW
FCAW
PTAW
Amperage (wire feed speed)
X
X
X
X
X
X
X
Arc voltage
X
X
X
X
X
X
X
Travel speed or runout length of
electrode
X
X
X
X
X
X
X
Current type and polarity
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Welding flux
Shielding gas and flow rate
Arc energy (when applicable)
X
X
X
X
X
X
X
X
Electrode stick out
Purging gas and flow rate
X
Tungsten electrode (diameter and type)
X
Nozzle diameter
X
X
X
X
X
Gas type and pressure
X
Flame characteristic
X
Number of electrodes and configuration
X
X
Oscillation width and dwell periods
X
Slag depth
X
Special baking temperature of electrodes
X
Special baking temperature of flux
X
LEGEND:
MMAW = manual metal-arc welding.
GTAW = gas tungsten-arc welding.
GMAW = gas metal-arc welding.
SAW
= submerged arc welding.
ESW
= electroslag welding.
GW
= oxy-acetylene (gas) welding.
FCAW
= flux cored arc welding.
X
PTAW
= plasma transferred arc welding.
X
= item to be recorded when applicable.
NOTE: For multi-wire arc processes record details for each wire.
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S E C T I O N 5
E S S E N T I A L V A R I A B L E S F O R
W E L D I N G P R O C E D U R E Q U A L I F I C A T I O N
The items and essential variables listed in Table 5.1 shall be considered in qualifying a
welding procedure.
When changes are made to a qualified welding procedure, requalification of the welding
procedure is required when any of the changes to the essential variables, as listed in
Table 5.1, are applicable. Changes to other items of Table 4.1 which are not classified as
essential variables by Table 5.1 may be made to a qualified welding procedure without
requalification.
Table 5.3 uses the material grouping system applied throughout the Australian pressure
equipment Standards. The basis for the grouping of ferrous material is given in
Appendix G.
NOTE: Some examples of the application of essential variables to welding procedures for
pressure equipment construction are given in Appendix H.
TABLE
5.1
ESSENTIAL VARIABLES FOR WELDING PROCEDURE QUALIFICATION
Item
Essential variable
1 Parent material specification
(see Note 1)
A change from a material group to any other material group or for a
combination of material groups, as listed in Table 5.3, except as
permitted in Table 5.2
2 Parent material thickness and
form (see Notes 2 and 3)
Material thicknesses outside the limits given in Table 5.4 where ‘t’ is
dependent on joint details as given in Table 5.6
3 Weld joint detail (see Note 4)
Omission of backing strip or consumable backing ring in a butt joint.
For fillet welds, see Clause 6.1.2
4 Welding position and weld
direction (see Note 5)
(a) When impact tests are not required, change to or from vertical
down
(b) When impact tests are required, any change in fundamental
welding position (flat, horizontal — vertical, vertical and
overhead), or change in weld direction (see Figures 5.1 and 5.2)
5 Welding consumables (see
Note 6)
(a) For all welding processes, a change in the numerical grouping
(F number) of an electrode as shown in Table 5.5
(b) For ferrous metals only, an increase or decrease in the weld metal
specified minimum strength outside the parent metal specified
tensile strength range
(c) For ferrous metals only, a variation of the alloy content of the
weld metal outside of the specified range of the welding
consumables used in the procedure test except that for carbon and
carbon manganese steels the addition or deletion of 0.5%
molybdenum from the weld metal composition shall not require
requalification
(d) For flux cored arc welding and gas metal-arc welding, any change
in flux formulations (e.g. rutile, basic or metal core) other than
that which varies iron powder content only (see Note 7)
(e) For submerged arc welding:
(i) a change in flux classification as listed in AS 1858.1; or
(ii) a change from a flux recommended for one to three weld runs
to a multi-pass flux or vice versa
(continued)
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19
TABLE
5.1
AS/NZS 3992:1998
(continued)
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Item
Essential variable
5 Welding consumables (see
Note 6) (continued)
(f) A change in the nominal composition of a shielding or backing
gas; or a decrease in gas flow rate of the shielding gas by more
than 10%
6 Welding process (see Note 8)
A change in welding processes or combination of welding processes
7 Welding energy input (see
Note 9)
(a) For Groups F and G steels, an increase or decrease in arc energy
greater than 15%
(b) For low temperature operation requiring impact testing of weld
metal, an increase in arc energy greater than 15%
(c) For material group M, arc energy outside the range 1 to 3 KJ/mm
(d) For conditions other than Items (a), (b) or (c), an increase in arc
energy greater than 80% or decrease in arc energy greater than
50%
8 Welding current and polarity
(see Note 10)
For all processes, any change in the type of welding current and
polarity
9 Preheat and interrun temperature (a) An increase of more than 50°C —
(i) for Groups F and G steels; or
(ii) when impact tests are required on the weld or heat affected
zone.
(b) An increase of more than 100°C in preheat or interrun temperature
for all other ferrous materials
(c) A decrease of more than 50°C in preheat or interrun temperature
for all ferrous materials provided that the temperature is not less
than that defined in Note 3 and that specified in the welding
procedure specification
10 Delayed cooling
Any change in the control of cooling rate after welding when specified
in the qualified welding procedure
11 Postweld heat treatment
For steel groups A1, A2, A3, B, C, D1, D2, E, F, G and H, a change in
postweld heat treatment which requires the deletion of postweld heat
treatment, or the addition of any of the following:
(a) Postweld heat treatment within the specified range of the
application Standard
(b) Postweld heat treatment above the upper transformation
temperature (e.g. normalizing)
(c) Postweld heat treatment above the upper transformation
temperature followed by heat treatment below the lower
transformation temperature (e.g. normalizing or quenching
followed by tempering)
(d) Postweld heat treatment between the upper and lower
transformation temperatures
For all other materials, a change in postweld heat treatment which
requires -the deletion of postweld heat treatment; or the addition of
postweld heat treatment within a temperature range
NOTES TO TABLE 5.1:
1 For Group K and M materials, requalification of a welding procedure is required when specific corrosion
resistance tests are required or where parent metal impact tests are required by the pressure equipment
Standard for cryogenic service. In such instances the procedure is only applicable to the stainless steel
grade of material used in the procedure test. Refer to Appendix D for typical ferrous material
specifications.
2 A change from flat to tubular form of product or vice versa is not an essential variable.
3 Where the parent metal thickness of the production weld differs from that used in the test weld
adjustment should be made to achieve a satisfactory cooling rate by complying with the preheats listed
in the pressure equipment Standard, or Welding Technology Institute of Australia Tech Note 1.
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AS/NZS 3992:1998
20
4 Single or double V, J, U or bevel or a square butt may be changed without requalification provided the
form of the weld preparation is in agreement with recommended joint detail as listed in the pressure
equipment Standards.
5 For the limits of deviation from fundamental welding positions, see AS 3545.
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6 Where impact testing of weld metals is required by the application Standard, any change in filler metal
group F number shall require requalification. (See Table 5.5.)
7 ‘All-positional’ coating or flux core formulations do not require requalification for single position welds
provided there is no designated increase in the deposited weld metal hydrogen content.
8 For multi-process procedures, each welding process may be approved separately or in combination with
other processes. Similarly, one or more processes may be deleted from an approved welding procedure
provided the joint thickness is within the thickness range of the remaining process or processes. See also
Item 8 Table 9.1.
9 Welding energy input is determined from the following equation:
Q =
60EI
v × 103
where
Q = welding energy input, in kilojoules per millimetre
E = arc voltage, in volts (r.m.s. value for a.c.)
I = welding current, in amperes (r.m.s. value for a.c.)
v = welding speed, in millimetres per minute
10 For gas metal-arc welding this includes a change from spray arc, globular arc or pulsating arc to
short-circuiting arc or vice versa.
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21
TABLE
AS/NZS 3992:1998
5.2
PROCEDURE QUALIFICATION OF OTHER MATERIAL GROUPS
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A1


Material group(s) of original
qualified welding procedure
Other material groups or combinations of steel
groups (see Note 1)

A1 to A1
A1 to A2 (see Note 2(b)); A2 to A2 (see Note 2)

A1 to A2
A1 to A1; A2 to A2 (see Note 2)

A2 to A2
A1 to A1; A1 to A2

A3 to A1, A2 or A3
Nil



B to B
B to A2 or A1
B to A2 or A1



C to B, A2 or A1

D1 to D1
D1 to D2 (Note 3), D1 to C

D2 to D2 (Note 3)
D2 (Note 2) to C, B, A2 or A1 (Note 4)

D2 to C, B, A2

K to A1, A2, B, C, D1 or D2
C to C
C to B, A2 or A1
K to any lower ferritic steel group provided nickel based
alloy welding consumables are used (see Table 5.5)
NOTES:
1
Appropriate compliance with Item 5(b) of Table 5.1 is required.
2
Qualification of a welding procedure using A1 to A1 (or A1 to A2) as the steel group
originally qualified is only permitted for A2 materials if —
(a)
the test values of transverse tensile test, all weld metal tensile test, and notch bar
impact tests, when required, exceed the minimum properties required for A2 group
materials; and
(b)
weld preheat temperatures are applied in accordance with the requirement of
AS 4458 or WTIA Technical Note 1. Where a production test plate is required,
other pre-heat temperatures are permitted.
3
D2 is limited to less than 3% Cr.
4
When welding Group A1, A2 or B material to Group D2, the postweld heat treatment
temperature shall not exceed 700°C.
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AS/NZS 3992:1998
22
TABLE
5.3
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PARENT MATERIAL GROUPING
Material
group
A1

Typical nominal compositions or
specifications
Material type
Ferrous materials (see Note 1)
Carbon steel
A1
Carbon and carbon-manganese steel
(low strength) (see Note 2)
A2
A3
Carbon and carbon-manganese steel
(medium strength) (see Note 3)
Carbon and carbon-manganese steel
(High-yield strength)
Low alloy steel
B
Alloy steel (alloy <¾)
C
Alloy steel (¾≤ total alloy < 3)
A1




D1
D2
Alloy steel (vanadium type)
Alloy steel (3 ≤ total alloy < 10)
E
F
G
A1

3½ nickel steel
9 nickel steel
Quenched and tempered low alloy
steel
High alloy steel
H
Martensitic chromium steel
J
K
L
M
Ferritic high chromium steel
(11–13Cr)
Austenitic chromium-nickel steel
High chromium steel (>25Cr)
Ferritic-austenitic chromium-nickel
steel
Non-ferrous materials
Aluminium and aluminium alloys
Al 21 Aluminium and its alloys 1000 series
and 3003
Al 22 Aluminium alloys 3004 and low strength 5000 series
Al 23 Aluminium alloys (selected 6000
series)
Al 25 Aluminium alloys (High strength
5000 series)
Copper and copper alloys
Cu 31 Copper (min 99.0Cu)
Cu 32 Copper-zinc alloys
Cu 33 Copper-silicon alloys
Cu 34 Copper-nickel alloys
Cu 35 Aluminium bronze alloys (> 5Al)
ANSI/ASME
BPV-IX
classification
P
Group
number number
AS 1548: 7-430, 7-460
AS/NZS 1594: HU300, HA 300/1
ASTM A 106B
AS 1548: 5-490, 7-490
1
1
1
2
API 5L: X52, X60, X65, and X70 all
with carbon equivalent ≤ 0.40.
AS/NZS 1594: HA350, XF 400 and
XF 500.
—
—
C-½Mo; ½Cr-½Mo; 1Mn-½Mo
1Cr-½Mo; 1¼Cr-½Mo;
¾Cr-¾Ni-Cu-A1
½Cr-½Mo-¼V
2¼Cr-1Mo
5Cr-½Mo;
9Cr-1Mo;
9Cr-1Mo-V
3½Ni
9Ni
ASTM A 517; AS 3597:700 PV
3
4
1, 2, 3
1, 2
—
5A
5B
9B
11A
11B
—
1
1
1
2
1
1
1 to 8
6
1,2, 3, 4
7
1
8
1
10I
10H
1
1
Al (99.0 min) and Al-1.25Mn
21
—
Al-2.5Mg; Al-2.75Mg-0.75Mn; Al-1.2,
Mn-1.0Mg
Al-Mg-Si-Cr alloys
22
—
23
—
Al-4.5Mg-0.75Mn; Al-4Mg-0.5Mn
25
—
99.9Cu + Ag
Cu-40Zn
CU-3.3Si
Cu-10Ni
Cu-11Al
31
32
33
34
35
13Cr (Type 410); 15Cr (Type 429)
12Cr-1Mo-V(W)
12Cr-Al (Type 405)
13Cr-Low C (Type 410S)
18Cr-8Ni (Type 304)
18Cr-12Ni-2.5Mo (Type 316)
18Cr-10Ni-Ti (Type 321)
27 Cr-1Mo (S44627)
22Cr-5Ni-3Mo-N (S31803)
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—
—
—
—
—
(continued)
23
TABLE
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Material
group
A1
(continued)
Typical nominal compositions or
specifications
Material type
Nickel and nickel alloys
Ni 41 Nickel and low carbon nickel
Ni 42 Nickel-copper alloy
Ni 43 Nickel-chromium-iron, nickelchromium-molybdenum-iron
Ni 44 Nickel-molybdenum, nickelmolybdenum-chromium-iron
Ni 45 Nickel-chromium-molybdenumcopper, nickel-iron-chromiummolybdenum-copper, nickel-ironchromium
Ni 46 Nickel-chromium-silicon
Titanium and titanium alloys
Ti 51
Unalloyed and alloyed titanium Rm
≤420 MPa
Ti 52
5.3
AS/NZS 3992:1998
Unalloyed and alloyed titanium Rm
>420 MPa
 Zirconium

Zr 61
Unalloyed Zr

Zr 62
Alloyed Zr
ANSI/ASME
BPV-IX
classification
P
Group
number number
99.0Ni
67Ni-30Cu only
72Ni-15Cr-8Fe
41
42
43
—
—
—
55Ni-21Cr-13Mo
44
—
25Ni-20Cr-6Mo-Cu
45
—
35Ni-19Cr-1.3Si
46
—
Unalloyed Ti
51
—
Alloyed 0.3Mo-0.8Ni
52
—
99.0 Zr
95.5 Zr-2.5 Nb
61
62
—
—
LEGEND:
Rm = specified minimum tensile strength
NOTES:
1 See Appendix D for a list of common material specifications cross-referenced to material group.
2 For these steels, an upper limit of 580 MPa applies to the actual tensile strength reported on the material
certificate.
3 For these steels, an upper limit of 620 MPa applies to the actual tensile strength reported on the material
certificate.
TABLE
5.4
RANGE OF MATERIAL THICKNESS QUALIFIED
Item
1
2
A1




3
4
5
Welding process
Gas welding
Single-run or multi-run welding where any run is greater
than 12 mm throat
Gas metal arc welding with short circuiting arc transfer
Single or multi-run manual metal-arc (except for Item 2),
submerged arc, gas-tungsten arc, gas metal-arc welding
(except short-circuiting arc transfer) and flux cored-arc
welding
Electroslag welding
NOTES:
1 t = thickness of test plate or pipe.
2 Pre-heat shall comply with Note 3 to Table 5.1.
3 Where impact tests are required, the minimum thickness qualified is —
(a) 0.5t when the test plate thickness (t) < 15 mm; and
(b) 15 mm when test plate thickness (t) ≥ 15 mm.
COPYRIGHT
Range of material
thickness qualified
(Notes 1 and 2)
1.5 mm to t
12 mm to 1.1t
1.5 mm to 1.1t
1.5 mm to 2t for t ≤ 10 mm
5 mm to 2t for t > 10 mm
(Note 3)
0.5t to 1.1t
AS/NZS 3992:1998
24
TABLE
5.5
FILLER METAL GROUP CLASSIFICATION
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F
number
Welding
process
Ferrous materials
F1
MMAW
F2
MMAW
F3
MMAW
F4
MMAW
MMAW
F5
MMAW
F6
Oxy
acetylene
welding
SAW
SAW
SAW
GTAW
GMAW
GTAW
GMAW
GTAW
GMAW
FCAW
FCAW
FCAW
Aluminium alloys
F21
GTAW
GMAW
F22
GTAW
GMAW
F23
F24
GTAW
GMAW
Welding consumable description
(see Notes 1 and 2)
Relevant Australian
welding consumable
(see Note 3)
ASME BPV Code Sect. II Part C
Classification
Spec. No.
High iron powder or iron oxide
electrode for carbon and carbon
manganese and low alloy steels
High titania (rutile) electrode for
carbon and carbon manganese and low
alloy steels
High cellulose electrode for carbon
and carbon manganese and low alloy
steels
Hydrogen controlled basic electrode
for carbon and carbon manganese and
low alloy steels
Hydrogen controlled basic electrode
for high chromium other than
austenitic and duplex steels
Hydrogen controlled basic electrode
for high alloy austenitic and duplex
steels
Filler metal rods for carbon and low
alloy steels
AS/NZS 1553.1
SFA 5.1 & 5.5
AS/NZS 1553.1
SFA 5.1 & 5.51
AS/NZS 1553.1
SFA 5.1 & 5.5
EXX10, EXX11
AS/NZS 1553.1
SFA 5.1 & 5.5
EXX15, EXX16,
EXX18, EXX48
—
SFA 5.4
EXX15, EXX16,
EXX17
—
SFA 5.4
EXX15, EXX16,
EXX17
AS 1167.2,
Table 3
SFA 5.2
RX
Electrodes for carbon and carbon
manganese steels
Electrodes for low alloy steels
Electrodes for high alloy austenitic
steels
Electrodes for high alloy austenitic
steels
Electrodes for carbon and carbon
manganese steels
Electrodes for low alloy steels
AS 1858.1
SFA 5.17
FXX-EXX
AS 1858.2, Table 2
—
SFA 5.23
SFA 5.9
FX-EXXX-X
ERXX
AS 1167.2, Table 4
AS 2717.3
AS 1167.2, Table 3
AS/NZS 2717.1
AS 1167.2, Table 3
AS/NZS 2717.1
AS 2203.1
SFA 5.9
ERXX
SFA 5.18
ERXX5-X
SFA 5.28
SFA 5.20
ERXXX-X
ERXXX-X
EXXT-X
—
—
SFA 5.29
SFA 5.22
EXXTX-X
EXXXT-X
Electrodes for carbon and carbon
manganese steels
Electrodes for low alloy steels
Electrodes for high alloy steels
EXX20, EXX22,
ESXX24, EXX27,
EXX28
EXX12, EXX13,
EXX14, EXX19
Aluminium welding rod
(99% aluminium)
Aluminium alloy welding rod
(magnesium chromium alloy)
AS
AS
AS
AS
1167.2 Table 8
2717.2
1167.2 Table 8
2717.2
SFA 5.10
ER 1100
SFA 5.10
Aluminium alloy welding rod
(silicon 4.5-6%)
AS 1167.2 Table 8
AS 2717.2
SFA 5.10
AS 1167.2 Table 8
SFA 5.10
ER 5183
ER 5356
ER 5554
ER 5556
ER 5654
ER 4043, ER 4009
ER 4047, ER 4010
ER 4145
R 356.0
AS 1167.2 Table 6
SFA 5.7
ER Cu
AS 1167.2 Table 6
SFA 5.7
ER Cu Si-A
GTAW
Aluminium alloy
GMAW
Copper and copper alloys
F31
GTAW
Copper rod
GMAW
(Copper 98% minimum)
F32
GTAW
Copper silicon rod (silicon bronze)
GMAW
(continued)
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25
TABLE
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F
number
Welding
process
5.5
Welding consumable description
(see Notes 1 and 2)
Copper and copper alloys (continued)
F33
GTAW
Copper tin rod (phosphor bronze)
GMAW
F34
GTAW
Copper nickel rod
GMAW
F35
GW
Copper alloy rod (copper zinc)
F36
GTAW
GMAW
Copper aluminium rod
(aluminium bronze)
F37
GTAW
Copper alloy gas welding rods
GMAW
(copper-nickel-aluminium)
Nickel and nickel based alloys
F41
MMAW
Nickel welding electrode
(nickel 92% minimum)
GMAW
Nickel welding rod
GTAW
F42
MMAW
Nickel copper welding electrode
(monel metal)
GMAW
Nickel copper welding rod
GTAW
(monel metal)
SAW
F43
MMAW
Nickel chromium iron and nickel
chromium molybdenum electrode
F44
F45
AS/NZS 3992:1998
(continued)
Relevant Australian
welding consumable
(see Note 3)
ASME BPV Code Sect. II Part C
Classification
Spec. No.
AS 1167.2
SFA 5.7
ER Cu Sn-A
AS 1167.2
SFA 5.7
ER Cu Ni
AS 1167.2
SFA 5.27
AS 1167.2
SFA 5.7
AS 1167.2
SFA 5.7
RB
RB
RB
RB
ER
ER
ER
ER
ER
—
SFA 5.11
E Ni-1
AS 1167.2
SFA 5.14
ER Ni-1
—
SFA 5.11
E Ni Cu-7
AS 1167.2
SFA 5.14
ER Ni Cu-7
—
SFA 5.11
E Ni Cr Fe-1
E Ni Cr Fe-2
E Ni Cr Fe-3
E Ni Cr Fe-4
E Ni Cr Mo-2
E Ni Cr Mo-3
E Ni Cr Mo-6
ER Ni Cr-3
ER Ni Cr Fe-5
ER Ni Cr Fe-6
ER Ni Cr Mo-2
ER Ni Cr Mo-3
E Ni Mo-1
E Ni Mo-3
E Ni Mo-7
E Ni Cr Mo-4
E Ni Cr Mo-5
E Ni Cr Mo-7
ER Ni Mo-1
ER Ni Mo-2
ER Ni Mo-7
ER Ni Cr Mo-4
ER Ni Cr Mo-5
Er Ni Cr Mo-7
E Ni Cr Mo-1
E Ni Cr Mo-9
ER Ni Cr Mo-1
ER Ni Fe Cr-1
Er Ni Cr Mo-8
Er Ni Cr Mo-9
GMAW
GTAW
SAW
Nickel chromium, nickel chromium
iron and nickel chromium
molybdenum welding rod
AS 1167.2
SFA 5.14
MMAW
Nickel molybdenum and nickel
chromium molybdenum electrodes
—
SFA 5.11
GMAW
GTAW
Nickel molybdenum and nickel
chromium molybdenum welding rod
AS 1167.2
SFA 5.14
MMAW
Nickel chromium molybdenum
electrode
Nickel chromium molybdenum and
nickel iron chromium
—
SFA 5.11
AS 1167.2
SFA 5.14
—
SFA 5.16
GMAW
GTAW
Titanium and titanium alloys
F51
GTAW
Titanium alloy welding rod
GMAW
ER
ER
ER
ER
Cu
Cu
Cu
Cu
Cu
Cu
Cu
Cu
Cu
Zn-A
Zn-B
Zn-C
Zn-D
Al-A1
Al-A2
Al-A3
Ni Al
Mn Ni Al
Ti-1
Ti-2
Ti-3
Ti-4
NOTES:
1 F-number grouping of consumables is based primarily on their useability characteristics, which largely determine the ability of
welders to make satisfactory welds with a given filler metal. The grouping is made to reduce the number of welding procedure and
performance qualifications, where this can logically be done.
Grouping is not to imply the parent metals or filler metals within a group may be indiscriminately substituted for a metal which was
used in the qualification test without consideration of the compatibility of the parent and filler metals in respect of metallurgical
properties, postweld heat treatment, design and service requirements, and mechanical properties. See also Table 5.1, Item 5(b).
2 It is a requirement that consumables are to be used within the limits of the applicable weld consumable Standards.
3 For classification of the consumable, use the equivalent of the ASME classification in the right hand column.
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AS/NZS 3992:1998
26
TABLE
5.6
PARENT MATERIAL THICKNESS FOR VARIOUS JOINT CONFIGURATIONS
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Type of weld
Typical weld preparation
Parent material thickness for
Item 2 Table 5.1
Butt welds
1.1
Double welded butt
ts2
1.2
Single welded butt
ts2
Single welded butt with retaining
backing strip
ts2
1.3
Branch welds
2.1
Full penetration
through shell
ts
2.2
Partial penetration through shell
b1 + b2
b2 = throat thickness
(continued)
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27
TABLE
Type of weld
5.6
AS/NZS 3992:1998
(continued)
Typical weld preparation
Parent material thickness for
Item 2 Table 5.1
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2.3
Set on nozzle
tb
2.4
Set on nozzle with backing strip
tb
2.5
Fillet to shell
Greater of f1 or f2
2.6
Greater of
(b1 + b2),
tp, or f1
Joint with compensating plate
Flange welds
3.1
Weld neck flange
ts
(continued)
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AS/NZS 3992:1998
28
TABLE
Type of weld
5.6
(continued)
Typical weld preparation
Parent material thickness for
Item 2 Table 5.1
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3.2
Double fillet on slip on flange
Greater of f1 or f2
3.3
Full penetration weld on flange
tf
3.4
b1 + b2
Face and back weld on flange
b2 = throat thickness
3.5
Face and fillet weld on flange
Greater of b1 & f
3.6
Bore and back welded on flange
Greater of b1 and ts
b1 = throat thickness
(continued)
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29
TABLE
Type of weld
5.6
AS/NZS 3992:1998
(continued)
Typical weld preparation
Parent material thickness for
Item 2 Table 5.1
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Attachments to studded connections
4.1
Butt weld to shell
ts1
4.2
Partial penetration weld to shell
b1 + b2
but not greater than ts1
b1 and b2 = throat thickness
4.3
Fillet weld to shell
Greater of f1 and f2
Attachments to shell welds
5.1
Full penetration weld through
attachment
ta
5.2
Fillet weld to shell
Greater of f1 and f2
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AS/NZS 3992:1998
30
Fundamental welding position (see Notes 1 and 2)
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Type of weld
Flat
Horizontal
Vertical
Overhead
1G
2G
3G
4G
1F
2F
3F
4F
1G
2G
—
—
Butt
Plate
Fillet
Butt
Pipe
1F
2F or 2FR
Fillet
4F
—
NOTES:
1 The direction of making a weld is not pertinent to a fundamental welding position. See Table 5.1, Item 4 and
Table 9.1, Item 4 for welding direction as an essential variable.
2 Electrode angle shown is nominal and may be varied in practice.
FIGURE 5.1
FUNDAMENTAL WELDING POSITIONS
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Type of weld
AS/NZS 3992:1998
Position (see Notes 1 and 2)
5G
6G
5F
6F
Butt
Fillet
NOTES:
1 All welds are performed with the workpiece in the fixed position.
2 For convenience only round pipe is illustrated.
FIGURE 5.2
VARIATIONS TO THE FUNDAMENTAL WELDING POSITIONS IN PIPE
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32
S E C T I O N
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6.1
6
W E L D
T E S T
P I E C E S
TEST PIECES
6.1.1 When required When a welding procedure or production weld test is required an
appropriate test piece shall be prepared to assess the mechanical properties of the joint.
For weld overlay procedure qualification tests, see Section 8.
6.1.2
Form
A test piece shall consist of one of the following:
(a)
A butt joint (plate or pipe) as shown in Figure 6.1 or Figure 6.2.
(b)
A fillet weld (plate) as shown in Figure 6.3.
Tests on butt welds qualify welding procedures for use on branch welds and fillet welds,
except that for fillet welds, tests as shown in Figure 6.3 are required where doubt exists as
to whether butt welds adequately assess the properties of fillet welds, e.g. joints under
high restraint.
Fillet welds qualified by a fillet weld or butt weld test may be used in all fillet weld sizes
in all base metal thicknesses and in all diameters, provided all other essential variables are
complied with.
6.1.3 Dimensions The dimensions and number of test pieces shall be such as to
provide for the appropriate test specimens given in Table 6.1 for qualification of welding
procedures and Table 10.1 for production welds.
Figures 6.4 and 6.5 show typical layouts of test pieces for plates and pipes respectively.
Additional test specimens may be required to fully assess a welding procedure when any
of the following conditions apply:
(a)
Soundness in joints with restrictive access for welding.
(b)
Severe thermal restraint.
(c)
Joints which may produce lamellar tearing.
(d)
Special fillet shapes or fillet welds between dissimilar metals especially when
service requirements are in corrosive environments.
6.1.4 Preparation Test pieces shall be prepared using the appropriate welding
procedure and conditions.
Test pieces shall be suitably identified.
Surface defects in completed test welds shall not be repaired or dressed prior to visual
examination by the fabricator.
6.1.5
Assessment
Test pieces shall be assessed in the following manner and sequence:
(a)
Visual examination.
(b)
Non-destructive examination using the same methods as those proposed for the
assessment of production welds.
(c)
Destructive tests.
The assessment may be stopped at any stage when the results are unsatisfactory.
Final non-destructive examination shall not be carried out until 24 h after the weld has
been completed for crack sensitive materials as defined in AS 4037.
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TABLE
AS/NZS 3992:1998
6.1
NUMBER OF TEST SPECIMENS REQUIRED FOR WELDING
PROCEDURE QUALIFICATION
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Butt joint in plate
Test specimen
A1
Thickness
Fillet
weld in
Thickness
plate
<10 mm ≥10 mm (Note 2)
Butt joint in pipe
Fillet
weld in
pipe
<10 mm
≥10 mm
Macro-examination (Note 1)
1
1
2
2
2
4
Hardness survey (Note 3)
1
1
1
1
1
—
Transverse tensile (Notes 4, 5 & 6)
1
1
1
2
—
—
All-weld-metal tensile (Notes 7 & 12)
—
1
—
—
—
—
Root bend (Notes 5, 8, & 9)
1
1
2
1
—
—
 Face bend (Notes 5 & 8)
(Note 14)
—
(Note 14)
—
—
—
Side bend (Notes 5 & 8)
—
2
—
2
—
—
Fillet weld fracture (for test piece with
only single side weld)
—
—
—
—
3
—
Impact test (Charpy V) weld
For requirements see Notes 10 and 11
Impact test (Charpy V) HAZ
Chemical analysis
See Note 13
NOTES:
1 One specimen for macro-examination shall be taken from that part of the joint considered to have been
welded in the most difficult welding position or from a stop/start position.
2 Fillet tests are only required to assess the properties of fillet welded joints not reasonably assessed by a
butt joint (see Clause 6.1).
3 The hardness survey shall only be undertaken when required by Clauses 7.9 and 8.3.5.
4 For material over 30 mm thickness additional test specimens may be required to ensure that the full weld
thickness is subject to test.
5 For aluminium alloys, parent metal in tempered (thermally treated) condition test pieces shall be naturally
aged at 15°C to 25°C for three days prior to testing.
6 Where postweld heat treatment is to be applied to Group Al 23 alloys, the value obtained in the tensile
test shall equal or exceed that used for design purposes specified in the pressure equipment Standard.
7 An additional test piece for elevated temperature testing is necessary when required by the pressure
equipment Standard.
8 For a butt joint in plate when the weld metal and parent metal differ markedly in bending properties,
either between dissimilar parent metals or between weld metal and parent metal, two longitudinal bend
test specimens may be used instead of root and face or side bend tests, in which case the side to be
placed in tension shall be recorded.
9 Required only for a butt joint made from one side only in plate or of pipe.
10 Impact tests on weld metal and HAZ are only required when specified in Table 7.2.
A1
 11 Refer to Figure 7.1 for location, size and number of test specimens.
12 Required only for Group A3 carbon and carbon manganese steels and for alloy steel butt welds in
material over 10 mm thickness used for —
(a)
Class 1 boilers to AS 1228; or
(b)
Classes 1, 1H and 2H vessels (AS 1210) and Class 1 piping (AS 4041) where the weld metal strength
may undermatch the parent metal strength. The weld metal strength may be Rm, Re or Ret, whichever
determines the design strength ‘f’. See Clause 7.5.2 for acceptance criteria.
Examples are as follows:
(i)
The welds in Groups F and G steels.
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AS/NZS 3992:1998
(ii)
34
The use of consumables with specified minimum strength, equal to or less than the specified
minimum strength of the parent material.
(iii) The use of consumables with strength specified or not proven.
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13 Chemical analysis of weld deposit is only required by agreement and only on ferritic steel weld deposits of
material Groups B to E inclusive for principal alloy elements only. The alloy content shall comply with
the analysis limits of the welding consumables.
A1
 14 Single-sided welds require one face bend test and double-sided welds require one bend test for each side.
6.2 VISUAL EXAMINATION Prior to carrying out non-destructive examination as
required by Clause 6.3, all completed test pieces shall be subjected to visual examination
and shall comply with the requirements of AS 4458.
When visual examination reveals defects outside the acceptance limits of the pressure
equipment Standard, the test piece is not acceptable as a welder qualification test weld.
6.3 NON-DESTRUCTIVE EXAMINATION OF TEST PIECES Radiographic or
ultrasonic examination shall be carried out for welding procedure qualification and for
combined welding procedure and welder qualification test pieces, in accordance with the
pressure equipment Standard. The purpose of the examination is to ensure that only sound
weld metal is subjected to the destructive tests. Weld metal or parent metal cracking of
any type shall be cause for rejection of the test piece.
When non-destructive examination reveals defects outside the acceptance limits of the
pressure equipment Standard, the test piece is not acceptable as a welder qualification test
weld, nor as a procedure qualification test weld where the defects are not attributed to the
welder.
6.4
POSTWELD HEAT TREATMENT
6.4.1 Test piece The welding procedure qualification test piece shall be subjected to
any postweld heat treatment applied to the finished component.
6.4.2 Heat treatment parameters
AS 4458 and the welding procedure.
Heat treatment parameters shall comply with
6.4.3 Operation The postweld heat treatment operation, when required by the pressure
equipment Standard, shall be carried out before final non-destructive examination for
Groups D1, F, G, H, J, K, L and M materials.
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AS/NZS 3992:1998
DIMENSIONS IN MILLIMETRES
FIGURE 6.1
RECOMMENDED TEST PIECE FOR BUTT WELD IN PLATE
DIMENSIONS IN MILLIMETRES
FIGURE 6.2
RECOMMENDED TEST PIECE FOR BUTT WELD IN PIPE
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AS/NZS 3992:1998
FIGURE 6.3
36
DIMENSIONS IN MILLIMETRES
RECOMMENDED TEST PIECE FOR FILLET WELD IN PLATE
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AS/NZS 3992:1998
NOTES:
1
For plates over 30 mm thick, additional specimens may be required, see Clause 7.4.1, 7.5.1 and 7.7.1.
2
For type of bend test required, see Clause 7.6.1.
3
Impact tests are only required when specified by Table 7.2.
4
Not required when test plate is radiographed.
5
The nick-break specimen is not referenced in Table 6.1 for use in the testing of welding procedure test
pieces. It is referenced in this Figure and Clause 7.11 for convenience when production weld testing is
required (see Section 10).
FIGURE 6.4
TYPICAL LAYOUT OF TEST SPECIMENS TAKEN FROM
WELDED PLATE TEST PIECES
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AS/NZS 3992:1998
38
NOTES:
1 Where pipe diameter does not permit the removal of sufficient specimens an additional test piece shall be
provided.
2 The location of macro specimens is not shown. Such specimens should be taken in accordance with Note 1
to Table 6.1.
3 Transverse tensile test shall be taken from pipe section at 180 degree intervals. For 5G and 6G positions,
they shall be taken from 0 degree and 180 degree locations.
FIGURE 6.5
TYPICAL LAYOUT OF TEST SPECIMENS TAKEN FROM
PIPE TEST PIECES
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AS/NZS 3992:1998
S E C T I O N 7
M E C H A N I C A L T E S T I N G O F
W E L D S F O R P R O C E D U R E Q U A L I F I C A T I O N
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7.1 GENERAL Whilst this Section (7) applies directly to testing requirements for
welding procedure qualifications, the test methods and requirements are also used for the
qualification of welders and production weld test plates.
7.2 RESPONSIBILITY FOR TESTING The manufacturer shall be responsible for
conducting or having conducted competently all mechanical tests specified in this
Section (7).
7.3
TEST SPECIMENS
7.3.1 Types of tests and number of test specimens The types of tests and number of
test specimens required shall be as shown in Table 6.1.
7.3.2 Removal of test specimens
shown in Figures 6.4 and 6.5.
Test specimens shall be taken from the locations
Test specimens may be cut from the test piece by any method which does not affect the
properties of the finished test specimen.
For procedure test pieces, the test specimens shall be taken from part of the test piece free
from any non-complying defects revealed by non-destructive examination.
Where plates of different thickness are used, the thicker plate may be machined to the
thickness of the thinner plate.
7.3.3
7.4
Identification of specimens
Test specimens shall be suitably identified.
TRANSVERSE TENSILE TEST
7.4.1 Method A transverse tensile test shall be carried out at room temperature in
accordance with either AS 2205.2.1 for transverse butt tensile test or AS 2205.2.3 for
transverse joggle butt tensile test, subject to the following conditions:
(a)
Weld reinforcement shall be dressed flush.
(b)
The test specimen shall be machined to the reduced form except that:
(i)
For pipe of DN 32 or smaller, a full section transverse tensile test specimen
shall be used.
(ii)
For pipe of nominal size greater than DN 32 up to and including DN 100,
the minimum specimen width ‘b’ (see AS 2205.2.1) requirement in the
reduced section parallel portion may be decreased to 20 mm.
7.4.2 Requirements The weld strength shall be greater than or equal to the specified
minimum tensile strength of the plate (or the weaker plate in the combination).
If the specimen breaks in the parent metal outside of the weld, the test shall be accepted
as meeting the requirements provided that the tensile strength is not less than 95 percent
of the specified minimum for the parent material (see Note 6 to Table 6.1 for
requirements of A1 22 alloys).
A1
 Where the transverse tensile test uses multiple test specimens to represent the full test
 piece and one test specimen fails, the test may be repeated with a full thickness test piece.
The report of results shall indicate whether fracture occurred in the weld, at the edge of
the weld, or in the parent metal, and whether weld defects are present on the fractured
surfaces.
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7.5
40
ALL-WELD-METAL TENSILE TEST
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7.5.1 Method The all-weld-metal tensile test shall be carried out in accordance with
AS 2205.2.2, with the following conditions:
(a)
The diameter of the parallel tested portion of the test specimen shall be the
maximum possible consistent with the cross-section of the weld but need not be
more than 20 mm.
(b)
Where the weld metal has a tensile strength (as deduced from the transverse tensile
test) less than the specified minimum tensile strength of the parent metal or where
there may be serious doubt concerning the yield strength of the weld metal at
elevated temperatures, the yield strength also shall be measured.
(c)
The yield point (or 0.2 percent proof stress) shall be determined at room
temperature.
(d)
When serious doubt exists for the proof stress of the weld metal at elevated
temperature, this value shall also be determined by test at the relevant temperature.
7.5.2 Requirements The tensile strength shall not be less than 95 percent of the
specified minimum tensile strength of the parent metal. The yield strength shall exceed
the specified minimum yield strength of the parent metal or the yield strength required by
the design calculation, whichever is less.
The elongation measured on a gauge length of 5.65 (cross-sectional area) shall be not less
than 10 percent, or 80 percent of the equivalent specified minimum elongation of the
parent material, whichever is the greater.
Where two plates of different specified minimum tensile strength, yield strength, and
elongation are welded, the lower values shall be used.
When elevated temperature proof stress is relevant (see Clause 7.5.1(d)), the proof stress
shall not be less than the value for the parent material at the relevant temperature required
by design.
7.6
BEND TEST
7.6.1 Method A bend test shall be carried out in accordance with the appropriate test
method, as follows:
(a)
For transverse guided bend test, AS 2205.3.1.
(b)
For transverse free bend test, AS 2205.3.2.
(c)
For longitudinal guided bend test, AS 2205.3.3.
(d)
For transverse joggle butt wrap-around bend test, AS 2205.3.4.
(e)
For tongue bend test, AS 2205.3.5.
The following conditions apply:
(i)
Where a combination of welding consumables or processes is used in the joint, each
separate part of the joint shall be tested for ductility by suitable bend tests.
(ii)
Where the thickness of the test piece exceeds 10 mm, side bend test specimens shall
be substituted for transverse bend specimens; except for single-sided butt joints with
plate or pipe thickness exceeding 10 mm (see Note 9 to Table 6.1).
For side bend specimens, the thickness of the specimen (dimension ‘t’) shall be not
less than 10 mm and shall be such that the maximum width of the weld will be
always contained within the limits of the former used during the test.
NOTE: Normally the former diameter will first be selected to suit the weld width and the
thickness made a proportion of the former diameter in accordance with Table 7.1.
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(iii) The specimen shall be formed around a former having the diameter specified in
Table 7.1 so that the specimen is bent through 180 degrees.
(iv)
For transverse face and root bend tests, the width of plate specimens shall be 1.5t
with a 45 mm maximum and 30 mm minimum limit.
(v)
Longitudinal face and root bend tests should be used instead of transverse side or
transverse face and root bend tests for testing weld metal or parent metal
combinations including HAZ which differ markedly in the yield strength between
the two parent metals or between the weld metal and parent metal.
(vi)
For welded joints with large variation in ductility in different parts of the joint, the
fully guided bend test or wrap-around guided bend test is preferred.
7.6.2 Requirements On completion of the test, no crack or defect on the outer surface
of the specimen shall be greater than 3 mm in any direction.
In root bend test specimens, for single sided welds, flaws due to incomplete root
penetration or lack of root fusion shall not be considered as a cause for rejection provided
that the flaw after bending of the test specimen does not exceed 3 mm measured in any
direction along the test specimen, and that the flaw has sound metal at the back and on
each side. For corrosion-resistant weld overlay cladding, the flaw shall not exceed 1.5 mm
into the cladding or overlay.
TABLE
7.1
BEND TEST DIMENSIONS
Material group
A1, A2, A3
B, C, D1, D2 & E
F
G
H, J, K, L & M
Al 21 & 22
A1


Al 23
Al 23
Al 25
Al 25
Cu 31, 32, 33, & 34
Cu 35
Ni 41, 42, 43, 44, 45 & 46
Ti 51
Ti 52
Zr 61
Zr 62
Material type
Carbon and carbon manganese steels
Low alloy steels (see Note 3)
9% Ni steel
Quenched and tempered low alloy steels
High alloy steels
Aluminium and aluminium alloy (see
Note 4)
Aluminium alloy (see Notes 5 and 4)
Al 23 welded to other aluminium alloys
Aluminium alloy (see Note 5)
A1 25 welded to Al 21 or Al 22
Copper and copper alloys
Aluminium bronze
Nickel and nickel alloys
Titanium alloy (low strength)
Titanium alloy (higher strength)
Unalloyed Zr
Alloyed Zr
Diameter of former
(see Notes 1 and 2)
4t
4t
6.7t
6.7t
4t
4t
16.5t
16.5t
6.7t
6.7t
4t
16.5t
4t
8t
10t
10t
10t
NOTES:
1 t = nominal thickness of specimen, in millimetres.
2 For dissimilar metal joints, use larger former diameter required for the materials under test.
3 For steels with a specified minimum tensile strength > 650 MPa, use former diameters for Group F and
G steels.
4 For any aluminium (Al 21-Al 25) welded with 4000 series aluminium weld metal, use former diameter
16.5t.
5 Parent metal in other than the annealed condition before welding should be annealed after welding and
prior to testing.
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7.7
42
CHARPY V-NOTCH IMPACT TEST
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7.7.1 Method Charpy V-notch impact test shall be carried out in accordance with the
requirements of AS 2205.7.1, with the following conditions:
A1
(a)
The number and location of the test specimens shall be as shown in Figure 7.1 and
in accordance with the requirements listed in Table 7.2.
(b)
Each specimen shall be tested at no more than 2°C above the required test
temperature. See Table 7.2 for test temperature requirements.
(c)
Where impact testing is required for a pressure component which is to be
pneumatically tested, the impact tests shall be conducted at a temperature to meet
the requirements of the pressure equipment Standard.
(d)
Where applicable, at least two specimens shall be taken from weld metal and HAZ
in parts of the weld made with processes or consumables markedly different from
the remainder of the weld.
 (e)

Where impact testing is required in accordance with Note 2(b) to Table 10.1 of this
Standard, the test temperature shall be as specified in Note 2(b) to Table 10.1.
(f)
Where lateral expansion values are required, they shall be determined and reported
in accordance with ASTM A370.
7.7.2 Requirements The Charpy V-notch impact energy values or lateral expansion
values obtained in the tests shall comply with the relevant requirements set out in
Table 7.2 for 10 mm × 10 mm specimens. For specimens less than 10 mm × 10 mm, the
energy shall be not less than the required value multiplied by the appropriate energy
factor given in Table 7.3.
7.7.3 Retests
follows:
According to the nature of failure of a test, retests may be performed as
(a)
Failure of one specimen If the average of the three Charpy impact tests exceeds
the specified minimum average energy value specified in Table 7.2 but one
specimen fails to give the specified minimum individual value, three more impact
specimens shall be cut from the same test piece and retested. If all three specimens
give not less than the specified minimum average value, the test piece represented
shall be deemed to comply with this Standard.
(b)
Failure of average of tests If the average of the three impact tests fails to attain
the specified minimum average energy value or if two of the test results fall below
the specified minimum individual value, the test piece represented shall be deemed
not to comply with this Standard.
(c)
Failure due to specimen defect or procedure error Where failure is the result of a
weld defect in the specimen or to an error in the mechanical test procedure, the
result shall be discarded and a further specimen substituted.
(d)
Failure in lateral expansion test for all size specimens If the value of the lateral
expansion for one specimen is below 0.38 mm but not below 0.25 mm, and the
average value for the three specimens equals or exceeds 0.38 mm, then a retest of
three additional specimens may be made, each of which shall attain values equal to
or exceeding 0.38 mm. If the required values are not obtained in the retest or if the
values in the initial test are below the minimum required for retest, the material
shall be either rejected or submitted to a further heat treatment. After such reheat
treatment, three specimens shall be tested and the lateral expansion for each shall
equal or exceed 0.38 mm.
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AS/NZS 3992:1998
NOTES:
1 For weld metal impact specimens, the base of the notch shall be located approximately on the centreline of
the weld.
2 For HAZ impact specimens, the base of the notch shall be located within 1 mm to 2 mm of the fusion
boundary.
DIMENSIONS IN MILLIMETRES
FIGURE 7.1 CHARPY V-NOTCH IMPACT SPECIMENS – LOCATION, SIZE AND
NUMBER OF SPECIMENS IN RELATION TO MATERIAL THICKNESS AND WELD
CROSS-SECTION
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TABLE
7.2
PROCEDURE WELD IMPACT TESTS
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Parent metal
(See Table 5.3)
Where weld impact tests are required
(See Note 1)
Material
Type
group
Carbon and carbon-manganese steels
A1, A2, & A3 C, C-Mn steels—
as welded
C, C-Mn steels —
postweld heat treated
Low alloy steels
B
Alloy
C
Alloy
D1
Alloy
D2
Alloy
steel
steel
steel
steel
(alloy <¾)
(¾ ≤ total alloy <3)
(Vanadium type)
(3 ≤ total alloy <10)
E
A1 
3½ Grade D
Ni
steel Grade E
F
9 Ni steel (Note 9)
G
Quenched and tempered low
alloy steel (Note 9)
High alloy steels
H
Martensitic Cr steel
J
Ferritic high-Cr steel (Note 10)
K
Austenitic Cr-Ni C > 0.1
steel; (except
steels to Note 6)
C ≤ 0.1
A1 
L
M
Austenitic Cr-Ni steel (Note 6)
High chromium steel (Note 10)
Ferritic-austenitic Cr-Ni steel
(Note 11)
On weld metal
On HAZ
Class 1 boilers to
AS 1228. Pressure
vessels and piping where
parent metal requires
impact testing from
Figure 2.6.2(A) of
AS 1210 — 1997 or
Figure 2.11.2(A) of
AS 4041 — 1992,
respectively
Class 1 boilers to
AS 1228. Pressure
vessels and piping where
parent metal requires
impact testing from
Figure 2.6.2(B) of
AS 1210 — 1997 or
Figure 2.11.2(B) of
AS 4041 — 1992,
respectively
Pressure vessels and
piping, as for weld
metal where the heat
input exceeds 5 kJ/mm,
or where H/t (Note 4)
exceeds — 0.1 for
preheat or interrun
temperatures ≤100°C,
or 0.08 for preheat or
interrun temperatures
>100°C, but heat input
limits do not apply for
normalized steels
Class 1 boilers to
AS 1228. Pressure
vessels and piping where
the required MDMT for
parent metal < −30°C; or
is below Curve A of
Figure 2.6.2 of
AS 1210 — 1997 or
Figure 2.11.2 of
AS 4041 — 1992,
respectively
As for groups B to D2
steels
Minimum impact values at impact
test temperatures (Notes 2 and 3)
Weld metal
HAZ
When tested at required
impact test temperature
for parent metal —
30 J for Rm ≤ 450 MPa
40 J for Rm > 450 MPa
When tested at required
impact test temperature
for parent metal increased
as per Note 5—
30 J for Rm ≤ 450 MPa
40 J for Rm > 450 MPa
When tested at required
impact test temperature
for parent metal
18 J for Rm ≤ 450 MPa
20 J for Rm > 450 MPa
≤ 520 MPa
27 J for Rm > 520 MPa
≤ 650 MPa
0.38 mm lateral expansion
for R m > 650 MPa
18 J at required MDMT
As for weld metal
20 J at required MDMT
As for
parent
metal; or
where
there is
no data
for parent
metal use
value for
weld
metal
All
As for Groups B to D2
steels
Class 1 boilers to
AS 1228. Pressure
vessels and piping when
the required
MDMT <−30°C
0.38 mm minimum lateral
(see Note 8)
expansion at required
Class 1 boilers to
Where parent metal
MDMT
AS 1228. Pressure
requires impact testing
vessels and piping when
the required
MDMT <−30°C
(see Note 7 and 8 )
All
As for weld metal
As for Groups B to D2
steels
(continued)
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Parent metal
(See Table 5.3)
Material
Type
group
Non-ferrous metal
Al 21–25
Aluminium and its alloyswrought
AL 21–25
Aluminium and its alloys-cast
Cu 31–35
Copper and its alloys
Ni 41–46
Nickel and its alloys
Ti 51, 52
Titanium and its alloys
Dissimilar metals
AS/NZS 3992:1998
Where weld impact tests are required
(See Note 1)
On weld metal
Minimum impact values at impact
test temperatures (Notes 2 and 3)
On HAZ
Weld metal
HAZ
For required MDMT
<−270°C
By agreement
For required MDMT
< −200°C
As for
parent
metal; or
where
there is
no data
for parent
20J at required MDMT
metal use
value for
As for weld metal having weld
metal
less stringent
requirements for parent
metals
As for weld metal
As required MDMT
<−60°C
As for both parent
metals above
As for both HAZs
above
LEGEND:
MDMT = material design minimum temperature
HAZ = heat-affected zone
Rm
= specified minimum tensile strength of parent metal
NOTES:
1 Impact tests are not required for material thicknesses below 3 mm or where it is impracticable to obtain a
10 mm × 2.5 mm specimen. Straightening is permitted where agreed between the parties concerned.
2 Charpy V-notch impact values in joules, average of three 10 mm × 10 mm specimens. See Clause 7.7.2 for impact
values and energy factors for smaller specimens. The minimum individual value is to be not be less than 70 percent of
the specified minimum average value. Lateral expansion values are the minimum for each specimen (see Clause 7.7.3
for retests).
3 Where the resulting test temperature exceeds 20°C, the impact tests are to be carried out at room temperature.
heat input (in kilojoules per millimetre)
sum of parent metal thickness at weld (in millimetres)
5 The increase in test temperature as a function of the maximum thickness at the weld is to be as follows:
4 H/t =
Maximum throat thickness at weld (or thickness of thicker
component) whichever is less, mm
Increase in
temperature, °C
>60
>40 ≤60
>30 ≤40
0
10
20
>20 ≤30
≤20
30
50
However, the test temperature need not be lower than that for a non-postweld heat treated weld of the same thickness.
6 Where austenitic chromium-nickel stainless steel has been heat-treated between 480°C and 900°C, impact testing of the
weld metal and HAZ is required.
7 Impact tests are not required for austenitic chromium nickel stainless steel at minimum operating temperatures above
−100°C when —
A1


(a) the deposited weld metal is of Type 308, 308L, 309, 310 or 316L with carbon < 0.10 percent or welds without
filler metal are made between 304, 304L, 316, 316L, 321 and 347 materials; and
(b) welding processes are limited to gas metal-arc, gas tungsten-arc and submerged arc.
8 Where the calculated average stress does not exceed 50 MPa, impact testing is not required.
9 Welds made with high nickel-alloy filler metal conforming to ANSI/AWS A5.11 ENiCrFe-2;
ANSI/AWS A5.11 ENiCrFe-3; ANSI/ASTM A5.14 ERNiCrFe-6 and ANSI/AWS A5.14 ERNiCr-3, are exempt from
impact tests of the weld metal under the following conditions:
(a) Impact tests of the heat-affected zone are performed in accordance with Clause 7.7.
(b) The welding processes are limited to gas metal-arc, manual metal-arc and gas tungsten-arc.
(c) The minimum operating temperature of the vessel is not lower than −200°C.
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CAUTION: THE PROPERTIES OF THE BASE METAL MAY BE ADVERSELY AFFECTED BY
EXCESSIVE LOCAL HEAT INPUTS.
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10 Where ferritic-chromium stainless steels have been thermally treated between 430°C and 730°C, impact testing of the
weld metal and heat affected zone is required
11 Where ferritic-austenitic steels have been thermally treated between 320°C and 955°C, impact testing of the weld
metal and heat affected zone is required.
TABLE 7.3
EQUIVALENT ENERGY FACTORS FOR
SUBSIDIARY TEST SPECIMENS
Width of test specimen, mm
10 (standard)
7.5
5.0
2.5
A1
Equivalent energy factor
1.0
0.8
0.7
0.35
7.8 MACRO EXAMINATION
7.8.1 Method A macro cross-section examination shall be carried out in accordance
with AS 2205.5.1, using a magnification of approximately five times and with the
following conditions:
(a) The specimen for macro examination shall be taken from the test piece transverse to
the weld. It shall be the full thickness of the material at the welded joint and of
sufficient length to include the weld, heat-affected zone and parent metal, on both
sides of the weld.
(b) The surface transverse to the weld shall be prepared by machining to ensure
removal of all material affected by flame or other cutting methods.
(c) Additional etching techniques to those listed in AS 2205.5.1 are given in
Appendix E.
7.8.2 Requirements On examination, the weld and parent metal shall be free from —
(a) cracks, lack of fusion, or incomplete penetration unless the procedure is based on a
joint with incomplete penetration; and
(b) porosity, slag inclusions or surface cavities, the size and distribution of which
exceeds the acceptance limits in AS 4037.
 Excess weld reinforcement or penetration shall not be cause for rejection of a welding
 procedure test but shall be reported.
The macro test report shall include a full-size sketch or photograph of a representative
macro showing the outline of the fusion boundary and in addition the approximate number
of runs is to be reported.
A sketch or photograph of the macro specimen should be retained by the fabricator to
allow cross-checking of production test plates or production welding with the qualified
welding procedure.
7.9 WELD JOINT HARDNESS TEST Hardness values are dependent upon factors
such as alloy content, weld preheat and postweld heat treatment. Specific hardness values
for welded joints are not specified in this Standard.
However, it is recognized that specified maximum hardness values may be required by the
purchaser for welds in service when corrosive environments are encountered. Under these
circumstances, the purchaser shall specify —
(a) the method of hardness testing; and
(b) the maximum permitted hardness value in the welded joint, inclusive of the heat
affected zone.
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7.10
AS/NZS 3992:1998
FILLET BREAK TEST
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7.10.1 Method A fillet break test shall be carried out in accordance with AS 2205.4.2,
under the following conditions:
The load shall be applied with the root of the weld in tension and until the test specimen
bends flat upon itself or it breaks along the weld, whichever occurs first.
7.10.2 Requirements The weld shall be deemed to be satisfactory where the test
specimen bends flat upon itself, or —
(a)
the test specimen breaks along the weld;
(b)
the weld metal and heat-affected zones are free of prior cracks;
(c)
the exposed surfaces show penetration to and fusion at the root of the weld for a
sum total of at least 80 percent of the weld length (penetration may not necessarily
extend beyond the root position); and
(d)
the sum of the areas of incomplete penetration, inclusions, porosity, wormholes,
lack of fusion and any other weld discontinuities does not exceed a value equal to
5 percent of the longitudinal cross-section through the plane of the weld at the
effective throat thickness position.
7.11
NICK-BREAK TEST
7.11.1 Method When required by Table 10.1, a nick-break test shall be carried out in
accordance with the requirements of AS 2205.4.1 and the following:
Radiographic examination of the test piece may be substituted for the nick-break test.
Where this option is exercised, requirements for retesting under Table 7.4 prevail and no
alternative exists to revert to the nick-break test.
7.11.2 Requirements
surface shows —
The weld shall be deemed to be satisfactory where the fracture
(a)
the weld metal and heat-affected zones are free of prior cracks;
(b)
no evidence of lack of fusion and, in the case of full penetration welds, lack of
penetration; and
(c)
freedom of porosity, inclusions and other weld discontinuities exceeding 3 mm in
maximum dimension. The sum of the maximum dimension of all discontinuities in
any 650 mm2 area on the fracture face of the weld shall not exceed 10 mm total.
7.12
ADDITIONAL TESTS BEFORE REJECTION
7.12.1 Number of retests If any of the test specimens taken from the test piece fails to
meet the specified requirements, additional tests in accordance with Table 7.4 shall be
allowed on the spare portion of the original test piece or on an additional test piece
prepared using the same weld procedure.
7.12.2 Requirement If the results of any of the retests do not meet the specified
requirements, the procedure shall be regarded as not complying with this Standard.
7.13 REPORTING OF RESULTS A report shall be prepared in accordance with the
requirements of the relevant parts of AS 2205. The report shall indicate the following
additional information:
(a)
Name of laboratory and date of testing.
(b)
Description of the test piece.
(c)
Traceable test piece reference number or identity.
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(d)
48
Any additional information as directed by the fabricator to ensure traceability of test
piece to the relevant production test plate, procedure or welder qualification test
weld documentation.
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TABLE
7.4
RETESTS
Test failed
Transverse tensile (see Note 2)
All-weld tensile:
(a) Tensile and yield strength
(b) Elongation and reductions of area
Bend (see Note 2)
Nick break
Impact test (see Note 2)
Macro test
Fillet break
Initial test result as
percentage of required
result
Minimum
number of
specimens
for retests
(see Note 1)
Notes
≥ 95 (parent metal fracture)
0
Complies
≥ 95 (weld metal fracture)
< 95 and ≥ 90 (weld or
parent metal fracture)
< 90
1
2
—
—
0
Test plate fails
to comply
As for transverse tensile
≥ 90
< 90 ≥ 80
< 80
1
2
0
—
2
—
See Clause 7.7
2
See
Clause 7.7
2
2
—
—
—
—
—
Test plate fails
to comply
For each
original
specimen
which failed
—
—
—
—
NOTES:
1 If the unsatisfactory results of the tests are shown to be caused by local or accidental mechanical defects in
the test specimen preparation and these would not exist in the component, the test affected may be repeated.
2 If unsatisfactory results of the retest are due to a permitted weld defect (e.g. permitted slag inclusion) or
error in the testing method, then the test affected may be repeated.
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AS/NZS 3992:1998
S E C T I O N 8
W E L D O V E R L A Y
Q U A L I F I C A T I O N T E S T I N G
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8.1
CLAD PLATE CONSTRUCTION
8.1.1 Items to be recorded for welding procedure testing The items to be recorded
for clad plate procedure test welds shall be in accordance with the applicable requirements
of Section 4.
8.1.2 Essential variables Welding procedures shall require requalification when
changes are made to a qualified welding procedure in accordance with Section 5 or when
any of the following conditions apply:
(a)
An increase in arc energy or volume of deposited weld metal of more than
10 percent used in the first layer of the deposited overlay weld metal.
(b)
An increase in arc energy or volume of deposited weld metal of more than
20 percent in any subsequent layer of deposited overlay weld metal.
8.1.3
Test piece
Test pieces shall be prepared in accordance with Clause 6.1.
8.1.4 Non-destructive examination Non-destructive examination shall be in
accordance with Clause 6.3 with the additional requirement that the corrosion resistant
weld overlay shall be examined by the liquid penetrant method in accordance with
AS 2062 or ISO 3452.
The examination shall show that the test piece is free from cracks, porosity or other
defects which penetrate the outer surface of the weld overlay.
8.1.5 Test specimen Mechanical test specimens shall be taken in accordance with
Table 6.1 and tested in accordance with Section 7. Joint tensile and bend tests shall be
carried out without removal of weld overlay. The penetration of the weld overlay into the
parent material past the clad thickness should not exceed 2 mm. All-weld-metal tensile
test specimens shall be taken entirely from the base weld metal without inclusion of
fusion weld zone between weld overlay and parent metal. Test results shall comply with
the requirements of Section 7.
8.1.6 Chemical analysis A chemical analysis shall be taken from the corrosion
resistant weld metal within 2 mm of the outer surface. The analysis shall comply with the
analysis limits of the welding consumables used in the final layer or as specified by the
purchaser.
8.2
CORROSION-RESISTANT WELD METAL OVERLAY
8.2.1 Items to be recorded for welding procedure testing The items to be recorded
for corrosion-resistant weld metal overlay procedure test welds shall be in accordance
with the applicable requirements of Section 4.
8.2.2 Essential variables Welding procedures shall require requalification when
changes are made to a qualified welding procedure in accordance with Section 5 or when
any of the following conditions are applied:
A1
(a)
An increase in arc energy or volume of deposited weld metal of more than
10 percent used in the first layer of the deposited overlay weld metal.
(b)
An increase in arc energy or volume of deposited weld metal of more than
20 percent in any subsequent layer of deposited overlay weld metal.
 (c)
A reduction in the number of layers of weld metal.
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8.2.3 Test piece Weld overlay testing shall be carried out on material of the group
letter corresponding to the requirement of the material specification. Parent material
thickness of 25 mm or greater qualifies for all material thicknesses over 25 mm. Base
material thickness below 25 mm qualifies only for that thickness and all thicknesses up to
25 mm.
8.2.4 Non-destructive examination The weld overlay surface shall be examined by the
liquid penetrant method in accordance with the methods and procedures in AS 2062.
The examination shall show that the test piece is free from cracks, porosity or other
defects which penetrate the outer surface of the weld overlay.
8.2.5 Test specimen Bend test specimens in accordance with Table 6.1 shall be
machined from each test piece and subjected to bend tests in accordance with Section 7.
The bend test pieces after bending shall comply with Clause 7.6.2
8.2.6 Chemical analysis A chemical analysis shall be taken from the overlay surface
within 2 mm of the outer surface. The analysis shall comply with the analysis limits of
the welding consumables used in the final layer or as specified by the purchaser.
8.3
HARDFACING WELD METAL OVERLAY
8.3.1 Items to be recorded for welding procedure testing The items to be recorded
for hardfacing weld metal overlay test welds shall be in accordance with the applicable
requirements of Section 4.
8.3.2 Essential variables Welding procedures shall require qualification when being
established for the first time or requalification when changes are made to a qualified
procedure in accordance with Section 5 or when any of the following conditions apply:
(a)
An increase in arc energy or volume of deposited weld metal of more than
10 percent of that used in the first layer of the deposited overlay.
(b)
An increase in arc energy or volume of deposited weld metal of more than
20 percent of that used in any subsequent layer of deposited overlay.
8.3.3 Test piece Weld overlay testing shall be carried out on material of the group
letter corresponding to the requirements of the material specification.
Parent metal thickness of 25 mm or greater qualifies for all material thickness over
25 mm. Parent metal thickness below 25 mm qualifies only for the thickness used and
thicknesses up to 25 mm.
The test piece shall be 50 mm wide × 120 mm long (minimum) with a hardfacing overlay
25 mm wide × 100 mm long (minimum) on one face and a thickness specified in the
welding procedure specification. Alternatively, qualification may be made on a test
sample that suitably represents the production part.
8.3.4 Non-destructive examination The completed weld overlay shall be examined by
the penetrant test method in accordance with the methods and procedures in AS 2062.
The examined surface shall be free of cracks, porosity, lack of fusion and other defects
which penetrate the surface, except where otherwise specified in the welding procedure
specification.
NOTE: Some hardfacing materials and processes result in surface craze cracking and minor
porosity, which may be acceptable to the parties concerned for some service conditions e.g.
parts subject to low tensile stress or using ductile parent metal, where unacceptable leakage will
not result from the surface defects and suitable tests or experience show any feasible crack
propagation by fatigue, corrosion or brittle fracture will not be a safety issue. For high pressure
valve seats, such defects are not permitted.
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8.3.5 Test specimen
to the weld overlay.
AS/NZS 3992:1998
The test piece shall be sectioned transverse (at any suitable angle)
Both faces exposed by the sectioning shall be polished and etched with a suitable etchant
and be visually examined at ×5 magnification; one for the macro and hardness traverse
and the second for chemical analyses. The weld overlay, heat-affected zone and adjacent
parent metal shall comply with the thickness and sequence of runs specified in the
welding procedure and defect acceptance specified in Clause 8.3.4.
Hardness measurements shall be made in accordance with AS 1817 (i.e. HV) or other
method specified in the welding procedure, in at least three positions in the heat-affected
zone, in each overlay layer, and on the external surface representing the wear surface. All
readings shall meet the hardness requirements of the range specified in the welding
procedure specification or as otherwise specified by the purchaser or manufacturer.
External surface readings are intended to provide guidance for any quality control tests
required for production welds.
8.3.6 Chemical analysis A chemical analysis shall be made on the weld overlay within
the outer 0.5 mm thick surface layer, or if the overlay thickness is over 25 mm, within a
0.5 mm thick layer at the minimum thickness qualified. The analysis shall comply with
the analysis limits of the welding consumables used in the final layer or as specified in
welding procedure specification.
Dilution may affect the analysis, the amount depending mainly on the number of layers
used.
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S E C T I O N
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9
W E L D E R
Q U A L I F I C A T I O N
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9.1 GENERAL Where required by the pressure equipment Standard or AS 4458,
welder qualification shall be carried out in accordance with this Section (9).
9.2
(a)
A1
A1




METHODS OF QUALIFICATION The methods of qualifications are as follows:
Welding a test piece which simulates the production weld and examining and testing
the test piece in accordance with Clause 9.5.
Where the option in Clause 9.5.1(a) is taken to approve a welder by non-destructive
examination methods the parent material for the test piece may be from Group A1
or A2 materials welded using the preheat and consumables of the required welding
procedure. This option is only permitted for the parent material specification listing
in Table 9.1.
(b) Presentation of documentary evidence of having satisfactorily welded a production
joint which has complied with the appropriate requirements of the pressure
equipment Standard for radiographic or ultrasonic testing within the previous six
months.
(c) Presentation of documentary evidence of having welded the test piece of a qualified
welding procedure within the last six months.
(d) Holding an appropriate certificate specified in AS 1796 (for Australia), or the NZIW
welding supervisor’s certificate or the NZIW certificate in welding engineering (for
New Zealand) which shall qualify the welder within the range covered by that
certificate provided that welder has made production welds complying with this
Standard within the previous six months.
(e) Part of the first production weld or a complete pipe weld carried out by a welder to
an approved welding procedure is shown by either radiographic or ultrasonic
examination to comply with the pressure equipment Standard.
(f)
The length of weld examined in a production weld or test piece shall be at least
300 mm or the circumference of a pipe weld, whichever is less.
Welders qualified in accordance with the above are permitted to undertake production
welding within the limits of the essential variables listed in Table 9.1 using welding
procedures documented in accordance with the requirements of this Standard.
9.3 EXTENT OF APPROVAL OF WELDER QUALIFICATION A welder qualified
to an approved welding procedure in accordance with any method as laid down in
Clause 9.2 shall be requalified when the essential variables of additional production welds
exceed the requirements laid down in Table 9.1 for the items as listed.
9.4 INFORMATION TO BE GIVEN TO WELDER FOR QUALIFICATION TEST
WELDS When a welder undertakes a test weld for qualification purposes in accordance
with Clause 9.2(a), the welder shall be provided with full details of the approved welding
procedure.
9.5 EXAMINATION AND TESTING OF WELDER QUALIFICATION TEST
WELDS
9.5.1 Methods of examination and testing All tests pieces shall be examined visually.
If acceptable in accordance with the pressure equipment Standard they shall then at the
fabricator’s option be —
(a) examined by radiographic examination, or by ultrasonic examination (supplemented
by surface NDE methods when applicable), and assessed for acceptability in
accordance with AS 4037; or
NOTE: Macro examination may be used, if necessary, to assist in the interpretation of the
non-destructive testing results.
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AS/NZS 3992:1998
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(b) tested using the test specimens given in Table 9.3.
Test pieces welded by the gas metal-arc welding process and examined by radiographic or
ultrasonic examination as in Item (a) above shall additionally be subjected to the bend
tests specified in Table 9.3.
Unless otherwise specified, the first and last 25 mm of the length of a butt joint in plate
shall be ignored in both non-destructive and destructive testing.
9.5.2 Preparation and testing of specimens for destructive testing When destructive
tests are required, test specimens, using the tests specified in Table 9.3, shall be removed
in accordance with Figures 6.4, and 6.5 as appropriate, and tested in accordance with
Clauses 7.6, 7.8, 7.10 and 7.11.
It is permissible to take the test specimens from locations that avoid areas showing visual
imperfections.
9.6 RECORDING OF WELDER QUALIFICATION TESTS A statement of the
results of assessing each test piece, including repeat tests, shall be made for each welder.
In addition, the weld procedure used for the qualification is to be recorded with the test
results. The items required by Clause 9.5 shall be included together with details of any
features that do not comply. If no unacceptable features are found, a statement that the
test piece made by the particular welder satisfied the requirements of this Standard in
respect of that type of test piece shall be signed by the person conducting the test.
The welder’s employer shall hold and regularly maintain adequate records of all approval
tests for each welder and such records shall be accessible to the inspection body.
Welder approval tests carried out in accordance with this Standard and witnessed and
signed by an inspection body should be accepted by other inspecting agencies.
9.7 RETESTS If any test specimen fails to satisfy the relevant requirements given in
Clause 9.5 two further test specimens for each failed specimen shall be obtained, either
from the same test piece, if there is sufficient material available, or from a new test piece,
and subjected to the same test. If either of these additional test specimens does not meet
the required standard, the cause of failure shall be established. If this failure is established
as being the result of metallurgical or extraneous causes and is not attributable to the
welder’s workmanship, then a further repeat test shall be taken. If the failure is
established as being attributable to the welder’s workmanship, then the welder is
permitted to repeat the test weld which shall be subjected to the same test procedure.
A1
A1
A1
 Where the failure of a welder qualification is determined by radiographic or ultrasonic
 examination of a test piece or production weld, an additional test piece or production weld
 shall be made and examined in accordance with the requirements of Clause 9.5
 If the additional test specimens, test piece or production weld pass the required tests, then
the welder shall be accepted as qualified to weld production welds within the limits of the
essential variables of the welding procedure and the welder’s qualifications.
 If the additional test specimens, test piece or production weld do not pass the required
tests, then the welder shall not be regarded as capable of meeting the requirements of this
Standard without further training and examination.
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TABLE
9.1
ESSENTIAL VARIABLES FOR QUALIFICATION OF WELDERS
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Item
1
Parent material
specification
Essential variables
Ferrous materials
A change in material group number (see Table 5.3) requires requalification, except
qualification on any material group within A1, A2, A3, B, C, D1 and D2 up to 6%
alloy content qualifies for all material groups within this range.
Non-ferrous materials
A change in material group number (see Table 5.3) requires requalification.
Qualification in any alloy of a base material qualifies for all other alloys of that base
material.
2
Welding
consumables
A change in electrode or filler metal classification requires requalification of a
welder except in the following cases:
(a) For manual metal-arc welding of ferrous materials, qualifications using an
electrode in the range F2 to F5 inclusive of Table 5.5 qualifies for all electrode
types of lower number.
For ferrous materials, qualification in submerged arc, gas metal-arc, gas
tungsten-arc and flux cored arc welding in any F number applicable to the
welding process qualifies for all other F number of that welding process.
(b) For aluminium welding, qualification using an aluminium electrode or filler
metal qualifies for all other aluminium electrodes or filler metal classifications.
(c) For nickel alloy welding, qualification using a nickel alloy electrode or filler
metal qualifies for all other nickel alloy electrodes or filler metal classifications.
(d) For copper alloy welding, qualification using a copper alloy electrode or filler
metal qualifies for all other copper alloy electrodes or filler metal classifications.
A1
A1

3
Welding position
(see Figures 5.1
and 5.2)
Refer to Table 9.2 for essential variables for welding position.
4
Direction of
welding
Qualification in the 3G position only qualifies for the 1G position when direction of
welding is vertical up. Vertical down welding qualifies for welding only in the
vertical down direction for position 3G.
5
Range of
thickness
A change in material thickness as listed in Table 5.4, except that qualification on a
test piece thickness of 10 mm qualifies for all thickness above 10 mm for manual
metal-arc, submerged arc, flux cored arc welding, gas tungsten-arc, and gas metalarc welding (except short-circuiting arc transfer).
 6 Range of

diameter







Requalification is required when the pipe outside diameter is smaller than the
following values:
(a) D where D < 25 mm.
(b) 25 mm where 25 ≤ D < 73 mm.
(c) 73 mm where D ≥ 73 mm.
D = outside diameter of the welder’s test pipe.
NOTE: Requalification is not required for pipe diameters greater than the welder’s
test pipe.
7
Weld joint detail
Omission of backing strip or consumable backing ring detail.
8
Welding process
(see Note)
A change in welding process or combination of welding processes.
NOTE: For multi-process procedures, welder qualification may be approved for a welder covering an
individual welding process, or all welding processes at the option of the fabricator provided that the welder’s
skill is adequately assessed, for example, the deletion of a GTAW root run shall require requalification of
the welder performing the root pass using a different process for a single-sided weld.
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TABLE
AS/NZS 3992:1998
9.2
QUALIFICATION OF WELDING POSITIONS
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Qualification test
Weld type
performed
Plate butt
Plate fillet
Pipe butt
Pipe fillet
Weld type and position qualified
Weld position
Plate
butt
Plate
fillet
Pipe butt
≥DN 500
Pipe butt
<DN 500
Pipe
fillet
1G
1G
1F
1G
See Note
1F
2G
1G 2G
1F 2F
1G 2G
See Note
1F 2F 2FR
3G
1G 3G
1F 2F 3F
1G
—
1F 2FR 3F
4G
1G 4G
1F 2F 4F
1G
—
1F 2FR 4F
3G + 4G
1G 3G 4G
any
1G
—
any
2G + 3G + 4G
any
any
any
—
any
1F
—
1F
—
—
1F
2F
—
1F 2F
—
—
1F 2F 2FR
3F
—
1F 2F 3F
—
—
1F 2F 2FR 3F
4F
—
1F 2F 4F
—
—
1F 2F 2FR 4F
3F + 4F
—
any
—
—
any
1G
1G
1F
1G
1G
1F
2G
1G 2G
1F 2F
1G 2G
1G 2G
1F 2F 2FR
5G
1G 3G 4G
1F 2F 3F 4F
1G 5G
1G 5G
any
6G
any
any
any
any
any
2G + 5G
any
any
any
any
any
1F
—
1F
—
—
IF
2F
—
1F 2F
—
—
1F 2F 2FR
2FR
—
1F 2F
—
—
1F 2FR
4F
—
1F 2F 4F
—
—
1F 2F 2FR 4F
5F
—
any
—
—
any
NOTE: Qualification on plate butt welds welded in the 1G and 2G positions includes approval for butt joints
in pipes of outside diameter ≥ 150 mm welded in the same position.
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TABLE
9.3
NUMBER OF TEST SPECIMENS REQUIRED
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Butt joint in pipe
Test specimen
Butt joint in
plate
Outside diameter or
dimension
≤88.9 mm
>88.9 mm
Fillet weld in
plate
Branch
connection
Macro examination
1
2
2
2
4
Root bend (for plate and pipe
less than 10 mm thick and for
all welds made from one side
only)
1
2
3
—
—
Face bend (for plate and pipe
less than 10 mm thick)
1
—
1
—
—
Side bend (for plate and pipe at
least 10 mm thick)
2
1
1
—
—
Fillet weld fracture (for singleside weld only)
—
—
—
3
—
9.8 RENEWAL OF WELDER QUALIFICATION A welder’s qualification to weld
to a specified welding procedure shall remain valid provided that it can be shown from
records maintained by the organization employing the welder that the welder has been
employed with reasonable continuity using the relevant welding processes and has
continued to produce satisfactory welds as verified by the non-destructive examination,
workmanship and pressure testing requirements of the relevant pressure equipment
Standard.
Reapproval shall be required if any of the following conditions apply:
(a)
Six months or more have elapsed since the welder was employed on the relevant
welding processes.
(b)
The welder changes employment. Under such circumstances the employer shall
qualify the welder who has changed employment.
(c)
There is some specific reason to question the welder’s ability.
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S E C T I O N
1 0
W E L D
P R O D U C T I O N
AS/NZS 3992:1998
T E S T S
10.1 PRODUCTION TEST PLATES When required by the pressure equipment
Standard, welded production test plates shall be prepared in accordance with Figures 6.1
or 6.2, as applicable.
Such test plates shall be subjected to —
(a)
visual examination in accordance with Clause 6.2; and
(b)
where required by Table 10.1, non-destructive examination, using the same nondestructive examination method as required by the pressure equipment represented
by the test piece (refer to ‘extent of non-destructive examination of welded joints’
in AS 4037).
The location of any imperfections revealed in the above examinations shall be clearly
marked on the test plate and test specimens shall be selected from those parts of the test
plate which do not contain weld imperfections.
Test plates which contain imperfections of sufficient magnitude so as to not permit the
selection of test specimens from acceptable weld metal shall be rejected. Such test plates
shall not be repaired by welding but shall be re-made. In the event that the test plates
again fail to give sufficient length of sound weld metal for the required test plate
specimens, the welding procedure used for the test plate shall be rejected.
When production test plates, representative of pressure equipment requiring spot
examination by non-destructive examination methods, show imperfections in excess of the
limitations permitted by AS 4037, and give sufficient sound weld metal to prepare the
required test specimens, then a spot examination shall be carried out on each weld using
the welding procedure of the production test plate. Such welds shall be treated in
accordance with Clause 9.3 of AS 4037 — 1992.
Test plates complying with the acceptance criteria after the above examination shall then
be subject to —
(i)
post-weld heat treatment, when specified for the pressure equipment in the relevant
Standard, in accordance with Clause 6.4; and
(ii)
special conditioning when specified by the pressure equipment Standard.
The test specimens required for the various classes of pressure equipment construction are
given in Table 10.1. Such specimens shall be prepared and tested in accordance with the
requirements of Section 7 and shall meet the test requirements for the various specimens
as listed therein.
10.2 ADDITIONAL TESTS BEFORE REJECTION If any test specimen taken from
a production test plate fails to meet the requirements of Section 7, additional tests shall be
taken from the spare portion of the test plate in accordance with Table 7.4.
If the additional test specimens do not meet the requirements of Section 7, the production
test plate shall be regarded as not complying with the requirements of the pressure
equipment Standard.
10.3 RECORDS The results of production weld tests should be suitably recorded and
identified to the test plate welding procedure and equipment represented. Refer to
AS 4458 for reporting.
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TABLE
10.1
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TYPE OF TEST SPECIMENS
Bend tests Impact tests
Class of construction Transverse
(Notes 2, 3,
tensile
(Note 1)
4, 5 and 6)
AS 1210 Class 1
(Note 9)
X
X
AS 1210 Class 2A
—
X
X
AS 1210 Class 2B
—
X
X
AS 1210 Class 3
—
—
X
AS 1210 Class 1H
X
X
X
AS 1210
X
X
X
Class 2HA & 2HB
AS 1228 Class 1
X
X
X
AS 1228 Class 2
—
X
—
LEGEND:
X
—
—
—
X
X
Chemical
analysis
(Note 7)
X
—
—
—
X
—
X
—
X
—
Macro
Nick-break Non-destructive
examination
—
—
X (Note 8)
—
—
—
X
X
X (Note 8)
—
X
X
—
X (Note 8)
X
X (Note 8)
X = test specimen required
— = test specimen not required
NOTES:
1 The type and number of bend tests shall be in accordance with Table 6.1 for shell thickness as nominated.
2 Impact tests are only required as follows:
(a) When specified by the pressure equipment Standard and when tested at a test temperature as specified in
Section 7.7.
A1 
(b) When shell thickness exceeds twice the thickness requiring postweld heat treatment by the pressure equipment
Standard. The required value shall be as required by Table 2.6.2 or Table 2.6.3 of AS 1210–1997 for the material
of construction when tested at 10°C.
3 Welds made with high nickel-alloy filler metal conforming to ANSI/AWS A5.11 ENiCrFe-2; ANSI/AWS A5.11
ENiCrFe-3; ANSI/AWS A5.14 ERNiCrFe-6 and ANSI/AWS A5.14 ERNiCr-3 are exempt from production impact tests
of the weld metal under the following conditions:
(a) All required impact tests are performed as part of the procedure qualification tests as specified in Section 6.
(b) Production impact tests of the heat-affected zone are performed in accordance with Clause 7.7.
(c) The welding processes are limited to manual metal-arc welding, gas metal-arc welding, submerged arc welding and
gas tungsten-arc welding.
(d) The minimum operating temperature of the pressure equipment is not lower than −200°C.
The properties of the parent metal may be adversely affected by excessive local heat inputs.
4 Production impact tests are not required for austenitic chromium-nickel stainless steel at minimum operating
temperatures above −200°C when —
(a) the deposited weld metal is produced by filler metal for austenitic steel listed in Table 5.5 e.g. of Type 308, 308L,
309, 310 or 316L, and with carbon <0.10 percent;
(b) weld metal has been impact tested when required at the minimum operating temperature or lower in weld
procedure qualification tests; and
(c) welding processes are limited to gas metal-arc, manual metal-arc, gas tungsten-arc, submerged arc and plasma arc.
5 Where the calculated average stress does not exceed 50 MPa, impact testing is not required.
6 Where Type 309, 310, 316, 309Cb, 310Cb or 316Cb stainless steel has been postweld heat treated at temperatures
below 900°C, impact testing of the weld metal and heat affected zone is required.
7 Chemical analysis of weld deposit is only required by agreement and only on ferritic steel weld deposits of material
Groups B to E inclusive for principal alloy elements only. The alloy content shall comply with the analysis limits of
the welding consumables.
Chemical analysis of weld deposit is required for clad plate construction in accordance with Clause 8.1.6 and for
corrosion-resistant welded metal overlay in accordance with Clause 8.2.6 and for hard facing weld overlay in
accordance with Clause 8.3.6.
8 Nick-break test is not required when test plate is examined by either radiographic or ultrasonic methods.
9 Only required for construction in Groups F and G materials.
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S E C T I O N
1 1
B R A Z I N G
AS/NZS 3992:1998
Q U A L I F I C A T I O N
11.1 GENERAL This Section, together with Sections 1, 12, 13 and 14, specifies
requirements for the qualification of brazing procedures and brazing personnel (i.e.
brazers and brazing operators) for all brazing processes.
Brazing is the joining of metals using filler metals —
(a)
with a melting point greater than 450°C and which is less than the melting point of
the metals joined; and
(b)
distributed by capillary action.
Braze welding is a form of brazing where filler metal is not distributed by capillary
action.
In this Standard, brazing includes braze welding.
It is intended that brazing be permitted for the following conditions:
(i)
All joints other than those consisting of fillets only or those subject to severe cyclic
service.
(ii)
Containers for all fluids other than those which are lethal or will cause serious
corrosion of the joint materials.
(iii) Containers for fluids which are flammable, toxic or damaging to human tissue only
where safety precautions are provided for; e.g. by limiting location, site, or
conditions where a feasible amount of fluid release will not severely impair safety.
(iv)
Use in areas of possible exposure to fire or elevated temperatures only where the
low melting point of brazing alloys is considered acceptable.
11.2 QUALIFICATION REQUIRED Procedures and personnel employed in brazing
in the fabrication of pressure components shall be qualified and subject to production tests
in accordance with Sections 11 to 14 when specified in the pressure equipment Standard
(AS 1210, AS 1228 and AS 4041).
The fabricator is responsible for the brazing carried out by the fabricator’s organization
and for brazing qualifications.
11.3 GROUPING OF MATERIALS FOR BRAZING QUALIFICATION To reduce
the number of brazing qualifications required, parent metals which are to be brazed have
been grouped as shown in Table 11.1.
The grouping is based on comparable parent metal characteristics, such as compositions,
brazability and mechanical properties, so that generally a procedure qualified for one
metal in a group can be used for other metals in the same group. However, in doing this,
suitability of metallurgical properties, post-braze heat treatment, design, mechanical
properties and service conditions shall be considered.
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TABLE
11.1
GROUPING OF PARENT METALS FOR BRAZING
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Material group
ANSI/ASME BPV-IX
P number for
brazing
Type of parent metal
Specified
minimum tensile
strength, MPa
A, B
101
Carbon, carbon manganese and low alloy steels —
Chromium <0.90% (excludes quenched and
tempered boron-treated steels — Group G)
<625
C (selected) D2,
E, F, H, J, K
102
Ferrous alloys — chromium > 0.90% and 9%
nickel steel
<700
Iron castings
103
Malleable, grey and nodular iron castings
<420
Al 21
104
Aluminium and aluminium alloys (1000 series
and 3004)
<160
Al 23
105
Aluminium and aluminium alloys (6000 series)
<125
Cu 31, Cu 32, Cu
33, Cu 34
107
Copper and copper alloys — aluminium < 0.5%
<360
Cu 35
108
Copper and copper alloys —a luminium >0.5%
<690
Ni 41 & Ni 42
110
Nickel and nickel alloys — chromium < 1%
<490
Ni 43, 45 and 46
111
Nickel and nickel alloys — chromium > 1%
<830
Ni 44
112
Nickel and Nickel alloys — molybdenum > 10%
<800
Ti 51 & 52
(selected)
115
Titanium — unalloyed only
<450
11.4 GROUPING OF BRAZING FILLER METALS To reduce the number of
brazing qualifications required, brazing filler metals are grouped as shown in Table 11.2.
The grouping is based essentially on filler metal useability characteristics which determine
the ability of brazers and brazing operators to make brazed joints with a given filler
metal.
The grouping does not imply that filler metals within a group may be indiscriminantly
substituted for a filler metal used in the qualification test without consideration of the
suitability of metallurgical properties, post-braze heat treatment, design, mechanical
properties and service conditions.
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TABLE
AS/NZS 3992:1998
11.2
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GROUPING OF BRAZING FILLER METALS
ANSI/ASME
BPV-IX
F number
101
AS 1167.1
classification
AWS classification
BAg-1, -1a, -8, -8a, -22, -23
BVAg-0, -8, -8b, -30
BAg-other than above
BVAg-other than above
A1, A4, A6
103
104
105
BCuP-1 to 7
BA1 Si-2 to 11
BCu-1, -1a, -2; BVCu-1x
B1-B4
R4073, R4043, R4342
—
106
RBCuZn-A, -C, -D
BCuZn-E, -F, -G, -H
BNi-1 to 8
BAu-1 to 6
BVAu-2, -4, -7, -8
RCuZn-A, -C, -D
BMg-1
BCo-1
BVPd-1
—
—
—
102
107
108
109
110
111
Ag2, Ag3, Ag5, Ag8, Ag10, Ag12
Ag4
—
—
11.5
BRAZING FLOW POSITIONS
Basic positions for brazing are classified by —
(a)
the orientation of the brazed surface (i.e. lap or mating surfaces); and
(b)
the direction of flow of brazing filler metal in the joint.
These positions are shown in Figure 11.1.
11.6 RECORDS The fabricator shall maintain a record of the test results and date in
qualifying brazing procedures, brazers and the brazing operators employed. These records
shall be certified by the fabricator and shall be accessible to the inspector.
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AS/NZS 3992:1998
NOTE: The positions shall be suitable for applying brazing filler metal in rod, strip or other suitable form to
permit the flow shown.
FIGURE 11.1
BRAZING FLOW POSITIONS
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S E C T I O N
1 2
Q U A L I F I C A T I O N
P R O C E D U R E
AS/NZS 3992:1998
O F
B R A Z I N G
12.1 GENERAL With the exception of prequalified brazing procedures (see
Clause 12.4) each brazing procedure which is to be used in the fabrication of a pressure
component shall be qualified by the fabricator in accordance with this Standard in order to
prove the suitability of the brazing procedure for the material used in the fabrication and
demonstrate that the organization is capable of using this procedure. Only qualified
brazing procedures shall be used in the fabrication of components.
Qualification of a brazing procedure may be carried out simultaneously with the brazing
and testing of a production component or test plate provided that the fabricator accepts
the risk of rejection. Such circumstances are recognised as being most representative of
production brazing and should be endorsed whenever the fabricator prefers such action.
Each procedure shall be recorded in detail with the results of qualification tests, by the
fabricator, and these records shall be accessible to the inspector. The qualification of a
brazing procedure shall be carried out as required by an inspection body which may
require that it witness qualification brazing and tests.
The type, number and methods of tests required to prove the suitability of the procedure
for the brazing of joints in the components shall be in accordance with this Standard.
Where necessary, additional tests may be required to assess corrosion resistance or other
properties of a brazed joint.
12.2 REQUALIFICATION OF A BRAZING PROCEDURE Provided that there are
no changes in the essential variables (in accordance with Clause 12.6), a qualified brazing
procedure shall remain in force indefinitely. Requalification of a brazing procedure is only
required where there is any change in the essential variables.
12.3 PORTABILITY OF QUALIFIED BRAZING PROCEDURE A brazing
procedure qualified by one fabricator is valid for use by another fabricator provided that —
(a)
the original qualification tests were carried out in accordance with this Standard,
were witnessed by an inspection body, and were fully documented;
(b)
the second fabricator demonstrates successful brazing or brazing operator
qualification or production tests using the qualified procedure; and
(c)
the application of the brazing procedure is acceptable to both the fabricators and the
purchaser.
12.4 PREQUALIFIED BRAZING PROCEDURE A brazing procedure which has
been widely and successfully used in the fabrication of pressure components is recognized
as a prequalified brazing procedure.
The use of a prequalified brazing procedure does not relieve the fabricator of
responsibilities in respect of the brazer qualification provisions of this Standard.
The prequalified procedure used shall be suitably documented and shall have a signed
endorsement that the procedure has been successfully used by a (named) brazer employed
by the fabricator and has passed a brazer qualification test (with the date of the test
given).
12.5 ITEMS TO BE RECORDED FOR BRAZING PROCEDURE
QUALIFICATION TEST BRAZES The applicable items listed in Appendix F shall be
recorded for each brazing welding procedure required to be qualified.
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12.6 ESSENTIAL VARIABLES FOR BRAZING PROCEDURE QUALIFICATION
Essential variables in a brazing procedure are listed in Table 12.1. When any of the
changes to the essential variables are made, the brazing procedure shall be requalified.
12.7 TEST PIECES FOR BRAZING PROCEDURE QUALIFICATION Test pieces
for brazing procedure qualification shall be made in accordance with the specified
procedure.
The dimensions and number of the test pieces shall be such as to provide the appropriate
test specimens given in Table 12.2.
Parent metals should be of a form which represents the production brazing, but if this is
not practicable plate, pipe, or other product form may be used. Test positions shall be as
shown in Figure 11.1.
Figure 12.1 shows typical layout of test pieces.
For service temperatures above 95°C, additional test pieces shall be carried out at
temperatures of 50°C increments up to and including the design temperature and shall
comply with the following:
(a)
Tensile tests of the joint, the resulting tensile and yield strength of which shall be
not less than the minimum tensile or yield strength of the weaker of the parent
materials at the test temperature.
(b)
When the design stress of one of the parent materials is based on creep rupture
properties at the design temperature, creep or rupture tests shall be performed to
ensure that the creep or rupture strength of the joint is not less than that of the
weaker of the parent materials.
12.8 VISUAL EXAMINATION Prior to carrying out any mechanical testing, all test
pieces shall be examined visually to estimate soundness by external appearance, e.g.
adequacy of fit up; continuity of brazing filler metal; size, contour and wetting of filler
along the joint; and where appropriate that the filler metal flowed completely through the
joint.
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TABLE
AS/NZS 3992:1998
12.1
ESSENTIAL BRAZING VARIABLES
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Item
Applicable
processes
(see Note 1)
Essential variable
1 Parent
material
specification
A change from one material group to any other group listed in Table 11.1
or any material not listed. The brazing of dissimilar metal joints need not
be requalified if each parent metal involved is qualified individually for the
same filler metal, flux, atmosphere and process. Similarly, the brazing of a
dissimilar metal joint qualified the individual parent metal brazed to itself
and for the same filler metal. See Item 8(d)
TB, FB, IB, RB,
DB
2 Parent
material
thickness
A change in parent metal thickness beyond the range qualified in
Table 12.2
All
3 Brazing filler
metal
(a) A change from one F number in Table 11.2 to any other F number, or
to any other filler metal of a type not listed
(b) A change in filler metal from one product form to another (e.g. from
reformed ring to paste)
All
4 Brazing
temperature
A change in brazing temperature to a value outside the range specified in
the procedure
FB, IB, RB, DB
(i.e. not applicable
to TB)
5 Brazing
process
A change from one process to another process or to another combination of
processes
All
6 Brazing flux,
gas, or
atmosphere
(a) A change in the nominal chemical composition of brazing flux, fuel
gas, or atmosphere
(b) A change in furnace atmosphere from one type to another e.g.
(i)
reducing to inert
(ii)
carbonizing to decarbonizing
(iii) hydrogen to dissociated hydrogen
All
7 Flow position
A change from one basic flow position to another as shown in Figure 11.1
NOTE: Requalification may be required for change of location of filler
metal application to comply with Figure 11.1. Qualification in the flat,
vertical up and horizontal flow positions qualifies for the vertical down
flow position
All
8 Joint design
(a)
(b)
(c)
(d)
A change in joint type i.e. from a butt to a lap or socket
A change in lap length of lap or socket joints of ±25% or more
A change in clearance outside specified range
Use in areas of possible exposure to fire or elevated temperatures,
only where the low melting point of brazing alloy is considered
acceptable
All
All
All
All
9 Post-braze
heat treatment
(a) A change in the specified post-braze heat treatment temperature range
where —
(i)
no post-braze heat treatment is used;
(ii)
post-braze heat treatment is used (i.e. defined as below the
critical range); or
(iii) the brazement is heat treated above the critical range with or
without additional post-braze heat treatment.
(b) A change in the specified post-braze heat treatment temperature and
time where notch toughness is a requirement
(c) The addition or deletion of a solution or stabilizing heat treatment
from Group K (austenitic) steels
(d) An increase of more than 10% in the thickness tested where the postbraze heat treatment temperature exceed the lower critical temperature
All
This is not an essential variable but will affect the soundness of the joint.
Therefore see Clause 14.2 for brazer qualification essential variables
—
10
Technique
LEGEND:
DB = dip braze
FB = furnace braze
IB = induction braze
RB = resistance braze
TB = torch braze
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All
All
All
All
AS/NZS 3992:1998
66
TABLE
12.2
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BRAZING PROCEDURE QUALIFICATION
NUMBER OF TEST SPECIMENS AND TESTS REQUIRED
Type and number of test specimens and test required
Range of thickness of
materials
qualified
by
Thickness
WorkmanButt and scarf joints
Lap joints
Rabbet joints
test plate or pipe
of test
ship joints
specimens
Transverse
First
Second
mm
as brazed
Peel
Transverse
Sectioning
tensile
surface
surface Transverse
(t), mm
Sectioning
bend
bend
tensile
(Note 2)
tensile
(Note 3)
Min.
Max.
(Note 4)
(Note 1) (Note 1)
<3
≥3 <10
≥10
0.5t
2t
2
2
2
2
2
2
2
2
1.5 mm
2t
2
2
2
2
2
2
2
2
5 mm
2t
2
2
2
2
2
2
2
2
NOTES:
1 Longitudinal bend tests shall replace these transverse bend tests where braze metal or parent metal combinations differ markedly in
bending properties.
First surface specimens are those which have the first surface (i.e. the side from which brazing filler metal is applied and fed by
capillary action into the joint) located on the convex (outer) sides of the bent specimens.
Second surface specimens are those which have the second surface (i.e. opposite to the first surface) located on the convex (outer)
sides of the bent specimens.
Transverse specimens are those with the axis (length) of the joint transverse to the longitudinal axis of the specimen.
Longitudinal specimens are those with the axis (length) of the joint parallel to the longitudinal axis of the specimen.
2 Sectioning tests in accordance with Clause 13.5 shall replace these peel tests where the filler metal has a tensile strength equal to
greater than either metal being joined.
3 This test in itself does not constitute a procedure qualification, which is to be validated by tests on butt or lap joints as appropriate,
as follows:
(a) For joints connecting tension members such as stays — use a butt joint.
(b) For joints connecting members in shear such as saddle or spud joints — use a lap joint.
4 See Clause 12.7 for additional tests at elevated temperatures when service temperature is above 95°C.
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67
FIGURE 12.1 (in part)
AS/NZS 3992:1998
TEST PIECES
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AS/NZS 3992:1998
68
NOTE: For test pieces 80 mm OD or less, two test pieces are required for peel or section tests. One specimen
is to be removed from each test piece. For pieces <25 mm OD, the specimen width is to be one-half section of
the test piece.
FIGURE 12.1 (in part)
TEST PIECES
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S E C T I O N
1 3
E X A M I N A T I O N A N D
O F B R A Z E D J O I N T S
AS/NZS 3992:1998
T E S T I N G
13.1 REMOVAL OF TEST SPECIMENS The required test specimens shall be cut
from the test piece by any method which does not affect the properties of the finished test
specimen and taken from parts of the test piece free from any defects revealed by
non-destructive examination.
13.2
TRANSVERSE TENSILE TEST
13.2.1 Preparation Test specimens shall be prepared in accordance with Figure 13.1,
or for pipe less than 80 mm outside diameter a full section pipe may be used.
13.2.2 Test method Test specimens shall be tested for tensile strength in accordance
with AS 1391. Additional test specimens are required when service temperature exceeds
95°C (see Clause 12.7).
13.2.3 Requirements The joint strength shall be greater than or equal to the specified
minimum tensile strength of the weaker component in the annealed condition.
If the specimen breaks in the parent metal outside the joint, the tensile strength shall be at
least 95 percent of the above value.
The report of results shall indicate the joint strength, where the joint failed and any
defects on the fractured surface. Additionally, for specimens tested at elevated
temperatures in accordance with Clause 12.7, the test temperature shall be recorded.
NOTES:
1 Width of lap shall be at least four times the thickness of specimen or as specified by design.
2 For pipe, machine the minimum amount needed to obtain plain parallel faces over a 15 mm wide reduced
section.
DIMENSIONS IN MILLIMETRES
FIGURE 13.1
TRANSVERSE TENSILE SPECIMEN
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13.3
BEND TEST
13.3.1
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Preparation
The specimens shall be prepared in accordance with Figure 13.2.
13.3.2 Method Specimens shall be bent in a suitable guided bend jig to ensure
reasonably uniform bending of the specimen through 180° over a former with diameter of
4t, where t is specimen thickness.
13.3.3 Requirements Bent specimens shall have no open defect exceeding 3 mm,
measured in any direction on the convex surface. Cracks at the corners may be ignored
unless there is clear evidence they result from flux inclusions, voids or other defects.
Material thickness, mm
Specimen thickness ( t ), mm
Width, ( b ) (Note 1) mm
≤1.5
≥10
>10
Material thickness
10 (Note 2)
30–40
30–40
NOTES:
1
Where is not practicable to achieve this width, each standard specimen may be replaced by three
specimens with width = 4t or 10 mm, whichever is lesser.
2
Machine opposite side to test side.
DIMENSIONS IN MILLIMETRES
FIGURE 13.2
13.4
BEND SPECIMENS
PEEL TEST
13.4.1
Preparation
Test specimens shall be prepared in accordance with Figure 13.3.
13.4.2 Method The two components shall be separated or peeled by clamping
Section A and striking Section B (Figure 13.3) with a suitable tool such that bending
occurs at the fulcrum point, or by clamping Sections A and B and separating by tension.
13.4.3 Requirements
each edge of the joint.
The specimen shall show evidence of brazing filler metal along
After separation, the faying surfaces shall have —
(a)
total area of defects (e.g. unbrazed areas or flux inclusions) equal to or less than
30 percent of the total area of any individual faying surface;
(b)
total length of defects measured on any one line in the direction of the lap equal to
or less than 25 percent of the lap width; and
(c)
no defect extending continuously from one edge of the joint to the other edge.
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AS/NZS 3992:1998
NOTES:
1
Length may vary to fit testing machine.
2
X = 4t min. or as required by design.
3
Flange may be omitted from Section B when peeling is accomplished in a suitable tension machine.
4
Specimen shall be brazed from this side.
DIMENSIONS IN MILLIMETRES
FIGURE 13.3
13.5
LAP JOINT PEEL SPECIMEN
SECTIONING TEST
13.5.1 Preparation The test specimen shall be cut transverse to the lap or rabbet joint
and polished on each section to permit accurate viewing.
13.5.2 Method The sectioned surfaces shall be examined with a four power magnifying
glass, as a minimum magnification.
13.5.3 Requirements The total length of unbrazed areas on either side, considered
individually, shall not exceed 20 percent of the length of the joint overlap.
13.6
WORKMANSHIP SPECIMEN TEST
13.6.1 Preparation The dimensions and configuration of the test piece shall
approximate as closely as possible the finished product.
The test piece shall be sectioned as specified in Clause 13.5.1.
13.6.2 Method The sectioned surfaces shall be examined with a four power magnifying
glass, as a minimum magnification.
13.6.3
Requirements
These shall comply with Clause 13.5.3.
13.7 RETESTS If any specimen fails to satisfy the specified requirements, two further
test specimens for each one that failed shall be obtained, either from the same test piece,
if there is sufficient material available, or from a new test piece, and subjected to the
same test.
If either of these additional test specimens does not meet the required standard, the cause
of failure shall be established.
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If this failure is established as being the result of metallurgical or extraneous causes and
is not attributable to the brazer’s workmanship, then a further repeat test shall be taken.
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If the failure is established as being attributable to the brazer’s workmanship, then the
brazer shall not be regarded as capable of meeting the requirements of this Standard
without further training.
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S E C T I O N 1 4
B R A Z E R A N D B R A Z I N G
O P E R A T O R Q U A L I F I C A T I O N
14.1 METHODS OF QUALIFICATION Each brazer or brazing operator employed in
the construction of pressure components shall be qualified in accordance with this
Standard by one of the following methods:
(a)
Brazing a test piece which simulates the production joint and examining and testing
the test piece in accordance with Clause 14.5.
(b)
Presentation of documentary evidence of having brazed the test piece of a qualified
brazing procedure.
Such qualification tests shall only qualify the brazer or brazing operator within the limits
of essential variables specified in Clause 14.2.
14.2 ESSENTIAL VARIABLES FOR QUALIFICATION OF BRAZING
PERSONNEL The essential variables for the qualification of brazing personnel are the
same as those for qualifying the brazing procedure (see Table 12.1) except —
(a)
qualification in pipe qualifies for plate brazing but not vice versa;
(b)
Item 4, Table 12.1 does not apply;
(c)
Item 6, Table 12.1 does not apply;
(d)
Item 9, Table 12.1 does not apply;
(e)
Item 10, Table 12.1 applies to torch brazing; and
(f)
Item 7, Table 12.1 is modified to permit the following:
(i)
For plate, qualification in the flat flow, vertical up flow, or horizontal-flow
positions shall qualify for the vertical down flow position.
(ii)
For pipe, qualification in either the flat flow or vertical-up flow position
shall qualify for the vertical down flow position.
14.3 EXTENT OF APPROVAL OF BRAZING QUALIFICATION A brazer or
brazing operator qualified to a qualified brazing procedure in accordance with any method
as laid down in Clause 14.1 shall be requalified when the essential variables of additional
production welds exceed the requirements laid down in Clause 14.2.
14.4 INFORMATION TO BE GIVEN TO BRAZER OR BRAZING OPERATOR
FOR QUALIFICATION TEST JOINT A brazer or brazing operator undertaking a test
joint for qualification purposes in accordance with Clause 14.1(a) shall be provided with
full details of the qualified brazing procedure.
14.5
QUALIFICATION TEST JOINTS AND TESTING
14.5.1 Test joint The brazer or brazing operator shall produce a test joint or joints in
accordance with the qualified brazing procedure, and within the essential variables in
Clause 14.2, sufficient to provide the required test specimens.
14.5.2 Test specimens
Table 14.1.
The number of test specimens shall be in accordance with
14.5.3 Testing, examination and acceptance requirements
accordance with the tests specified in Table 14.1.
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AS/NZS 3992:1998
74
TABLE
14.1
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BRAZER AND BRAZING OPERATOR QUALIFICATION TESTS
Thickness (t) of
test piece as
brazed
mm
<3
≥3
≤10
>10
Range of thickness of material
qualified by test piece
mm
Min.
Max.
0.5t
2t
1.5
5
2t
2t
Type and number of test specimens
required
Butt, scarf, lap or
rabbet joints
Workmanship
specimen joints
2 peel tests
(see Note 1)
2 peel tests
2 peel tests
1 section test
(see Note 2)
1 section test
1 section test
NOTES:
1
Tests are to comply with Clause 13.4, except that where the filler metal tensile strength is less than or
equal to that of the metal joined, the specimens are to be sectioned and are to comply with Clause 13.5.
2
Tests are to comply with Clause 13.6.
14.6 RECORDING OF BRAZER AND BRAZING OPERATOR QUALIFICATION
TESTS A statement of the results of assessing each test piece, including repeat tests,
shall be made for each brazer or brazing operator. In addition, the brazing procedure used
for the qualification is to be recorded with the test results. The items required under
Clause 14.4 shall be included together with details of any features that would be
rejectable. If no rejectable features are found, a statement that the test piece made by the
particular brazer satisfied the requirements of this Standard in respect of that type of test
piece shall be signed by the person conducting the test (see Appendix F).
The brazer’s employer shall hold and regularly maintain adequate records of all
qualification tests for each brazer.
Brazer and brazing operator qualification tests carried out in accordance with this
Standard and witnessed by an inspection body representative should be accepted by other
inspecting agencies, unless otherwise agreed.
14.7
RETESTS
Refer to Clause 13.7 for additional tests before rejection.
14.8 RENEWAL OF BRAZER QUALIFICATION A brazer’s or brazing operator’s
approval to braze to a specified brazing procedure shall remain valid provided that it can
be shown from records maintained by the organization that employs the brazer that the
brazer has been employed with reasonable continuity using the relevant brazing processes
and has continued to produce satisfactory brazed joints as verified by non-destructive
examination.
Requalification shall be required if any of the following conditions apply:
(a)
Twelve months or more have elapsed since the brazer was employed on the relevant
brazing processes.
(b)
The brazer changes employment. Under such circumstances the employer shall
qualify the brazer who has changed employment.
(c)
There is some specific reason to question the brazer’s ability.
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S E C T I O N 1 5
A L U M I N O T H E R M I C W E L D I N G
O F E L E C T R I C A L C O N D U C T O R S
Aluminothermic welding of electrical conductors to carbon and carbon-manganese steel
pipes by use of aluminium powder and copper oxide may be used without prior
qualification where the following limitations apply:
(a)
The size of the aluminium powder and copper oxide cartridge for aluminothermic
welding shall not exceed 15 g.
(b)
The cross-sectional area of the cable conductor for each weld nugget shall be not
greater than 10.5 square millimetres.
(c)
The depth of insertion of the conductor shall not be more than one half of the
mould chamber diameter.
(d)
The pipe surface shall be cleaned by filing or grinding to remove all surface
markings from an area not less than 50 square millimetres.
Other aluminothermic welds shall be qualified and tested as follows:
(i)
The welds shall be qualified separately for each material composition, conductor
size, cartridge size, and surface preparation.
(ii)
Procedure tests shall be conducted on three nuggets, each of which shall pass a test
of one firm side blow from a hammer having a mass of approximately 1 kg, after
which each nugget shall be visually examined for adequate bonding and the absence
of lifting.
(iii) One of the test nuggets shall then be sectioned and examined for copper penetration,
which shall not exceed 0.4 mm.
Each production aluminothermic weld shall be subjected to the hammer test specified in
Item (ii) above.
Unsatisfactory welds shall be removed and remade in a new location, not less than 75 mm
distant.
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APPENDIX
A
LIST OF REFERENCED DOCUMENTS
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(Normative)
AS
1167
1167.1
1167.2
Welding and brazing — Filler metals
Part 1: Filler metal for brazing and braze welding
Part 2: Filler metal for welding
1210
Pressure vessels
1228
Pressure equipment — Boilers
1391
Methods for tensile testing of metals
1548
Steel plates for pressure equipment
1796
Certification of welders and welding supervisors
1817
Metallic materials — Vickers hardness test
1858
1858.1
1858.2
Electrodes and fluxes for submerged-arc welding
Part 1: Carbon steels and carbon-manganese steels
Part 2: Low and intermediate alloy steels
2030
The approval, filling, inspection, testing and maintenance of cylinders for the
storage and transport of compressed gases (know as the SAA Gas Cylinders
Code)
2062
Non-destructive testing — Penetrant testing of products and components
2074
Steel castings
2203
2203.1
Cored electrodes for arc-welding
Ferritic steel electrodes
2205
2205.2.1
2205.2.2
2205.2.3
2205.3.1
2205.3.2
2205.3.3
2205.3.4
2205.3.5
2205.4.1
2205.4.2
2205.5.1
2205.7.1
Methods of destructive testing of welds in metal
Tensile tests — Transverse butt tensile test
Tensile tests — All-weld-metal tensile test
Tensile tests — Transverse joggle-butt tensile test
Transverse guided bend test
Transverse free bend test
Longitudinal guided bend test
Transverse joggle-butt wrap-around-bend test
Tongue bend test
Nick-break test
Fillet break test
Macro metallographic test for cross-section examination
Charpy V-notch impact fracture toughness test
2717
2717.2
2717.3
Welding — Electrodes — Gas metal arc
Part 2: Aluminium and aluminium alloy
Part 3: Corrosion — Resisting chromium and chromium-nickel steel electrodes
2812
Welding, brazing and cutting of metals — Glossary of terms
2873
Carbon-manganese steel cylinders for compressed gases — Seamless — 0.1 kg to
500 kg
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AS
2885
2885.2
Pipelines — Gas and liquid petroleum
Part 2: Welding
2971
Serially produced pressure vessels
3545
Welding positions
3597
Structural and pressure vessel steel — Quenched and tempered plate
3920
3920.1
Assurance of product quality
Part 1: Pressure equipment manufacture
4037
Boilers and pressure vessels — Examination and testing
4041
Pressure piping
4413
Steel tubes — Pressure application — Flash butt welding
4458
Pressure equipment — Manufacture
AS/NZS
1200
Pressure equipment
AS/NZS 3992:1998
1553
1553.1
Covered electrodes for welding
Part 1: Low carbon steel electrodes for manual metal-arc welding of carbon
and carbon-manganese steels
1594
Hot-rolled steel flat products
2717
2717.1
Welding — Electrodes — Gas metal arc
Part 1: Ferritic steel electrodes
3509
LP Gas fuel vessels for automotive use
3788
Pressure equipment — In-service inspection
ISO
3452
Non-destructive testing — Penetrant inspection — General principles
ANSI/ASME
BPV-IIC Section II Boiler and Vessel Code, Materials, Part C — Welding rods,
electrodes and filler rods
BPV-IX
Section IX Boiler and Pressure Vessel Code, Qualification standard for welding
and brazing procedures, welders, brazers, and welding and brazing operators
ANSI/AWS
A5.11
Specification for nickel and nickel alloy welding electrodes for shielded metal
arc welding
A5.14
Specification for nickel and nickel alloy bare welding electrodes and rods
API
5L
Specification for line pipe
ASTM
A 105
Specification for forgings, carbon steel for piping components
A 106
Specification for seamless carbon steel pipe for high-temperature service
A 181
Specification for forgings, carbon steel for general purpose piping
A 182
Specification for forged or rolled alloy-steel pipe flanges, forged fittings, and
valves and parts for high-temperature service
A 203
Specification for pressure vessel plates, alloy steel, nickel
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ASTM
A 204
78
Specification for pressure vessel plates, alloy steel, molybdenum
A 216
Specification for steel castings, carbon suitable for fusion welding for hightemperature service
A 217
Specification for steel castings, martensitic stainless and alloy for pressurecontaining parts suitable for high-temperature service
A 234
Specification for piping fittings of wrought carbon steel and alloy steel for
moderate and elevated temperatures
A 240
Specification for heat-resisting chromium and chromium-nickel stainless steel
plate, sheet and strip for pressure vessels
A 312
Specification for seamless and welded austenitic stainless steel pipes
A 333
Specification for seamless and welded steel pipe for low-temperature service
A 335
Specification for seamless ferritic alloy-steel pipe for high-temperature service
A 350
Specification for forgings, carbon and low-alloy steel requiring notch toughness
testing for piping components
A 351
Specification for castings, austenitic, austenitic-ferritic, (duplex) for pressurecontaining parts
A 352
Specification for steel castings, ferritic and martensitic for pressure-containing
parts suitable for low-temperature service
A 370
Test methods and definitions for mechanical testing of steel products
A 387
Specification for pressure vessel plates, alloy steel, chromium-molybdenum
A 420
Specification for piping fittings of wrought carbon steel and alloy steel for
low-temperature service
A 493
Specification for stainless steel wire and wire rods for cold heading and cold
forging
A 516
Specification for pressure vessel plates, carbon steel, for moderate- and
lower-temperature service
A 517
Specification for pressure vessel plates, alloy steel, high-strength, quenched
and tempered
A 522
Specification for forged or rolled 8 and 9% nickel alloy steel flanges, fittings,
valves, and parts for low-temperature service
A 553
Specification for pressure vessel plates, alloy steel, quenched and tempered 8
and 9% nickel
A 790
Specification for seamless and welded ferritic/austenitic stainless steel pipe
BS
1501
1501.3
Steels for pressure purposes
Part 3: Specification for corrosion and heat-resisting steels, plates, sheet and
strip
1503
Specification for steel forgings for pressure purposes
3602
Steel pipes and tubes for pressure purposes: Carbon and carbon manganese
steel with specified elevated temperature properties
Part 1: Specification for seamless and electric resistance welded including
induction welded tubes
3602.1
3603
Specification for carbon and alloy steel pipes and tubes with specified low
temperature properties for pressure purposes
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BS
3604
AS/NZS 3992:1998
3604.1
3604.2
Specification for steel pipes and tubes for pressure purposes: ferritic alloy steel
with specified elevated temperature properties
Part 1: Specification for seamless and electric resistance welded tubes
Part 2: Specification for longitudinally arc welded tubes
3605
3605.1
3605.2
Austenitic stainless steel pipes and tubes for pressure purposes
Part 1: Specification for seamless tubes
Part 2: Specification for longitudinally welded tubes
3606
Specification for steel tubes for heat exchangers
BS EN
287
287.1
Approval testing of welders for fusion welding
Part 1: Steels
288
288.1
Specification and approval of welding procedures for metallic materials
Part 1: General rules for fusion welding
10028
10028.2
Specification for flat products made of steels for pressure
Part 2: Non-alloy and alloy steels with specified elevated temperature
properties
Part 3: Weldable fire grain steels, normalized
Part 4: Nickel alloy steels with specified low temperature properties
10028.3
10028.4
WTIA
Tech Note 1 The weldability of steels
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APPENDIX
B
WELDING PROCEDURE SPECIFICATION
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(Normative)
B1 GENERAL This Appendix gives information which shall be recorded, as
appropriate, for a welding procedure specification for the more commonly used welding
processes. A suggested form for recording these details is given in Figure B1. Figure B1
may be freely copied; Standards Australia waives copyright for the Figure only.
The format is additionally recommended for the detailing of prequalified welding
procedures using only those items as applicable.
Other formats of this form, inclusive of simplified work instructions may be used
provided that such formats contain all necessary information for the fabrication of
production welds.
B2 EXPLANATORY NOTES
the headings in Figure B1.
This Paragraph explains the requirements of some of
(a)
Material group number — nominate material group number on both sides of joint.
(b)
Pipe diameter range qualified—nominate minimum and maximum pipe diameter
range qualified by the procedure.
(c)
Thickness range qualified—nominate pipe or plate thickness and thickness range
qualified for relevant welding process (see Table 5.4).
(d)
Joint types—nominate type(s) of joint(s) qualified (butt, branch, etc.) by placing ‘x’
in applicable box and nominate drawing or standard sketch number if known.
(e)
Welding position—nominate welding position in accordance with Figure 5.1 or
Figure 5.2. Nominate weld direction when specific to weld procedure (e.g. vertical
up or down).
(f)
Preheat and interrun temperature (as applicable) — nominate minimum preheat
temperature and maximum interrun temperature.
(g)
Welding details:
(i)
Pass location — nominate as base run, root run or fill pass(es) as applicable to
welding process.
(ii)
Welding process. Use appropriate term e.g. MMAW and SAW, from those in
Table 4.1.
(iii)
Wire/electrode diameter—self explanatory.
(iv)
Current polarity—self explanatory.
(v)
Amps/voltage/speed—nominate range for each process and electrode size.
Electrode run out length may be used for MMAW.
(vi)
Arc energy—determine average arc energy for each process and set of
welding conditions.
(h)
Gas—nominate any shielding and purging gas when used together with flow rate.
(i)
Flux — nominate flux used in submerged arc welding by trade name or specification.
(j)
Interrun cleaning—use terms brush, de-slag, grind as applicable.
(k)
Back gouging—nominate method of back gouging and any subsequent treatment e.g.
arc/air grind.
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A1



AS/NZS 3992:1998
(l)
Heat treatment—nominate any details of intermediate or postweld heat treatment
when applicable.
(m)
NDE requirements—nominate requirements in accordance with pressure equipment
Standard or client specification.
(n)
Remarks — nominate any specific requirements or testing for production welding not
covered in the above, e.g. if weld run sequence is important such as may be
required in dissimilar metal joints, nominate requirements at this location or weld
metal hardness range when specified for production welds.
(o)
WPQ Record — nominate manufacturer’s weld procedure number and parent material
specification and thickness used in procedure. Where a welding procedure is
prequalified, insert ‘prequalified’ for the welding procedure number in the last
paragraph of Figure B1.
Do not leave any entry on the form blank. If a nominated entry is inapplicable to the
welding specification, write ‘not applicable’ or ‘N/A’.
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WELDING PROCEDURE SPECIFICATION (WPS)
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Company name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
For Material group No. . . . . . . . . to Material group No. . . . . . . . . . . . . . . . . . . . . . .
For pipe diameter range qualified . . . . . . . . . . . mm OD to . . . . . . . . . . . . . . mm OD
For pipe and plate thickness range qualified . . . . . . . . . mm to . . . . . . . . . . . . . . . mm
Joint types qualified
Double vee butt
Single vee butt
Branch to shell or equivalent component (SET IN)
Branch to shell or equivalent component (SET ON)
Fillet weld
Other joints . . . . . . . . .
Applicable drawing Nos. . .
Standard sketch Nos. . . . .
Welding position . . . . . . . .
Welding preheat temp. min.
.
.
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.........
.........
.........
.........
°C Interrun
..............
..............
..............
. Weld direction .
temp. max. . . . °C
.........
.........
.........
.........
Maintained
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h
Welding details
A1


Pass
number
Welding
process
Wire or
electrode
diameter
a.c. or d.c.
Amps range Volts range
polarity
Speed
mm/min
range
For submerged arc welding flux name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gas shielding type . . . . . . . . . . . . . . . . . . . . . . . . Flow rate . . . . . . . . . . . .
Gas backing type . . . . . . . . . . . . . . . . . . . . . . . . . Flow rate . . . . . . . . . . . .
Interrun cleaning method . . . . . . . . . . . . . . . . . . . . Back gouging . . . . . . . .
Heat treatment intermediate: Heating rate . . . . . . . . . . . . °C/h Temp. range
Time . . . . . . . . . . . . . . . . . h
Cooling rate
Postweld heat treatment:
Heating rate . . . . . . . . . . . . °C/h Temp. range
Time . . . . . . . . . . . . . . . . . h
Cooling rate
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Arc energy
kJ/mm
range
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.....
L/min
L/min
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. °C
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NDE requirements as appropriate
Remarks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
This welding procedure specification is based on qualified welding procedure No. . . . . . . . in which
parent material used was to specification. . . . . . . . . . of thickness . . . . . . . . . . . . . . . . . . . . . . mm
Fabricator’s signature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE B1
SUGGESTED FORM FOR THE RECORDING OF THE WELDING
PROCEDURE SPECIFICATION
83
APPENDIX
AS/NZS 3992:1998
C
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RECORD OF QUALIFICATION OF WELDING
PROCEDURE
(Normative)
C1 GENERAL This Appendix gives information, for recording as appropriate, details
of tests for the qualification of welding procedures for the more common welding
processes. In certain cases for the more unusual welding processes it will be necessary to
provide additional details on supplementary sheets. The form illustrated in Figure C1
gives a recommended method of presenting the information. Figure C1 may be freely
copied; Standards Australia waives copyright for the Figure only.
A1
C2 EXPLANATORY NOTES This Paragraph explains the requirements of some of
the headings in the recommended form (see Figure C1).
(a) Weld type Give the relevant description, e.g. butt, fillet, branch.
(b) Material specification Nominate material specification on both sides of joint.
(c) Material thickness and pipe outside diameter Nominate plate thickness or pipe
outside diameter as applicable.
(d) Weld position Nominate weld position as shown in Figure 5.1 or Figure 5.2.
(e) Group number Nominate group letter from Table 5.3 for material on both sides of
joint.
(f)
Interrun cleaning Use terms, brush, de-slag, ground, as applicable.
(g) Joint sketch Show details of initial joint plus plate number(s), if applicable, and
heat number(s) of material(s) used in test weld for both sides of joint.
(h) Pass sequence Show pass sequence of each weld run, together with extent of back

gouge and layer numbers as applicable to welding record. Show the deposit

thickness for each process for multiple pass process.
(i)
Thermal treatment Record details of preheat, maximum interrun temperature and
postweld heat treatment, inclusive of time at temperature and heating and cooling
rate.
(j)
Welding details Record the following:
(i)
Welding process Use appropriate term e.g. MMAW and SAW, from those
in Table 4.1.
(ii)
Electrodes The diameter and electrode classification.
(iii) Details Amps, volts, travel speed in mm/min, or run out length of
electrode, and type of current and polarity.
(iv)
Flux or shielding gas The flux classification for submerged arc welding,
and shielding gas for gas tungsten arc, gas metal arc and flux cored arc (gas
shielded) for process utilized.
(k) Additional details Record electrode stick out, shielding gas flow rate and other
details specific to the welding procedure when applicable.
(l)
NDE test details Record type of tests carried out and list NDE certificates covering
same.
(m) Mechanical test details Record type of tests carried out and list test certificates
covering same.
Test certificates for both Items (l) and (m) shall be retained by the fabricator and shall be
made available to all purchaser and inspection body representatives when requested.
Do not leave any entry on the form blank. If a nominated entry is inapplicable to the
welding procedure under consideration, write ‘not applicable’ or ‘N/A’.
COPYRIGHT
AS/NZS 3992:1998
A1



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84

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
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
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
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
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














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
PROCEDURE QUALIFICATION RECORD (PQR)
Company name
Shop
Welder
Address
Site
Date of test
Welding procedure No.
Weld type
Material
specification
Weld position
Group No.
............
to
............
(Material
thickness)
Pipe
Plate
Pipe
OD
mm
mm
mm
Thickness
range
qualified
. . . . . . . . . . mm
to
. . . . . . . . . . mm
Joint details
Root opening . .
Root face . . . .
Groove angle . .
Interrun cleaning
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°C
°C
°C
..
..
Thermal treatment
Heat No. . . . . . . . . . . . . . . . . . .
Plate No. . . . . . . . . . . . . . . . . . .
Joint detail (sketch)
Preheat . . . .
Max. interrun
PWHT . . . . .
Heating rate .
Cooling rate .
Pass sequence (sketch)
Show deposit thickness for each
process used
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Welding details
Layer
No.
Runs per Welding
layer
process
Electrode
diameter
Electrode
Classification
Amps
Travel
Current Flux or
speed type and shielding
mm/min polarity
gas
Volts
NDE tests and
test certificate reference
Additional details
Arc
energy
kJ/mm
Mechanical tests and test
certificate reference
Test Cert. Ref.
Electrode stickout
.......
mm
Shielding gas
flow rate
......
Other
...........
L/min
Visual
RT . .
UT . .
MT . .
PT . .
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Transverse tensile
All-weld tensile . .
Bends . . . . . . . .
Impacts . . . . . . .
Macro . . . . . . . .
Hardness . . . . . .
Other . . . . . . . . .
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Notes
The statements in this record are correct. The test welds were prepared, welded and tested in accordance with
the requirements of AS/NZS 3992.
Fabricator . . . . . . . . . . . .
Position
Date
. . . . . . . . . . . . (signed) Witnessed by . . . . . . . . . . . . . . . . . . . . . . . (signed)
.................................
..................................
FIGURE C1
Organization
Date
.............................
..................................
RECOMMENDED FORM FOR RECORDING THE QUALIFICATION
OF WELDING PROCEDURE
85
APPENDIX
AS/NZS 3992:1998
D
TYPICAL FERROUS MATERIAL SPECIFICATIONS
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(Informative)
Table D1 lists in tabular form some of the more common ferrous materials and gives
typical specifications as a ready guide to the use of the material group classification
system.
A complete list of material specifications with cross-reference to material group
classification is given in Table 3.3.1 of AS 1210 — 1997.
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AS/NZS 3992:1998
86
TABLE
D1
TYPICAL FERROUS MATERIAL SPECIFICATIONS
Material
group
Plates
Standard
Grade(s)
AS 1548
7−430, 7−460
ASTM A516
55, 60, 65
BS EN 10028.2
P265GH
BS EN 10028.3
P275N
AS 1548
5−490, 7−490
ASTM A516
70
BS EN 10028.2
P295 GH,
P355 GH
BS EN 10028.3
P355 N
AS/NZS 1594 XF400, XF500
Pipes
Standard
Grade(s)
ASTM A106
A, B
API 5L
B, X42
ASTM A333
1, 6
Forgings
Standard
Grade(s)
ASTM A181
60
BS 1503
221−430
ASTM A350
LF1
Fittings
Standard
Grade(s)
ASTM A234
WPB
ASTM A420
WPL6
Castings
Standard
Grade(s)
AS 2074
C7A−1
ASTM A216 WCA, WCB
ASTM A352
LCB
ASTM A106
BS 3602.1
—
C
460
—
ASTM A105
ASTM A350
BS 1503
—
LF2
223−460, 490
224−460, 490
ASTM A234
—
—
WPC
—
—
ASTM A216
—
—
WCC
—
—
API 5L
—
—
—
—
—
—
B
ASTM A204
BS EN 10028.2
A, B, C,
16 Mo 3
ASTM A182
—
F1, F1,
—
ASTM A234
—
WP1
—
ASTM A217
—
WC1
—
C
ASTM A387
BS EN 10028.2
12 C1 1 & 2
13Cr Mo 4-5
P11, P12
440, 460
ASTM A182
BS 1503
F11, F12
620, 621
ASTM A234
—
WP11, WP12
—
ASTM A217
—
WC6
—
D1
—
—
660
BS 1503
660
—
—
—
—
D2
ASTM A387
ASTM A217
—
WP22, WP5,
WP7, WP9
—
—
WC9, C5
C12
—
ASTM A203
BS EN 10028.4
D, E
503
ASTM 350
BS 1503
F21, F22, F5,
F7, F9
622, 623
625
LF3
503
ASTM A234
E
P21, P22,
P5, P7, P9
622, 625
629
3
—
ASTM A182
BS EN 10028.2
22 C1 1 & 2
5 C1 1 & 2
10Cr Mo 9-10
ASTM A335
BS 3603,
BS 3604
ASTM A335
BS 3603
BS 3604
BS 3606
BS 3604
ASTM A335
X52, X60,
X65, X70
P1, P2
243, 245
ASTM A240
—
WPL 3
—
ASTM A352
—
LC3
—
F
ASTM A553
BS EN 10028.4
—
509, 510
8
509
ASTM A522
BS 1503
1
509, 510
ASTM A420
—
WPL 8
—
ASTM A352
—
LC9
—
G
ASTM A517
A, B, D, E, F,
J, P
All 300
series
All 300 series
—
—
—
—
A1
A2
A3
K
ASTM A240
BS 1501.3
M
ASTM A240
S31803
S32550
BS 3603
BS 3604
ASTM A333
BS 3603
BS 3604
ASTM A333
BS 3603
BS 3604
—
ASTM A312
BS 3605.1, .2
BS 3606
ASTM A790
All 300
series
All 300
series
S31803
S32250
BS 1503
—
—
ASTM A351
ASTM A182
All 300 series
ASTM A493
—
All 300 series
BS 1503
All 300 series
—
—
—
All 300
series
—
ASTM A182
F51
—
—
—
—
COPYRIGHT
87
APPENDIX
AS/NZS 3992:1998
E
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MACRO-ETCHING OF WELDED JOINTS
(Normative)
E1 GENERAL Etchants suitable for preparing steels, coppers and copper alloys,
aluminium and aluminium alloys for macro tests are given in AS 2205.5.1. Etchants for
nickel, nickel alloys and titanium are given below.
Attention is drawn to the cautionary notes given in AS 2205.5.1 relating to the handling,
mixing and use of etching solutions.
E2
NICKEL AND NICKEL ALLOYS
E2.1 Preparation of surface
accordance with AS 2205.5.1.
E2.2
Etching solutions
The surface to be etched should be prepared in
Suitable etching solutions are:
(a)
For nickel, low-carbon nickel and nickel-copper (monel): Nitric acid.
(b)
For nickel-chromium-iron (inconel): Aqua regia (one part of concentrated nitric acid
and two parts of concentrated hydrochloric acid).
E2.3 Etching The etching solution is usually applied at room temperature by swabbing
or immersion of the specimen.
E3
TITANIUM
E3.1 Preparation of surface
accordance with AS 2205.5.1.
The surface to be etched should be prepared in
E3.2 Etching solution A suitable general purpose etching solution is Kroll’s etch, i.e.
1 mL to 3 mL hydrofluoric acid (48 percent), 2 mL to 6 mL nitric acid (concentrated) and
water to make 100 mL.
E3.3 Etching The etching solution is usually applied at room temperature by swabbing
or immersion of the specimen.
COPYRIGHT
AS/NZS 3992:1998
88
APPENDIX
F
RECORD OF QUALIFIED BRAZING PROCEDURE
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(Normative)
This Appendix gives information for recording details of the qualification of brazing
procedures. The presentation of the information as given in Figure F1 is recommended.
This Figure may be used also to record the brazing procedure specification and the
qualification of the brazer. Figure F1 may be freely copied; Standards Australia waives
copyright for the Figure only.
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AS/NZS 3992:1998
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RECORD OF QUALIFIED BRAZING PROCEDURE
Company name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Procedure No.
...........................................................
Date . . . . . . . . . . . . . . . . .
Brazing process(es) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Type(s)
Joints
.........
..............
Joint design used (sketch)
Type of joint(s)
....................
Joint clearance
....................
Length of overlap . . . . . . . . . . . . . . . . . . .
Other
...........................
Parent metals thickness range qualified
P-No. . . . . . . . . . . to P-No.
..........
Material spec.
.....................
Type or grade
.....................
Thickness range
...................
Blazing flux or atmosphere
Thickness used . . . . . . . . . . . . . . . . . . . .
Flux trade name or company . . . . . . . . . . . . . . . . . . . . . . . . . . .
Method of precleaning . . . . . . . . . . . . . . .
Atmosphere for furnace brazing
Other
...........................
F-No.
...........................
........................
AWS class No.
Size
Other
....................
............................
Method of applying filler metal
Temperature range
(face feeding, preplace rings, shims, spray deposit, cladding, etc.)
Other
...........................................
Technique
Post-braze heat treatment
.................
...........................
Brazing process
.........................
................................................
...........................
Brazing temperature
Other
Flow position
Flow position(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filler metals
Spec. No.
........................
............................
Type of ageing or stabilizing thermal temperature after brazing
................................................
Post-braze cleaning method . . . . . . . . . . . . . . . . . . . . . . . . . . .
.................................
Type of flame
Other
Torch tip size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
...........................
.....................................
Test results
1 Tensile test
Spec.
No.
2 Bend tests
Spec.
No.
3 Peel, sectioning
or other test
Width
mm
Thickness
mm
Tensile load
N
Tensile strength
MPa
Type of specimen
Type of failure
and location
Result
............................................................
............................................................
............................................................
Brazer’s name
I certify that the test brazers, specimens and results comply with AS/NZS 3992.
. . . . . . . . . . . . . . . . . . . . . . . . Fabricator . . . . . . . . . . . . . . . . . . . . . . . . . . (signed)
FIGURE F1
............
Date
RECOMMENDED FORM FOR RECORDING A QUALIFIED BRAZING PROCEDURE
AS/NZS 3992:1998
90
APPENDIX
G
BASIS FOR GROUPING OF STEELS
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(Normative)
This Appendix gives in Table G1 the main basis for the grouping of steels for the purpose
of specifying requirements for postweld heat treatment, welding procedure qualification,
fabrication, and non-destructive examination. The grouping of some of the more common
ferrous material specifications is shown in Appendix D.
It is presented to assist in grouping steels including those not covered by Australian
Standards, but it is not to be considered the basis of material specifications, as other
factors, not listed, need to be taken into account, particularly with borderline
compositions.
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91
TABLE
AS/NZS 3992:1998
G1
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BASIS FOR GROUPING OF STEELS
Maximum Maximum
value for value for
specified
specified
minimum minimum
yield or
tensile
proof
strength
Residual
stress
(Rm)
and other
(Re)
elements
(total)
(Note 3)
MPa
MPa
Composition limits
(based on specified maximum ladle analysis)
% max. (Note 1)
CE
Group Type of steel (Note 2)
(Max.)
C
Mn
Cr
Mo
V
Carbon steel
A1
Carbon and
carbonmanganese
steel (low
strength)
0.45
0.30
1.70
—
—
—
0.8
330
460
A2
Carbon and
carbonmanganese
steel (medium
strength)
0.55
0.35
1.70
—
—
—
0.8
430
No limit
Carbon and
carbonmanganese
steel (high
yield
strength)
0.40
0.15
1.70
—
—
—
0.8
530
620
A3
(Note 6)
Low alloy steel
B
Low alloy
steel (Cr or
Mo < 0.75)
0.62
0.25
1.60
0.60
0.65
—
0.8
430
No limit
C
Low alloy
steel Cr-Mo
(0.75 ≤ total
alloy < 3)
0.75
0.25
1.60
1.5
0.8
—
0.8
No limit
No limit
D1
Low alloy
steel
Cr-Mo-V
0.75
0.25
1.60
1.5
1.5
0.18
0.8
No limit
No limit
D2
Low alloy
steel Cr-Mo
(3 ≤ total
alloy < 10)
Max. Cr + Mo exceed limits of Group C
but with a maximum of 10
No limit
No limit
E
3.5 Ni steel
Max. nickel 4.0
No limit
No limit
F
9 Ni steel
Nickel > 4.0
No limit
No limit
(continued)
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TABLE
G1
(continued)
Maximum Maximum
value for value for
specified
specified
minimum minimum
yield or
tensile
proof
strength
Residual
stress
(Rm)
and other
(Re)
elements
(total)
(Note 3)
MPa
MPa
Composition limits
(based on specified maximum ladle analysis)
% max. (Note 1)
CE
Group Type of steel (Note 2)
(Max.)
C
Mn
Cr
Mo
V
Low alloy steel (continued)
G
Quenched and
tempered low
alloy steel
(Note 4)
Boron treated steels
500
(Note 5)
No limit
High alloy steels (Cr > 10%)
H
Martensitic
chromium
steel
To give martensitic structure
No limit
No limit
J
Ferritic high
chromium
steel
To give ferritic structure
No limit
No limit
K
Austenitic
Cr-Ni steel
To give austenitic structure
No limit
No limit
L
High Cr steel
Cr ≥ 19, Ni < 5
No limit
No limit
M
Ferriticaustenitic
Cr-Ni steel
To give ferritic-austenitic structure
No limit
No limit
NOTES:
1 Actual cast analysis is that reported on the material certificate and may be used for determining preheat
temperatures only.
2 CE = Carbon equivalent, based on cast or product analysis
Mn
Cr Mo V
Ni Cu
(percent)
6
5
15
3 Elements here include residuals, Cu and Ni and any of the following where values are not listed in
Table G1:
= C
Mo, Cr and V
4 These steels have tensile properties enhanced by quenching and tempering. These steels are not intended to
include low alloy steels in Groups B to F where used —
(a) in thickness where heat treatment involving accelerated cooling, including liquid quenching, is used to
attain structures comparable to those obtained by normalizing thinner sections; or
(b) in integrally-forged vessels, quenched and tempered, which do not contain welds.
5 This value is a minimum value.
6 The purchaser may need to order steels with special analysis limits.
COPYRIGHT
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APPENDIX
AS/NZS 3992:1998
H
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EXAMPLES OF THE APPLICATION OF THIS STANDARD TO PRESSURE
VESSEL AND PIPING FABRICATION
(Informative)
This Appendix gives examples of the application of this Standard to pressure vessel
fabrication in Examples 1 to 7 and for pressure piping fabrication in Example 8. The
principles applying in Examples 1 to 7 are equally applicable to boilers and pressure
piping fabrication. Figure H1 illustrates a typical pressure vessel to be used in conjunction
with the examples below.
FIGURE H1
TYPICAL PRESSURE VESSEL
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AS/NZS 3992:1998
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EXAMPLE 1
T = 10 mm
Tb (max.) = 10 mm
TR = 10 mm
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Material Group — A1 (CE 0.45% max.)
Design temperature 10°C
PWHT — Nil
Welding
processes
Seams, L 1, L2, C 1, C2 and C3; submerged arc welding
Branch to shell joints: manual metal arc
Attachments to shell: manual metal arc
Weld
preparation
In accordance with Table 2.3
Welding
consumables
In accordance with Table 2.2
Welding
procedure
qualification
All procedures prequalified, i.e. no welding procedure
testing required
Welding
procedure
specification
Required: see Clause 2.1
Welder
qualification
Required: see Clause 2.1
Production weld
test
requirements
Required only by construction class: see Clauses 2.1 and
10.1
NOTE: A design temperature of 10°C will not require impact testing of weld metal.
If the design temperature is reduced to a temperature where the construction
Standard requires impact testing, then welding procedures and weld production
testing in accordance with Sections 7 and 10 are required.
EXAMPLE 2
T = 20 mm
Tb (max.) = 12 mm
TR = 10 mm
Material Group — A2
Design temperature 10°C
PWHT — Nil
Welding
processes
Seams, L 1, L2, C 1, C2 and C3; submerged arc
Branch to shell joints: gas metal arc
Attachments to shell: gas metal arc
Weld procedure
qualification
Required for both welding processes
Min. thickness for SAW: 10 mm (see Table 5.4)
Min. thickness for GMAW: 10 mm (see Table 5.4)
All joints qualified by butt welds
Welder
qualification
Required in accordance with Clause 9.2 for each welding
process
Production weld
test
requirements
When required by construction standard for the class of
construction, testing in accordance with requirements of
Section 10
Other items listed
in Table 5.1
Within the limits stated for essential variables in
Table 5.1
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AS/NZS 3992:1998
EXAMPLE 3
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Assume a pressure vessel with all the conditions covering dimensions and welding
procedure and processes the same as Example 2 except that the design temperature is
reduced to −20°C.
The addition of impact testing of weld metal in accordance with the requirements of
Table 7.2 (40 J at impact test temperature of parent metal) will be required.
EXAMPLE 4
Assume a pressure vessel the same as Example 3 except that design temperature is
reduced to −40°C.
In this case the MDMT will be lower than that required for Example 3 and impact testing
in accordance with the requirements of Table 7.2 (40 J at impact test temperature of
parent metal) will be required.
EXAMPLE 5
T = 40 mm
Tb(max.) = 12 mm
TR = 30 mm
Design temperature 50°C
Material Group — A2
PWHT — Nil (Preheat 100°C)
Seams, L 1, L2, C 1, C2 and C3; submerged arc
Welding
Branch to shell joints: gas metal arc
processes
Attachments to shell: gas metal arc
Required for both welding processes
Min. thickness for SAW: 20 mm (see Table 5.4 and Notes
Weld procedure
below)
qualification
Min. thickness for GMAW: 20 MM (see table 5.4 and
Notes below)
All joints qualified by butt welds
Welder
Required in accordance with Clause 9.2 for each welding
qualification
process
When required by the construction Standard for the class
Production weld
of construction, testing in accordance with requirements
test requirements
of Section 10 (see Note 2 for example)
Other items listed Within the limits stated for essential variables in
in Table 5.1
Table 5.1
NOTES:
1
The procedure tests carried out for Example 2 would comply with the
requirements for the above example provided the following requirements are
met:
(a) Procedure plate thickness 20 mm.
(b) Filler metal complies with F numbers of Table 5.5. Submerged arc flux
complies with Item 5 of Table 5.1 for production welding.
(c) Weld joint details complies with the requirements of Item 3 of Table 5.1.
(d) Welding energy input in production welding complies with the requirements
of Item (7) of Table 5.1.
2
For a Class 1 Pressure Vessel, the test pieces required are two side bends and
one macro. For a Class 1H Pressure Vessel, the test pieces required are two side
bends, one macro and two transverse tensile tests.
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EXAMPLE 6
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Assume a pressure vessel with all conditions, dimensions and welding procedure and
processes the same as Example 5 except that vessel is postweld heat treated.
The addition of postweld heat treatment requires that all welding procedures be
requalified.
EXAMPLE 7
Assume a pressure vessel with all the conditions covering dimensions and welding
procedure and processes the same as Example 5 except that the vessel in constructed in
ASTM A387 Grade 12 Class 1 (Group C material of Table 5.3) and the vessel is postweld
heat treated.
The addition of postweld heat treatment and construction in a different material group
classification requires that all welding procedures be requalified.
These are no additional requirements for welder qualification.
Production test plate weld metal requires chemical analysis for chromium and
molybdenum content in addition to the test pieces nominated in Note 2 to Example 5.
EXAMPLE 8
Assume a welding procedure qualification test carried out in the 1G position on a butt
weld, in pressure piping of size DN 200 × 16 mm wall thickness.
The procedure qualification test qualifies for all other welding positions in Figures 5.1
and 5.2 provided that the welding variables for other positions are within the limits for
essential variables as listed in Table 5.1.
Welder qualification using this welding procedure is required for welding positions in
production welding as required by Table 9.2.
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