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welding and brazing qualifications
AS/NZS 3992:1998 Australian/New Zealand Standard ™ Pressure equipment—Welding and brazing qualification AS/NZS 3992:1998 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 Review of Standards. To keep abreast of progress in industry, Joint Australian/ New Zealand Standards are subject to periodic review and are kept up to date by the issue of amendments or new editions as necessary. It is important therefore that Standards users ensure that they are in possession of the latest edition, and any amendments thereto. Full details of all Joint Standards and related publications will be found in the Standards Australia and Standards New Zealand Catalogue of Publications; this information is supplemented each month by the magazines ‘The Australian Standard’ and ‘Standards New Zealand’, which subscribing members receive, and which give details of new publications, new editions and amendments, and of withdrawn Standards. Suggestions for improvements to Joint Standards, addressed to the head office of either Standards Australia or Standards New Zealand, are welcomed. Notification of any inaccuracy or ambiguity found in a Joint Australian/New Zealand Standard should be made without delay in order that the matter may be investigated and appropriate action taken. This Standard was issued in draft form for comment as DR 96090. AS/NZS 3992:1998 Australian/New Zealand Standard ™ Pressure equipment—Welding and brazing qualification Originated in Australia as AS 3992—1992. Revised and redesignated AS/NZS 3992:1998. PUBLISHED JOINTLY BY: STANDARDS AUSTRALIA 1 The Crescent, Homebush NSW 2140 Australia STANDARDS NEW ZEALAND Level 10, Radio New Zealand House, 155 The Terrace, Wellington 6001 New Zealand ISBN 0 7337 1876 0 AS/NZS 3992:1998 2 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 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 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. © Copyright STANDARDS AUSTRALIA/STANDARDS NEW ZEALAND Users of Standards are reminded that copyright subsists in all Standards Australia and Standards New Zealand publications and software. Except where the Copyright Act allows and except where provided for below no publications or software produced by Standards Australia or Standards New Zealand may be reproduced, stored in a retrieval system in any form or transmitted by any means without prior permission in writing from Standards Australia or Standards New Zealand. Permission may be conditional on an appropriate royalty payment. Australian requests for permission and information on commercial software royalties should be directed to the head office of Standards Australia. New Zealand requests should be directed to Standards New Zealand. Up to 10 percent of the technical content pages of a Standard may be copied for use exclusively in-house by purchasers of the Standard without payment of a royalty or advice to Standards Australia or Standards New Zealand. Inclusion of copyright material in computer software programs is also permitted without royalty payment provided such programs are used exclusively in-house by the creators of the programs. Care should be taken to ensure that material used is from the current edition of the Standard and that it is updated whenever the Standard is amended or revised. The number and date of the Standard should therefore be clearly identified. The use of material in print form or in computer software programs to be used commercially, with or without payment, or in commercial contracts is subject to the payment of a royalty. This policy may be varied by Standards Australia or Standards New Zealand at any time. AS/NZS 3992:1998 4 CONTENTS Page SECTION 1 SCOPE AND GENERAL 1.1 SCOPE 7 1.2 APPLICATION 7 1.3 REFERENCED DOCUMENTS 8 1.4 DEFINITIONS 8 1.5 OTHER PROCESSES 9 1.6 OTHER MATERIALS 9 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 13 3.2 METHODS OF QUALIFICATION OF WELDING PROCEDURE 13 3.3 RECORDING OF WELDING PROCEDURE DATA 13 3.4 TESTING OF WELDING PROCEDURE TEST WELDS 13 3.5 REQUALIFICATION OF A WELDING PROCEDURE 14 3.6 PORTABILITY OF QUALIFIED WELDING PROCEDURES 14 3.7 RECIPROCITY OF QUALIFIED WELDING PROCEDURES 14 3.8 WELDING PROCEDURE SPECIFICATION 14 3.9 WELDING PROCEDURES FOR REPAIR WELDING 14 3.10 REPAIRS, REPLACEMENT OR ALTERATION TO IN-SERVICE PRESSURE EQUIPMENT 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 32 6.2 VISUAL EXAMINATION 34 6.3 NON-DESTRUCTIVE EXAMINATION OF TEST PIECES 34 6.4 POSTWELD HEAT TREATMENT 34 5 AS/NZS 3992:1998 Page SECTION 7 MECHANICAL TESTING OF WELDS FOR PROCEDURE QUALIFICATION 7.1 GENERAL 39 7.2 RESPONSIBILITY FOR TESTING 39 7.3 TEST SPECIMENS 39 7.4 TRANSVERSE TENSILE TEST 39 7.5 ALL-WELD-METAL TENSILE TEST 40 7.6 BEND TEST 40 7.7 CHARPY V-NOTCH IMPACT TEST 42 7.8 MACRO EXAMINATION 46 7.9 WELD JOINT HARDNESS TEST 46 7.10 FILLET BREAK TEST 47 7.11 NICK-BREAK TEST 47 7.12 ADDITIONAL TESTS BEFORE REJECTION 47 7.13 REPORTING OF RESULTS 47 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 52 9.2 METHODS OF QUALIFICATION 52 9.3 EXTENT OF APPROVAL OF WELDER QUALIFICATION 52 9.4 INFORMATION TO BE GIVEN TO WELDER FOR QUALIFICATION TEST WELDS 52 9.5 EXAMINATION AND TESTING OF WELDER QUALIFICATION TEST WELDS 52 9.6 RECORDING OF WELDER QUALIFICATION TESTS 53 9.7 RETESTS 53 9.8 RENEWAL OF WELDER QUALIFICATION 56 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 59 11.2 QUALIFICATION REQUIRED 59 11.3 GROUPING OF MATERIALS FOR BRAZING QUALIFICATION 59 11.4 GROUPING OF BRAZING FILLER METALS 60 11.5 BRAZING FLOW POSITIONS 61 11.6 RECORDS 61 AS/NZS 3992:1998 6 Page SECTION 12 QUALIFICATION OF BRAZING PROCEDURE 12.1 GENERAL 63 12.2 REQUALIFICATION OF A BRAZING PROCEDURE 63 12.3 PORTABILITY OF QUALIFIED BRAZING PROCEDURE 63 12.4 PREQUALIFIED BRAZING PROCEDURE 63 12.5 ITEMS TO BE RECORDED FOR BRAZING PROCEDURE QUALIFICATION TEST BRAZES 63 12.6 ESSENTIAL VARIABLES FOR BRAZING PROCEDURE QUALIFICATION 64 12.7 TEST PIECES FOR BRAZING PROCEDURE QUALIFICATION 64 12.8 VISUAL EXAMINATION 64 SECTION 13 EXAMINATION AND TESTING OF BRAZED JOINTS 13.1 REMOVAL OF TEST SPECIMENS 69 13.2 TRANSVERSE TENSILE TEST 69 13.3 BEND TEST 70 13.4 PEEL TEST 70 13.5 SECTIONING TEST 71 13.6 WORKMANSHIP SPECIMEN TEST 71 13.7 RETESTS 71 SECTION 14 BRAZER AND BRAZING OPERATOR QUALIFICATION 14.1 METHODS OF QUALIFICATION 73 14.2 ESSENTIAL VARIABLES FOR QUALIFICATION OF BRAZING PERSONNEL 73 14.3 EXTENT OF APPROVAL OF BRAZING QUALIFICATION 73 14.4 INFORMATION TO BE GIVEN TO BRAZER OR BRAZING OPERATOR FOR QUALIFICATION TEST JOINT 73 14.5 QUALIFICATION TEST JOINTS AND TESTING 73 14.6 RECORDING OF BRAZER AND BRAZING OPERATOR QUALIFICATION TESTS 74 14.7 RETESTS 74 14.8 RENEWAL OF BRAZER QUALIFICATION 74 SECTION 15 ALUMINOTHERMIC WELDING OF ELECTRICAL CONDUCTORS 75 APPENDICES A LIST OF REFERENCED DOCUMENTS 76 B WELDING PROCEDURE SPECIFICATION 80 C RECORD OF QUALIFICATION OF WELDING PROCEDURE 83 D TYPICAL FERROUS MATERIAL SPECIFICATIONS 85 E MACRO-ETCHING OF WELDED JOINTS 87 F RECORD OF QUALIFIED BRAZING PROCEDURE 88 G BASIS FOR GROUPING OF STEELS 90 H EXAMPLES OF THE APPLICATION OF THIS STANDARD TO PRESSURE VESSEL AND PIPING FABRICATION 93 7 AS/NZS 3992:1998 STANDARDS AUSTRALIA/STANDARDS NEW ZEALAND Australian/New Zealand Standard Pressure equipment—Welding and brazing qualification SECTION 1 SCOPE AND GENERAL 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. COPYRIGHT 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 The documents listed in Appendix A are referred to in this Standard. 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 For the purpose of this Standard, the definitions in AS 2812 and those below apply. 1.4.1 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. COPYRIGHT [...]... XF 400 and XF 500 — — 3 4 1, 2, 3 1, 2 — 5 — 1, 2 E F G C-½Mo; ½Cr-½Mo; 1Mn-½Mo 1Cr-½Mo; 1¼Cr-½Mo; ¾Cr-¾Ni-Cu-A1 ½Cr-½Mo-¼V 2¼Cr-1Mo; 5Cr-½Mo; 7Cr-1⁄2 Mo; 9Cr-1Mo 3½Ni 9Ni ASTM A 517; AS 3597:700 PV 9B 11A 11B 1 1 1 to 8 6 7 1,2, 3, 4 1 8 1 L M 13Cr (Type 410); 15Cr (Type 429) 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)... 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 F45 AS 1167.2 SFA 5.14 MMAW Nickel molybdenum and nickel chromium molybdenum electrodes... 18Cr-8Ni (Type 304) 18Cr-12Ni-2.5Mo (Type 316) 18Cr-10Ni-Ti (Type 321) 27 Cr-1Mo (S44627) 22Cr-5Ni-3Mo-N (S31803) 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 Low alloy steel B Alloy steel (alloy