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  • BS 4871 - Part 1 - 1982 - Approval Test'g of WeldersS Work'g To Ap PDF

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    BS 4871 - Part 1 - 1982 - Approval Test'g of WeldersS Work'g To Ap PDF

    Transféré par

    Thiên Khánh

    Droits d'auteur :

    © All Rights Reserved
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    S| BS 4871 : Part 1: 1982 pc 621.794.007.2:931.11862:(669.14:621.791.88) (Reprinted, incorporating Amendments No. 1 and No, 2) ‘© British Standards Institution, No part of this publication may be photocopied tenis reproduced without the British Standard Specification for Approval testing of welders working to approved welding procedures Part 1. Fusion welding of steel ‘Spécification pour essai d’agrément des soudeurs qualifiés our les procédés de soudage agréés Partie 1. Soudage par fusion de I'acier Spezifikation fiir SchweiBerpriifung mit Verfahrenspriifung Teil 1. Schmelzschweiften von Stahlen British Standards Institution BS 4871 : Part 1: 1982 Contents Page Inside front cover Back cover Foreword Cooperating organizations Specification Scope Definitions. Information to be given to the welder tems to be recorded Changes not affecting approval |. Extent of approval Test pieces ‘Submission of test weld Examination and testing Statement of results Reapproval of welder Page Appendix A. Record of approval test of welder 9 Tables 1. Weld metal/parent metal combinations 2. Positional approval for pipe 3. Acceptance levels 4, Number of test specimens required Figures 1, Test piece for butt weld in plate 2. Test piece for butt weld in pipe 3. Test piece for fillet weld i plate 4. Test piece for branch connection in pipe Compliance with a British Standard does not of itself confer immunity from legal obligations, Foreword ‘This revision of this Part of BS 4871 has been prepared Under the direction of the Welding Standards Committee It incorporates alterations necessary to align the standard with BS 4870 : Part 1: 1981 and also embodies other technical changes developed from experience gained in the use of the standard since it was first published in 1974. This Part of BS 4871 supersedes BS 4871 : Part 1 : 1974 which is withdrawn, ‘This revision does not invalidate welder approvals previously accepted according to the requirements of the 1974 edition of the standard, provided the details of the Procedures are still relevant to the production work on Which the welders are to be employed. The extent of approval given by a previous test in accordance with the 1974 edition may now be related to those ranges indicated 1 this revised edition. All new approval testing of welders should be made in accordance with the requirements of this revised edition, This British Standard is one of a series of standards on the approval testing of welders and welding procedures, the latter having a bearing on the former for certain applications. This link has been used as a means of arranging the series of standards into: (a) approval testing of welding procadures (see BS 4870 : Part 1); (b) welder approval when approval of the welding procedure is réquired; {c} welder approval when approval of the welding Procedure is not required (for either technical or contract reasons) (see BS 4872 : Part 1). For the purposes of this Part of this standard, a welder working to.an approved procedure or a procedure being approved is considered to be sufficiently experienced in the appropriate welding process and hence already capable of passing training tests such as those given in BS 1295, When non-destructive testing is used for the examination of test welds, it should be appreciated that the acceptance levels given in this standard are for the purposes of the approval testing of welders and as such are not necessarily the same as those which might be specified for work on which approved welders will be employed. Depending upon the emphasis placed on quality control in the production of welded components, the approval of welding procedures covered in this series of standards ‘may be administered in one of several ways which should be stipulated at the enquiry and/or order stage. The alter- natives currently employed are the followin (1) each individual contractor (or sub-contractor) may have proved by actual test pieces every weld form he wishes to use, In every thiékness and material; or (2) each individual contractor (or sub-contractor) may have proved by actual test pieces a set of welds representative on a group basis ofall the various thicknesses and materials to be used in production; or (3) each individual contractor (or sub-contractor) need not make procedure test pieces provided he can prove by appropriate authentic documentation of an independent nature that he has previously satisfactorily ‘welded the type of joint and material in question, In respect of (1) and (2) it should be appreciated that once ‘the welding procedure tests have been approved, they need never be repeated unless there is a change in certain Variables, As an extension beyond (3), it may be possible by agreement between the contracting parties for fully documented welding procedures, developed independently Of the particular contractor, to be employed without the need for further approval tests, ‘thas been assumed in the drafting of this Brith Standard ‘that the execution of its provisions is entrusted to appropriately qualified and experienced people, for whose aquidance it has been prepared, BS 4871 : Part 1: 1982 British Standard Specification for Approval testing of welders working to approved welding procedures 1. Scope ‘This Part of this British Standard specifies requirements for the approval testing of welders to be engaged on the ‘manual, semi-automatic or mechanized fusion welding of those ferrtie steel or austenitic stainless steel fabrications for which an approved welding procedure has to be employed. This standard is not intended to apply to ‘operators of automatic welding equipment, Cast-to-cast fabrications are not included” The welder who successfully completes a welding procedure {test in accordance with BS-4870 : Part 1 is approved to the lextent given in clauses 8 and 6 of this standard without, further testing, NOTE. The tiles ofthe publications refered to in this stonderd ae listed on the inside back cover 2. Definitions For the purposes of this Part of BS 4871, the following definitions apply. 2.1. welding procedure. A specified course of action {allowed in welding including alist of materials and, where necessary, tools to be used 2.2 welding procedure test. The making and testing of a ‘welded joint representative of that to be used in production in order to prove the feasibility of a welding procedure. NOTE. This term isnot usally applied to any tests that may Nave been made during the development ofa welding procedure 23 approved welding procedure. A documented welding procedure that has been anproved by an inspecting authority either by means of a welding procedure test or as a result of authentic documented experience gained with the welding of joints similar to that to which the welding procedure applies. 2.4 welder approval test. A documented test, which has been approved by an inspecting authority, carried out by a welder working to an approved welding procedure 25 test piece. Components welded together in accordance with a specified welding procedure, ar a portion of a welded joint detached from a structure, for testt 26 test specimen. A portion detached from a test piece and prepared as required for testing! 2.7 inspecting authority. That competent independent body oF association which verifies compliance with this, standard, ‘See 8S 4570 for requirements for welder approval for ste! castings {This Geinition is taken from BS 499 : Part 1 3. Information to be given to the welder The welder shall be provided with full written details according to clause 4 of BS 4870 : Part 1: 1981 of the approved welding procedure (which may be modified as permitted by clause 5) which he shall follow in making his test weld (see also ciause 8 of this standard). 4, Items to be recorded The items given in appendix A shall be recorded for each welder approval test. NOTE, Detais of the welding procedure used should have been recorded previously by epprovel testing in accordonce with 18S 4970 Part |. 5. Changes not affecting approval The following changes betweon the approved welding procedure and the procedure used for the welder approval test shall nat entail reapproval of the welder. NOTE, Clause of 8S 4870 : Part 1 : 198% states the changes afeting an spproved welding procedure, but for wider approval purposes more latitude is permitted at only the welder’sabiity ie being testes, {a) A change in parent metal (but see item ()) within fone of the following ranges of steels# (see also table 1) (1) Carbon steels and low alloy steels with less than 6 % total alloy. NOTE. This range corresponds to groups At, A2, B,C. , 1, €2,F, Gaga K of table 1 of BS 4870: Part: 1981 (2) When high alloy ferritie wold metal is specified, ‘a change in parent metal within the range 11 % to 20 % chromium. NOTE, This range corresponds to groups M and N of tble 1 ‘of 8S 4870: Part 1: 1981 (2) When austenitic or high nickel alloy weld metal is specified, a change in parent metal or combinations of patent metal within the ranges of carbon, low alloy, high alloy ferritic and austenitic steels. NOTE. This range corresponds to groupe Al, R2, 8, C.D, £1, €2, F, 6,4, 4, K, L) M,N, R, §, T and U of table tof 88 4870 ! Part 171981 (©) A change in weld metal composition (but see item (d}) within one of the groups givan in table 1 Or change within the extent of approval gin Im | table 1a, {Certain combinations of parent metal and weld metal will not allow destructive testing to be carried outa ndieted in 9.1(0). In such cates non-destructive testing i to be used, {HA welder may need some period of training when changing from one electrode type to another, BS 4971 : Part 1: 1982 Table 1. Weld metal/parent metal combinations Wield metal Examples of British Standard Perant metal options for — designations for welding consumables tert joint Group | Nominal composition wi [<6% total alloy BS 639 : all types" ‘Carbon or low alloy steel with less BS 2493 : all types* than 6% total alloy ‘except 7CrMo B and 9CrMo B 8S 2901 : Part 1: all types BS 4165 : all types w2 | >6%cr<20%Cr BS 2493 : 7CrMo B, 9CrMo B Ferriticlmartensitic steel within the ferritic/martensitic steels 8S 2926 : 13 and 17 | range 11 % to 20 % chromium w3 | Austenitie/ferritic or {BS 2926 : all types except 13 and 17. | Carbon, low alloy, high alloy ferritic austenitic stainless steels BS 2901 : Part 2 all types ‘or austenitic stool in the following ranges, BS 5465 : all types 6 t0 29 %Cr 51022 %Ni Oto 4 %Mo Oto 1.5%Nb Oto 15%Ti wa | High nickel alloy BS 2901 : Part §: NA 35, NA 39 A change from a rutile electrode to base electoce requ Table 1a, Extent of approval for weld metal groups T (ore bie 1) wr [wz | ws | wa wr x we x | x w3 x wa x | x {e) A change from either (1) a basic 10 a rutile covered electrode for group W1 weld metal, (2) from one electrode type to another for other then group W1 weld metal . {c) A change in filler material composition or parent metal for mechanized welding (e) A change in position, thickness, pipe outside diameter or dimension, type of joint and shielding gas within the extent of approval given in clause 6. (#) A change from an unbacked single sided weld to a backed single sided weld or to a double sided weld (g} A change in pre-heating temperature. {h) A change in post-weld heat treatment. 6. Extent of approval 6.1 Position, The approval of a welder on a test joint in plate welded in one of the fundamental welding positions shall give approval for welding in the following positions: (a) 2 test in the flat position gives approval only for ‘that position; rs reepprova (ee item (c} of clause 8). (b) a test in the horizontal-vertical position includes approval for the horizontal-vertical and flat positions; {c} a test in the overhead position includes approval for the overhead, horizontal-vertical and flat positions; (4) a test in the vertical-up direction includes approval for the vertical-up direction and the flat position: {e} a test in the vertical-down direction gives approval only for that direction; (f) a test joint inclined at 45 ° to the horizontal involving the overhead position welded in the verticabup direction, includes approval for all welding positions bbut excludes the vertica-down direction. ‘Approval forall four fundamental positions includes approval for all intermediate positions. In the case of pipe welds, the extent of approval shall bbe as given in table 2. Table 2. Positional approval for pipe Pipe position | Pipe movement Welding postions for during tet | during est which approval is aiven Horizontal | Rotated Flat Vertical | Rotated orfixed | Horizontal-vertical, flat Horizontal | Fixed | Frat, vertical, | overnead 45° Fixed All 6.2 Thickness. For the purposes of this clause, thickness ¢ shalt have the following meanings (a) for a butt joint, the parent metal thickness (b) for a fillet weld, the leg length; (c} for @set-on branch connection, the thickness of the branch: (a) for a setin or set-through branch connection, the thickness of the main pipe, ‘The approval of a welder on thickness t shal include approval for thicknesses in the following ranges: Thickness, ¢ Range approved less than 1.6 mm. tto2t 1.6 mm up to but 1.6 mm to 2t, not including 10 mm 10 mm and over 4.8mm to 2t except that test made on a thickness ¢ of 20 mm or over shall give approval for welding al such thicknesses of 4.8 mm and above. 6.3 Pipe* outside diameter or dimension. The approval (of a welder on pipe of outside diameter or dimension D ‘of 25 mm or above shall include approval for diameters or dimensions in the range 0.5D to 2D with a minimum diameter or dimension of 25 mm, except that a test made fn pipe of outside diameter ar dimension 168.3 mm or larger shall give approval for welding outside diameters ‘or dimensions 88.9 mm and above. For approval to weld diameters or dimensions below 25 mm, a test made on | pipe of diameter or dimension D less than 25 mm shall include approval in the range D to 25 mm, For rectangular structural hollow sections D shall be the dimension of the smaller side. For branch connections D shall be the diameter or dimension of the branch, 6.4 Type of joint 6.4.1. The approval of a welder on @ test but joint in pipe shall include approval for a butt joint in plate for the same test conditions, but the converse shall not apply, except as stated in 6.4.2, 6.4.2 The approval of a welder on a test but joint in plate welded in the flat position shali include approval for a butt joint in pipe of outside diameter or dimension 88.9 mm or above welded in the flat position (pipe rotated) for the same test conditions, subject to the limitations of item (f) of clause 5. 6.4.3 The approval of @ welder on a test fillet wold on plate shall include approval fora filet weld on pipe of outside diameter or dimension 88.9 mm or above welded in the flat position (pipe rotated) for the same test conditions, and 6.44 For manual metal-arc and TIG welding the approval of welder ono test butt joint shall include approval for fille weld for the same test conditions NOTE. A water spproved for butt cints may ned some period St sing when chosing toilet was However the produc {ion work on which te waders to be employed presominanty Fie wei tmens9 approval et on aot wih it weld may oo cri 6.45 For manual metal-arc and TIG-welding, the approval [ of welder on e tst bute joint in pipe only shal include spproval fora branch connection for the same test Conditions, povided thatthe included angle between the axes of the main and the branch is not less than 60°. BS 4871 : Part 1: 1982 6.5 More than one welder. When more than one welder is employed on making a complete test weld, the satisfac tory testing of the test weld shall approve each welder only for his respective portion, When there are unacceptable defects prosent in a test weld and they ean be attributed to one welder, this shall not adversely affect the approval of the other welders. 66 Shielding gas 6.6.1 MIG/MAG welding. For the purposes of this clause, shielding gases for MIG/MAG welding shall be grouped as follows: MG 1 argon/oxygen mixtures MG 2 argon/carbon dioxide mixtures MG 3 earbon dioxide MG 4 helium/argon mixtures MG 5 self-shielded, ‘The approval of a welder on a test joint using a shielding 42s from one of the above groups shall only include approval within that group. For solid or tubular wires, approval of a welder using 2 shielding gas from group MG 1, MG 2 or MG 4 shall include approval for all combinations of mixtutes within the same group. For the dip transfer technique, approval of a welder using 3 shielding gas from group MG 2 shall include approval for the mixture used and any mixture with a higher carbon dioxide content 6.6.2 T1G welding. For the purposes of this clause, shielding gases for TIG welding, with or without filler (hot 6 cold wire), shall be grouped as follows: TG 1 argon TG 2 argon/hydrogen mixtures TG 3helium/argon/hydrogen mixtures TG 4 helium TG 5 nitrogen and nitrogenfargon mixtures ‘The approval of a welder on a test joint using a shielding 435 from one of the above groups shall only include approval within that group, Approval using a shielding gas ‘mixture from group.TG 2, TG 3 or TG 5 shall include ‘approval for all combinations of mixtures within the same group, 6.6.3 Plasma welding. A change in shielding eas composition for plasma welding shall not entail reapproval of 8 welder. 7. Test pieces Except as permitted by the requirements of 6.4 the welder shall weld a test piece or pieces representative of each type of joint to which the welding procedure will elate in production, preferably selected from the following (a) A butt joint (plate andor pipe). (See figures 1 and 2.) (b) A fillet weld (plate). (See figure 3.) (cl A branch connection {pipes) forming the minimum angle, likely to be involved in production. (See figure 4.) The root run of the test weld shall be stopped and restarted ‘within the central 50 mm of the length of the test piece 25 shown in figure 1 and at about 75 mm from one end of the test piece as shown in figure 3. In the ease of manual metal-arc welding, the restart shall be made with a fresh electrode. The test piece shall be marked so that the “le this standard the word ‘pipe alone or in combination is used to mean ‘pipe or ‘tue or structural hollow seston’ (circular oF rctanaulor), sthough these terms are often used for different eategores of product by different Industes, 3 BS 4871 : Part 1: 1982 stop/start position is identifiable after the test weld has been completed If the production joint design or application is such that none of the above types of test piece could be regarded as representative, eg, surfacing or attachment welds to thin pipes, then the welder shall make a special test piece which simulates the production joint in all essential features, eg. dimensions, restraint, access, heatsink effects, any special surface protection. The type of special test piece to be welded, and the tests to be carried out, shall be agreed between the contracting parties at the time of placing an order. ‘Tack welds to be incorporated in the final joint shall be made from the side to be welded and their location shall be identifiable after the test wald has been completed. Subsurface defects that break the surface or which are revealed as the result of grinding specified in the welding procedure shall not be repaired, There shall be no repair welding of a completed test piece, 8. Submission of test weld If the welder realizes that for some reason the test weld he has made is likely to fail the subsequent examination and testing, he may withhold the test piece and make @ second test weld. If the welder does choose to make a second test weld, itis the second test piece that shall bbe examined and tested, the first test piece being scrapped. 9. Examination and testing 11 General. All test pieces shall be examined visually in the as-welded condition, augmented if necessary by magnetic particle testing (see BS 6072) or peneirant testing (see BS 6443). If acceptable in accordance with 9.2.2 they shall then be either: {a) examined by non-destructive testing and assessed in accordance with 9.2.2, supplemented by (1) macro-examination if necessary to assist in the interpretation of the results of non-destructive testing, and (2) when radiography is used, the bend tests given in table 4 to detect any lack of side fusion that could occur when the dip transfer technique or ‘92s welding has been used: (b) tested using the test specimens given in table 4 when the test piece material permits satisfactory destructive testing or when it is agreed between the contracting parties that the use of non-destructive testing is not practicable When both non-destructive and destructive testing are required they shall be applied to the same test piece(s) Unless otherwise agreed between the contracting parties, the first and last 25 mm of the length of @ butt joint or fillet weld in plate shall be ignored in both non-desteuctive and destructive testing, If the test piece fails to comply with any of the require ments for visual examination of non-destructive testing specified in 9.2.2, one further test piece shall be welded and subjected to the same examination. If this additional test piece does not comply with the relevant requirements, 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 under taken, If the failure is established as being attributable to the welder’s workmanship, then the welder shall be regarded as incapable of complying with the requirements, of this standard without further training. If any test specimen fails to comply with the relevant, requirements of 9.3.3, then either (i) when any planar defect is found one further test piece shall be welded and subjected to the same test, (ii) when other than a planar defect is Found two further test specimons shall be obtained for each ane that failed 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 the further test piece for (i) above or either of the additional test specimens for (i) above daes not comply ‘with the relevant requirements, 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 undertaken, If the failure is established as being attributable to the welder’s workmanship, then the welder shall be regarded as incapable of complying with the requirements of this standard without further training 9.2 Nondestructive testing 9.2.1. Examination. After any post-weld heat treatment {and prior to the cutting of test specimens, all test pieces shall be examined visually. When non-destructive testing fs to be used (see 9.1) visual examination shall be followed by: (a) radiographic examination (see BS 2600 : Part 1 and Part 2 and BS 2910) {b) ultrasonic examination (see BS 3923 : Part 1 and Part 3) depending upon joint geometry, material and the requirements for production. work, using the appropriate application standard, Where no such standard exists, the non-destructive testing methods to be applied shall bbe agreed botween the contracting parties, preferably at the time of placing an order. 9.2.2 Acceptance levels, Oofects that are detected by visual examinstion and the other relevant methods of non-destructive testing shall be assessed in accordance with the details specified in table 3. The existence of any defect greater than the maximum permitted by table 3 shall be sufficient eause for rejection, The leg length(s) of a fillet weld shall be not less than the ‘minimum value(s) specified in the welding procedure, ‘The actual throat thickness of a fillet weld shall be equal to or greater than the perpendicular distance between the root of preparation and the plane joining the toes of a weld (of minimum specified leg lengths), except when a particular profile has been specified NOTE 1, Multiple fype faults contained within the same weld, ‘ther superimposed or interposed, which are individually acceptable {2 holeted imperfections may be considered acceptable provided that investigation shaw that there fe nothing fundomentally wrons ‘with the welding procedure, NOTE 2. It should be appreciated thatthe detail given in table 2 are being use for the approval testing of welders and oe uch ‘ay be different from those specified fora parttetarepatietion BS 4871 : Part 1: 1982 Edge preparation and fit-up as detailed in welding procedure >=—}—_ Root run to be stopped and restarted within central 50 mn, 25 min Figure 1. Test pi 2 for butt weld in plate (see clause 7) 9.3 Destructive tests 9.3.1 Test specimens. The number of specimens to be ‘obtained when certain destructive tests are required (see 9.1) shall be as given in table 4. It is permissible to take the test specimens from locations selected ta avoid areas showing defects, even if such defects are acceptable ‘according to 9.2.2. When the size and thickness of a pipe butt joint are such that the specified test specimens cannot be obtained, then some other method of test agreed between the contracting parties shall be used, e.g. a fullsize tensile test or a hydraulic pressure test, 913.2 Preparation and testing. The shape and dimensions of test specimens and the methods of testing them, shall be 2s described in BS 709, If backing material forms part of a butt joint it shall be removed prior to bend testing. Each bend test specimen shall be bent through at feast 90° round a former of diameter 4t, where ¢ is the thickness of the specimen, or of diameter (4 +), whichever is the greater, where d is the former diameter required to test the parent metal of the same thickness, when this is specified in the standard for the parent metal 9.3.3 Test results 9.3.3.1 Macro-examination and fillet weld fracture test, ‘The etched face for macro-examination and the fracture surface from the fillet weld test shall be assessed in accordance with the requirements of 9.2.2 100 min Edge preparation and fit-up as detaited in welding procedure | J 7 100 nin. 100 min, Figure 2. Test piece for butt weld in pipe (see clause 7) 2 Bend tests. If the specimen bends through 90° without failure, slight tearing at the edges or on the tension surface shall not be cause for rejection. If the specimen tears across the surface in tension, it shall be broken open and assessed in accordance with the requirements of 9.2.2. BS 4871 : Part 1: 1982 Wold one side or both ve | dead In welcing procedure 100 bo 50 Full length of weld this side Root run to be stopped and restarted about 75 mn from end (one macro- _- examination position} Lines of cuts 225| __| for. specimens when only one side welded 110 an length of a } weld when Second Se welded \, 100 __| All dimensions sre in millimetres. Figure 3. Test piece for filet wold in plate (soe clause 7) BS 4871 : Part 1: 1982 Edge preparations and fit-up as detailed in welding procedure “ 350 min “The same essential dimensions shal aply for rectangular hollow sections All cimeasions ate in milimetres Figure 4. Test piece for branch connection in pipe (see clause 7) BS 4871 : Part 1: 1982 Table 3. Acceptance levels Notation Ti he parent metal thickness. In tho cose of csi thicknesses ¢ applies 10 the thianer component ww is the width of defect 1 ig the teagth of detect ‘ni the height of cafect i the diameter of datect Detect typ Permitted maximum Planar defects | (a) Gracks and lamellar tears Not permitted (8) Lack of root fusion ‘Lack of side fusion Lack of inter-run fusion ‘Not permitted {c) Lack of root penetration Not permitted Cavities (a) Isolated pores (or individual pores ina group) GS t/4 and $3.0 mm for t up to and including 50 mm 84.5 mm for ¢ over 50 mm up to and including 75 mm. 46.0 mm for t over 75 mm ‘ (b) Uniformly distributed or localized porosity 2% by areat (as seen in a radiograph) {or t 50 mm and pro rata for greator thicknesses (c} Linear porosity (spaced as for ‘group of inclusions) Unies it can be shown that lack of fusion or lack of penetration is associated with this defect (which is not permitted) it shall be treated as for individual pores in a group (a) Wormholes isolated TS6mm,w= imam {6} Wormholes aligned As linear porosity (8) Crater pipes [As wormholes isolated Solid inclusions | (a) Slag inclusions (1) Individual and parallel 10 weld axis {2} Linear group (3) Individual and randomly orientated (4) Nonvtinear group tS 18mm ¢ >18mm<75mmr > 75mm 1

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