Materials and

Qualification
Procedures for
Ships

Book J

Procedure 11-1

Approval of Welding Consumables

Revision 1, December 2013

Material and Qualification Procedures for Ships Book J
Procedure 11-1

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Material and Qualification Procedures for Ships Book J
Procedure 11-1
Approval of Welding Consumables

1 Introduction

1.1 Application for approval

1.1.1 In order that consideration may be given to approval of welding consumables,

the local Surveyors are to submit a report to London office, Materials and NDE
Department giving the information listed in Sections 2 and 3 together with the
results of approval tests carried out under their survey. This report may be
submitted on Form 6223, copies of which may be printed from this procedure.

1.1.2 The use of Form 6223 is not mandatory. In many cases, reports prepared by the
manufacturer and endorsed by the Surveyor are acceptable, particularly where
they contain supplementary information and test results in addition to those
required by the Rules and Regulations for the Classification of Ships (hereinafter
referred to as the Rules for Ships).

1.1.3 Approved consumables will appear in LR's List of Approved Welding

Consumables for use in Ship Construction.

1.1.4 Approved consumables will be subject to annual re-approval, see Procedure 11-
2.

1.2 Scope

1.2.1 This procedure is applicable to the initial approval of welding consumables. The
procedure gives guidance on a suitable report form, with provision for a
description of the consumable and the grading requested by the manufacturer,
together with supporting information, and the reporting of tests and
examinations as required by Pt 2, Ch 11 of the Rules for Ships.

1.2.2 Welding consumables approved under this procedure are referred to as having
independent (IND) approval. Products may be approved under other procedures,
see Procedures 11-4 and 11-5.

1.3 Related Rules

1.3.1 Reference is made in this procedure to LR's Rules for Ships.

1.3.2 LR's Rules for the Manufacture, Testing and Certification of Materials
(hereinafter referred to as the Rules for Materials).

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Material and Qualification Procedures for Ships Book J
Procedure 11-1
2 Information required for approval

2.1 Works inspection

2.1.1 The Surveyor is to prepare and submit a full `works inspection report', which
may be supported by documents produced by the manufacturer. The Surveyor is
to comment on the following aspects in relation to their effect on the factory's
ability to produce and supply consumables of adequate and consistent quality:

(a) The efficiency of the operatives and the machinery at their disposal.

(b) The system for checking raw materials.

(c) Quality control operations during manufacture and on the finished

consumables.

(d) Packing, batch identification and labelling.

(e) Storage facilities.

(f) The ability of the record keeping system to relate finished batch numbers
to known batches of raw materials.

2.1.2 If the factory already has approval for one or more consumables of the same
type, it is sufficient to confirm that the factory continues unchanged in any
respect. This is to be done either by issuing an up-to-date `Surveyor's Statement'
of works inspection (see Appendix B in Procedure 11-2), or by reference to a
recent (not more than six months old) `Surveyor's Statement'.

2.2 Product details and tests

2.2.1 The Surveyor is to report all the product details and tests shown on Form 6223.
This form or the manufacturer's report is to be endorsed by office stamp and the
Surveyor's name and signature.

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Material and Qualification Procedures for Ships Book J
Procedure 11-1
3 Notes on Form 6223

3.1 General

3.1.1 Panel 0. Enter date of completing report.

3.1.2 Panel 1. The name of the plant is important particularly where the Company has
geographically separate factories with separate organization and manufacturing
control.

3.1.3 Panel 2. The name or designation of the consumable or combination should be

entered in the form in which the Company wishes it to appear on the Approval
Certificate and in the published version of the approved list.

3.1.4 Panel 3. Indicate the consumable or combination type by placing a cross (X) in
the space corresponding to the welding process or usage.

3.1.5 Panel 4. Indicate by deletion of the symbols and abbreviations not applicable.
(`Chem': chemical cargo use; `Cryo': cryogenic cargo use). For the newer grades
of approval, add appropriate references in the space alongside Panel 5.

3.1.6 Panel 5. Enter appropriate Section number according to Pt 2, Ch 11 of the Rules

for Ships.

3.1.7 Panel 6. Most of this information should be available from the manufacturer,
even if on a `commercially confidential' basis. The usual commercial secrets in
flux compositions can be easily retained by the manufacturer by use of the
finishing entry: `Others - %'. This last percentage can in some cases be as high as
10 or 15 per cent of the composition.

3.1.8 Panel 7. Complete by entry and deletion, as appropriate. The manufacturers'

recommendations for one-side welding, specialized automatic welding, and
non-standard two-run technique welding should be submitted on an appendix
sheet attached to the report, and notified: `Other: See Appendix Sheet No. -.'

3.1.9 Panel 8. Complete by entry and deletion, as appropriate. The gas composition
entry should show the percentages of principal gases in any mixture, any
unusual tolerances on the accuracy of the mixture and any significant impurities,
e.g. `80% Ar-20%CO2; 0-2%O2 as impurity'.

3.1.10 Panel 9. Normal entries in this panel will use only the thickness and LR grade
columns. Where the plate is not LR certified, enter the specification/grade
identity in the column `Other', enter the equivalent LR grading in the `LR'
column, and enter the details of the mechanical properties and analysis from the
`Other' certification on which basis the equivalence is claimed.

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Material and Qualification Procedures for Ships Book J
Procedure 11-1
3.1.11 Panel 10. In this panel, it may be necessary to make more than one entry in
some of the column/line spaces. For two-run technique butt welds, enter the
conditions for each of the two-runs in each assembly. For electroslag and
electrogas butt welds enter conditions for both thicknesses and each strength
level, if appropriate. If welding speed for manual or semi-automatic welding is
only approximate please indicate by an asterisk after each entry.

3.1.12 Panel 11. Enter results required by the Rules for Ships, paying particular
attention to meeting not only the limiting values imposed, but also the detailed
requirements where repeat or additional testing is required or permitted by the
Rules for Materials Ch 11,2.3.

3.1.13 Panel 12. Sufficient lines of entry exist in this panel to report the majority of
butt weld test programmes, including some space for repeat testing. An
informal appendix sheet should be inserted, if needed, and this should be
indicated at the foot of Panel 12. The allowance is for one entry line for each
manual or semi-automatically welded butt weld and two lines for each
automatic or mechanized butt weld.

Enter appropriate code letter(s) under:

`Technique':

m - manual
G - gravity
DP - deep penetration
S - semi-automatic multirun
M - automatic multirun
T - two-run
A - automatic (not more than 3 runs for 20 mm plate - Section 7
approvals only. See 3.1.6)
ES - electroslag
EG - electrogas
OS - oneside with temporary backing (Add:
m, S, M, A, as appropriate)

`Position':

D, X, Vu, Vd, O - as normally appropriate.

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Material and Qualification Procedures for Ships Book J
Procedure 11-1
`Steel':

Grade letter(s) from column `LR' in Panel

9, i.e. A, B, D, E, AH, DH or EH, as
appropriate.

Insert units for `Rm' and `KV'. (N/mm2 and J are preferred,
respectively). Enter appropriate letter under `Position of fracture':

P - parent steel (including HAZ)

W - weld metal

3.1.14 Panel 13. Delete descriptions in first column, as appropriate. Insert `OK' under
appropriate thickness headings. Use blank heading to insert other thickness
welded, if appropriate.

3.1.15 Panel 14. For those approval test programmes which involve making deposited
metal assemblies, the chemical analyses of the weld metal in these assemblies
should be reported here, and `Butt Weld' should be deleted from the heading.

For those programmes which do not require deposited metal assemblies, the
chemical analyses reported here will be from at least one of the butt welds
made, in which case `Deposited Metal Assembly' should be deleted from the
heading.

3.1.16 Panel 15. Insert briefest description of any failure or defect, e.g. lack of
penetration, poor profile, cracking, porosity, slag inclusions, undercut. Then add
`Repeat - Satisfactory' or `Repeat - OK'. Otherwise, insert `Satisfactory' or `OK',
or extent of penetration for `DP'.

3.1.17 Panel 16. Alongside `Method' delete and enter, as appropriate. If method used
normally reports in cm3/100 g, insert `100' in appropriate position.

3.1.18 Panel 17. Insert the corresponding hardness values from each of the three
macrosections, in the columns marked `1, 2 and 3' under the heading `Section'.

Note that the preferred hardness determination is by the Vickers method and
the indenting load should be indicated. Where hardness is determined by other
methods, please indicate the method, scale, etc., even in those cases where the
values have been converted to and reported in HV.

3.1.19 Other test results. These are to be reported on additional sheets, and reference
to these sheets is to be made at the end of Form 6223.

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