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Title Licensee Conditions of use This is a licensed electronic copy of a document where copyright is owned or managed by Standards Australia International. Your licence is a single user licence and the document may not be stored, transferred or otherwise distributed on a network. You may also make one paper copy of this document if required. Web Check-up AS/NZS 3992:1998 Pressure equipment - Welding and brazing qualification Licensed to SAIPEM (SPCM) on 11 Sep 2002 AS/NZS 3992:1998 (Incorporating Amendment No. 1) Australian/New Zealand Standard ™ Pressure equipment—Welding and brazing qualification AS/NZS 3992 Licensed to SAIPEM (SPCM) on 11 Sep 2002. Single user licence only. Storage, distribution or use on network prohibited. 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 Keeping Standards up-to-date Standards are living documents which reflect progress in science, technology and systems. To maintain their currency, all Standards are periodically reviewed, and new editions are published. Between editions, amendments may be issued. Standards may also be withdrawn. It is important that readers assure themselves they are using a current Standard, which should include any amendments which may have been published since the Standard was purchased. Detailed information about joint Australian/New Zealand Standards can be found by visiting the Standards Australia web site at www.standards.com.au or Standards New Zealand web site at www.standard.co.nz and looking up the relevant Standard in the on-line catalogue. Alternatively, both organizations publish an annual printed Catalogue with full details of all current Standards. For more frequent listings or notification of revisions, amendments and withdrawals, Standards Australia and Standards New Zealand offer a number of update options. For information about these services, users should contact their respective national Standards organization. We also welcome suggestions for improvement in our Standards, and especially encourage readers to notify us immediately of any apparent inaccuracies or ambiguities. 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. Licensed to SAIPEM (SPCM) on 11 Sep 2002. Single user licence only. Storage, distribution or use on network prohibited. AS/NZS 3992:1998 (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 Licensed to SAIPEM (SPCM) on 11 Sep 2002. Single user licence only. Storage, distribution or use on network prohibited. 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 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. Licensed to SAIPEM (SPCM) on 11 Sep 2002. Single user licence only. Storage, distribution or use on network prohibited. 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. Licensed to SAIPEM (SPCM) on 11 Sep 2002. Single user licence only. Storage, distribution or use on network prohibited. 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 Licensed to SAIPEM (SPCM) on 11 Sep 2002. 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Storage, distribution or use on network prohibited. 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 48 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 Licensed to SAIPEM (SPCM) on 11 Sep 2002. 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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 Licensed to SAIPEM (SPCM) on 11 Sep 2002. Single user licence only. Storage, distribution or use on network prohibited. 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 Licensed to SAIPEM (SPCM) on 11 Sep 2002. Single user licence only. Storage, distribution or use on network prohibited. [...]... welding procedure or where this is not practicable, to a repair procedure approved to this Standard COPYRIGHT 15 AS/ NZS 3992: 1998 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. .. COPYRIGHT 9 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 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... 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. .. 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, ... 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... 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 COPYRIGHT AS/ NZS 3992: 1998. .. in the pressure equipment Standard, or Welding Technology Institute of Australia Tech Note 1 COPYRIGHT 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. .. COPYRIGHT 11 TABLE AS/ NZS 3992: 1998 2.2 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.. .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... this Standard COPYRIGHT AS/ NZS 3992: 1998 10 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 . prohibited. 7 AS/ NZS 3992: 1998 STANDARDS AUSTRALIA/STANDARDS NEW ZEALAND Australian/New Zealand Standard Pressure equipment Welding and brazing qualification SECTION. required. Web Check-up AS/ NZS 3992: 1998 Pressure equipment - Welding and brazing qualification Licensed to SAIPEM (SPCM) on 11 Sep 2002 AS/ NZS 3992: 1998 (Incorporating