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SKIPL /QC/P - 08
PROCEDURE MANUAL PAGE : 1 OF 4
1.0 PURPOSE
The purpose of this procedure is to establish and maintain documented
procedure to ensure that the product analysis is carried out as per the
applicable specifications / standards.
2.0 SCOPE
This procedure covers the methodology for verification of weld joint soundness
for process control, acceptance norms and clearance of machine welded fillet
welds for main columns & Ceiling Girders only.
3.0 REFERENCE
ASME SEC IX: 2010 & 2011a addenda
AWS D1.1:2010
MPS
4.0 RESPONSIBILITY
Lab Assistance / Lab In charge or Engineer In charge shall be responsible for
carrying out & evaluation of testing.
5.0 SAFETY
Before testing, an Engineer/Supervisor shall be familiar with relevant
regulations covering health safety and hazardous substances, both local and
statutory, appropriate test method.
6.2 For Fillet joint – The production test coupon shall be attached to one
end of the maximum thick Column. The size of the coupon shall be:
Flange Width: 300 mm
Flange Length: 200mm
Web Length: 200mm
Web Height: 150mm
Thickness: Same of the column
The test coupon shall be subjected to the following mechanical tests
6.2.1 Macro Examination – shall meet the requirements of fusion as
specified in AWS D 1.1
The number of passes as determined by the minimum fillet weld
size and maximum fillet weld size for a single pass shall be
verified.
8.0 METOD
8.1 Measure the thickness & width of test specimen, calculate the effective
area in (mm2) & note down in testing log register/system.
8.2 Load the sample on the machine with proper gripping of the end strips.
8.3 Start to apply load to the sample.
8.4 Note down the Ultimate Load (N) at the breaking of the sample.
8.5 Find out the results by placing the values in following formulas:
8.6 For fillet weld, cut two samples from the coupon plate & check macro test
by using suitable etching solution.
11.0 RETEST
In case of any failure, the following will be the disposition:
11.1 The cause of the failure shall be clearly established & agreed
between SKIPL & Client.
11.2 100% RT in case of columns, at location wherever not done
earlier as called for in approved QAP
11.3 Cut all the representing welds and re weld if called for in the
agreed Conclusion / actions as per clause no. 11.1 above.
11.4 in case of re - welding, re – test coupon will be approved and all
other procedure requirements shall be applicable.
12.0 RECORDS
Each production test coupon & spliced portions shall be traceable to the column
& joint.
Column number & joint number shall be punched.
Following Results of testing shall be recorded in format.
12.1 Identification of test pieces (e.g. sample ID no.).
12.2 Size of test pieces.
12.3 Test Results.
12.4 Name & designation of testing & approving personnel.
15mm Discard
Thick T Weld 150 mm
300 mm
Figure 1
Web Thick T2
Discard 15 mm 200
mm
Flange Thick T1
300 mm
Note: Figure 2
1. The sketch does not indicate the cutting allowance which is about 5 mm for each cut.
2. If the thickness is 30mm & below, Top & Bottom is not required. One tensile specimen
covering the entire thickness is enough
3. In case any weld defects are indicated by NDE, those regions should be point marked so
that it can be avoided in taking specimen. These areas should not be stamped while marking
specimen.
4. Thickness of the slice & the capacity of UTM will be based on NABL approved Laboratory
Prepared By Reviewed By Approved By