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Reg. 610, Reg. 611 A, Reg. 611 B

QUALIFICATION TESTS FOR WELDERS ENGAGED IN WELDING OF BOILERS AND STEAM-PIPES UNDER CONSTRUCTION, ERECTION AND FABRICATION AT SITE IN INDIA AND IN REPAIRING BOILERS AND STEAM-PIPES BY WELDING

Reg 610

Tests for Requalification

At a requalification test a welder need not be examined in theoretical subjects, but he shall be required to qualify in the following practical tests:-

 
a) Plate Welding.-

A groove welded joint of two pieces of plates not less than 16 mm. (5/8 inch) thick over a length of 152 mm. (6 inches) in a position 45 degree to vertical, size of plates to be welded being 229 mm. x 152 mm. (9 inches x 6 inches). The main welding is to be carried from the underside only.
(b) Pipe Welding.-

The material of plates, tubes, pipes and electrodes used for these tests shall conform to the requirements of appropriate Regulations as may be applicable in each case.
  (i) A groove welded joint with the axis of the pipe in a horizontal position and without rotating the pipe.
  (ii) One weld of a branch to a pipe, as prescribed in Regulation 609.
(c)

 

 

(d)

Tube Welding.-

A butt welded joint of two pieces of boiler tubes with the axis in a vertical position, and tubes of same size fixed in adjoining positions. This test shall be in addition to the test for pipe welding under clause (b).

When a welder is continuously engaged on production weld, tests on the work in actual production to the satisfaction of the Competent Authority may be accepted as an alternative to the tests prescribed as above under clauses (a), (b) and (c).

 



Reg. 611 

Examination of test specimens for initial qualification tests:-

(a)
Groove welded plate specimens

The Groove welded plate specimens after welding may be lightly pressed cold to remove any distortion due to welding. The test specimen shall be similarly treated as required for the actual production weld.

After visual examination, the welded specimen shall be subjected to radiographic examination in the manner as provided in Regulation 265 (b), provided that this requirement may be waived when the welder is to be engaged on production work where radiographic examination is not required under these Regulations.

Thereafter test pieces shall be marked and cut out in order shown in Figure XIII/1.

The bend test specimens (B1 & B2) shall be prepared and tested as per Regulations 261 & 262. In the case of alloy steel specimen, the angle of the bend is to be decided by the Competent Authority, provided that the angle shall, in no case, be less than 120°.

Two each specimens (E1 & E2) shall be prepared, one for micro and the other for macro examination as per Regulations 265(a).


(b) Fillet welded plate specimens.-

The dimensions and preparation of the fillet-weld test specimen shall conform to Figure XIII/2. The test specimen shall not contain any visible cracks. It shall be cut transversely to provide a centre section (254 mm) (10 in.) long and two end sections each approximately (25 mm) (1 in.) long.

The stem of the (254 mm) (10 in.) centre section shall be loaded laterally in such a way that the root of the weld is in tension. The laod shall be steadily increased until the specimen fractures or bends flat upon itself. In order to pass the test.-


(1) The specimen shall not fracture, or
(2) If it fractures, the fractured surface shall show no evidence of cracks or incomplete root penetration, and the sum of the lengths of inclusions and gas pockets visible on the fractured surface shall not exceed (51 mm) (2 in.).

The cut end of one of the end sections shall be polished and etched with a suitable reagent to give a clear definition of the structure of the weld.
  In order to pass the test:-
  (i) Visual examination of the cross section of the weld shall show complete fusion at the root and freedom from cracks.
  (ii) The weld shall not have a concavity or convexity greater than (1.6 mm.) (1/16 in.); and
  (iii) There shall be not more than (1.6 mm) (1/16 in.) difference in the lengths of the legs of the fillet.
 
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