All 24.05.16
All 24.05.16
TESTING
PROCEDURES
CONTENTS
IS 1786:2008High Strength deformed steel bars and wires for concrete reinforcement
specification
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IMECH LABS ISSUE NO.: 01 REV. NO.: 00
WORK INSTRUCTION FOR TENSILE PAGE: 1 OF 4 DATE: 01.12.2015
TESTING
1.0 REFERENCE: IS: 1608/ 05, ASTM – A 370/ 15, ASTM E8/E8M, BS EN 10002-1-01
IS 1865-1991, IS 210-09, ASTM B 557-15
1.1 Tensile Test: (PERFORMED IN UNIVERSAL TESTING MACHINE).
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WORK INSTRUCTION FOR TENSILE PAGE: 2 OF 4 DATE: 01.12.2015
TESTING
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WORK INSTRUCTION FOR TENSILE PAGE: 3 OF 4 DATE: 01.12.2015
TESTING
PLOT THIS VALUES OF FORCE / EXTENSION IN A GRAPH PAPER
AND DRAW A LINE PARALLEL TO THE STRAIGHT PORTION OF
THE CURVE AT A DISTANCE EQUIVALENT TO THE PRESCRIBED
NON-PROPORTIONAL PERCENTAGE, FOR EXAMPLE 0.2 %.
CONSIDER THE FORCE AT WHICH THE LINE CUTS THE
CURVE.
THEN CALCULATE THE PROOF STRESS VALUE BY DIVIDING
THE FORCE BY ORIGINAL CROSS-SECTIONAL AREA OF THE
TEST PIECE.
MAINTAIN UNIT AS DESIRED BY THE SPECIFICATION.
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WORK INSTRUCTION FOR TENSILE PAGE: 4 OF 4 DATE: 01.12.2015
TESTING
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Diagrams As Per IS 1608:1608:2005
Initial Gauge Length is 50 mm for 12.5 mm reduced section and 80 mm for 20 mm reduced
section for these type
6
Initial gauge length calculation for plates above 3 mm thick is = 5.65 x Sqrt of
Area
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Initial gauge length calculation for Rods above 4 mm is = 5 x diameter
8
1) You can test any sample directly without any dumble shape
2) If the thickness above 25 mm then you will machined the sample
to round specimen
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Diagrams As Per ASTM A 370-15
For Sheet Type
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Diagrams As Per ASTM A 370-15
For Rod Type
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Threaded tensile samples shown in below figure
mm mm mm
G-Length of parallel Shall be equal to or greater than diameter D
D-Diameter 12.5± 0.25 0.750 ± 0.015 20.0 ± 0.40 30.0 ± 0.60
R-Radius of Þllet, min 25 25 50
A-Length of reduced section, min 32 38 60
L-Over-all length, min
95 100 160
B-Grip section, approximate
25 25 45
C-Diameter of end section,
approximate 20 30 48
E-Length of shoulder, min 6 6 8
F-Diameter of shoulder 16.0 ± 0.40 24.0 ± 0.40 36.5 ± 0.40
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Tensile Test Specimen for Tubular Products As per ASTM A370
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Diagram as Per ASTM E8/E8M for Sheet Type
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Diagram as Per ASTM E8/E8M for Rod Type
In ASTM E8M THE INITIAL GUAGE LENGTH FOR RODS IS 4 TIMES THE
DIAMETER (12.5X5=62.5 MM)
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Threaded tensile samples shown in below figure
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Tensile Test Specimen for Tubular Products as per ASTM E8/E8M
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Standard Tension test specimen for CAST IRON As Per ASTM E8/E8M
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BS EN 10002-
1-2001 IS
SAME AS IS
1608:2005
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Diagrams as Per IS 1865-1991
Tensile Test
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Diagram as Per IS 1865-1991
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Diagram as per IS 210-2009
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ASTM B 557-
15 IS SAME
AS ASTM
A 370-15
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BEND TESTING PROCEDURES
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WORK INSTRUCTION FOR BEND TEST PAGE: 1 OF 1 DATE: 01.12.2015
1.1.1 PRINCIPLE: THE TEST CONSISTS OF SUBMITTING A TEST PIECE OF ROUND, SQUARE,
RECTANGULAR CROSS SECTION TO PLASTIC DEFORMATION BY BENDING
AND WITHOUT CHANGING THE DIRECTION OF LOADING UNTIL A SPECIFIED
ANGLE OF BEND IS REACHED.
1.1.2 TEST PROCEDURE AFTER RECEIVING OF TEST SPECIMEN IN MECHANICAL LAB.
25
Diagram for Bend Test (Approximate)
26
Points to be remember for Bend Testing
4) The Length of the sample shall be minimum 210 mm and also it depending on
thickness of the sample
IS 2329:2005
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HARDNESS TESTING PROCEDURES
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IMECH LABS ISSUE NO.: 01 REV. NO.: 00
WORK INSTRUCTION FOR ROCKWELL PAGE: 1 OF 1 DATE: 01.12.2015
AND BRINELL HARDNESS
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These Tables are as per IS 1586
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In ASTM A370 CONVERSION TABLES FROM ONE HARDNESS TO OTHER
HARDNESS BASED ON NONAUSTENIC MATERIALS
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In ASTM A370 CONVERSION TABLES FROM ONE HARDNESS TO OTHER
HARDNESS BASED ON AUSTENIC MATERIALS
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For Brinell hardness Conversion Tables
37
.
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39
For HRC Testing
Load Applied is 150 Kgs
Indenter Used is DIAMOND
Reading Scale is BLACK- C SCALE
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IMPACT TESTING PROCEDURES
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WORK INSTRUCTION FOR IMPACT TESTING PAGE: 1 OF 2 DATE: 01.12.2015
12. Lift hammer slightly away from the charpy anvil and place a wooden block provided in
between and let the hammer rest on the wood on the charpy anvil.
13. Clear all tested materials from the work area and latch the safety door of the cage.
14. Report any damage to Technician before you leave.
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WORK INSTRUCTION FOR IMPACT TESTING PAGE: 1 OF 2 DATE: 01.12.2015
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WORK INSTRUCTION FOR IMPACT TESTING PAGE: 1 OF 2 DATE: 01.12.2015
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IMECH LABS ISSUE NO.: 01 REV. NO.: 00
WORK INSTRUCTION FOR IMPACT TESTING PAGE: 1 OF 2 DATE: 01.12.2015
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IMECH LABS ISSUE NO.: 01 REV. NO.: 00
WORK INSTRUCTION FOR IMPACT TESTING PAGE: 1 OF 2 DATE: 01.12.2015
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IMECH LABS ISSUE NO.: 01 REV. NO.: 00
WORK INSTRUCTION FOR IMPACT TESTING PAGE: 1 OF 2 DATE: 01.12.2015
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IMECH LABS ISSUE NO.: 01 REV. NO.: 00
WORK INSTRUCTION FOR IMPACT TESTING PAGE: 1 OF 2 DATE: 01.12.2015
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IMECH LABS ISSUE NO.: 01 REV. NO.: 00
WORK INSTRUCTION FOR IMPACT TESTING PAGE: 1 OF 2 DATE: 01.12.2015
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IMECH LABS ISSUE NO.: 01 REV. NO.: 00
WORK INSTRUCTION FOR IMPACT TESTING PAGE: 1 OF 2 DATE: 01.12.2015
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IMECH LABS ISSUE NO.: 01 REV. NO.: 00
WORK INSTRUCTION FOR IMPACT TESTING PAGE: 1 OF 2 DATE: 01.12.2015
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IMECH LABS ISSUE NO.: 01 REV. NO.: 00
WORK INSTRUCTION FOR IMPACT TESTING PAGE: 1 OF 2 DATE: 01.12.2015
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WORK INSTRUCTION FOR IMPACT TESTING PAGE: 1 OF 2 DATE: 01.12.2015
Lateral Expansion
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WORK INSTRUCTION FOR IMPACT TESTING PAGE: 1 OF 2 DATE: 01.12.2015
Calculations
1) J to J/sq cm
For Example: 27 J
3) Un-notched dimension is 8 mm
2) J to kgfm/sq cm
For Example: 27 J
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FLATTENING TESTING PROCEDURES
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IMECH LABS ISSUE NO.: 01 REV. NO.: 00
WORK INSTRUCTION FOR FLATTENING PAGE: 1 OF 1 DATE: 01.12.2015
TEST
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Diagram for Flattening Test (As per IS 2328)
Upper platen
Below platen
1) The length of the test piece no less than 10 mm or not more than 100 mm i.e. the
sample length is obtained by relevant product standard.
2) The edges of the test piece may be rounded by filing or chamfered by other
methods
3) Slight cracking at the edges shall not be considered cause for rejection.
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Samples Taken as per IS 1161:2008
Sample
Below Bed
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Samples Taken as per ASTM A530/530M
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For Seamless and Centrifugally Cast
1) Sample Length not less than 63 mm
The above Flattening test we calculate distance between the two platens
height i.e. H
H= (1+e) t / (e+t/D)
The Standard ASTM A106 Shows Height between the two platens in
the below table
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Dimensions are inches in above table
Dimensions are mm in below table
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ERICHSON CUPPING TEST PROCEDURE
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IMECH LABS ISSUE NO.: 01 REV. NO.: 00
WORK INSTRUCTION FOR ERICHSEN PAGE: 1 OF 1 DATE: 01.12.2015
CUPPING TEST
1.1.1 PRINCIPLE: Forming a cup shape by pressing a punch with a spherical end
Against a clamped test piece between a blank holder and a die until
a through crack appears. The measured depth of the cup is the result
of the test based on the movement of the-punch.
1.1.2 TEST PROCEDURE AFTER RECEIVING OF TEST SPECIMEN IN MECHANICAL LAB.
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Erichsen Cupping Test (As per IS 10175)
90 mm
45 mm
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Points to be remember for Erichsen Cupping Test
2) The edges of the test piece may be rounded by filing or chamfered by other
methods
3) Before testing, the test piece shall not be submitted to any hammering or cold or
hot working.
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Cupping Test as on IS 513-2008
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SPRING LOCK WASHER TEST PROCEDURE
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IMECH LABS ISSUE NO.: 01 REV. NO.: 00
WORK INSTRUCTION FOR SPRING LOCK PAGE: 1 OF 1 DATE: 01.12.2015
WASHERS TEST
1) Dimension test
2) Hardness test
5) Twist test
Dimension Test: - Spring lock washer looks like this below figure
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Hardness Test: -
=>The spring lock washers after coiling shall be suitably heat treated to
hardness HV (430-530).
Take two flattened and hardened washers and the hardness is not less than 60 HRC
The bolt with washers placed on lower bed of the UTM Machine
And take one pipe placed into that bolt, contact with the three washers
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After apply the compressive load on that pipe up to specified load as on table 2A, 2B
Measure the free height of the washer after release the load
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Same as the above procedure but take 10 spring washers and placed in between the
flattened washers one by one
Release the load and measure free height of the ten spring lock washers
Twist Test: -
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WELD TEST PROCEDURES FOR WELD COUPON
IBR 1950-2011 Indian Boiler Regulations, 1950
and Indian Boiler Act 1923
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IBR TEST PROCEDURE FOR WELD COUPON
IBR 1950-2011 Indian Boiler Regulations, 1950
and Indian Boiler Act 1923
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IMECH LABS ISSUE NO.: 01 REV. NO.: 00
WORK INSTRUCTION FOR IBR TEST PAGE: 1 OF 4 DATE: 01.12.2015
FOR WELD
The above figure shows how to mark the samples on weld plate
The below tests are conduct on weld plate as per IBR 1950-2011
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Transverse Tensile Test:-
When your cutting for gas cutting the tensile sample marking on the plate
shall be 45 mm why because after gas cutting will do milling of tensile
specimen total width, the width shall be 37 mm, reduced section shall be 25
mm and radius is R50
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1) In Transverse tensile test specimen is like as a tensile test and find
out the tensile strength
2) The tensile strength meets the specified value of parent metal Tensile
strength
3) Some cases the transverse tensile test broken inside the weld, in
those cases also compares the specified value of parent metal tensile
strength. The tensile strength meets the specified value then the
tensile test sample is satisfactory and the transverse tensile test is
acceptable
1) All Weld specimen cut only on hand saw machine why because will
do cut gas cutting some properties are changes due to heat.
2) The specimen cut longitudinally along the weld with the length of
180 mm and reduced section shall be not more than 20 mm as shown
in above figure.
3) In All weld specimen test like as a tensile test and to find out the
properties like as follows
a) Tensile strength
b) Yield Stress or 0.2% Proof Stress
c) % Elongation
d) % Reduction Area
4) The above properties are meets the specified values of parent metal
then the All weld test is Acceptable, if any one of the above properties
not meet the specified value then the test is not Acceptable.
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Bend Test:
80
1) The Bend Test specimen width shall be at least 30 mm
2) The surface of the specimen shall be machined just to remove the
surface irregularities of the plate and weld.
3) Where plate thickness does not exceed 38.1 mm the thickness of the
specimen shall be equal to the full thickness of the plate.
4) Where the plate thickness exceed 38.1 mm the thickness of the
specimen is reduced to 38.1 mm
Or
5) The plate thickness exceeds or equal to 38.1 mm then the plate
thickness reduced to 31.75 mm from one surface of the plate.
6) Bend tests are
a) Outer surface bend: The plate thickness more than or equal to
38.1 mm will reduce the thickness to 31.75 mm from inner surface
of the plate
b) Inner surface bend: The plate thickness more than or equal to 38.1
mm will reduce the thickness to 31.75 mm from outer surface of
the plate
7) The Bend test carried out 3 point bending as shown above figure
8) Mandrel used i.e.3T and bend angle 180°
9) Distance between the rollers after completion of test is 5.2T
Acceptance
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Impact Test:-
82
5) The above two parameters are measured with V-profile by Profile
Projector
6) The Notch cutting shall be
a) The center of the weld at outer surface
b) The center of the at Inner surface
7) Each plate have two Impact Izod test pieces
1) First take one steel bath and poured into water up to a certain level
2) Insert the samples in water steel bath
3) Insert the temperature controller sensor into that water steel bath
4) Then put a heater in to the water steel bath after that boil the water
by using heater
5) Water slowly increase the temperature and it shows on temperature
controller
6) After reaches the desired temperature will maintain the temperature
at 15 min i.e. holding time
7) Also take temperature controller sensor and put on the sample will
show temperature
8) Switch of the heater
9) Once will check the machine accuracy
10) Take the sample and put on machine, release the lock note
down the reading and same thing will do another sample also
1) J to kgfm/sq cm
For Example: 27 J
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WELD TEST PROCEDURE FOR WELD
COUPON AS PER ASME SEC-IX-2015
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WORK INSTRUCTION FOR WELD TEST FOR WELD COUPON AS PER ASME SEC-IX-2015
Section IX of the ASME Boiler and Pressure Vessel Code relates to the qualification of welders, welding
operators,brazers, and brazing operators, and the proceduresemployed in welding or brazing in
accordance with theASME Boiler and Pressure Vessel Code
1) Plate to Plate
2) Pipe to Pipe
WPS
WPS Tests to be conducted on Weld Plate or Pipe
1) Transverse tensile test - 2 No’s
2) Face Bend Tests - 2 No’s
3) Root Bend Tests - 2 No’s
4) Side Bend Tests - 4 No’s
Supplementary test
1) Impact Test
Plate to Plate and Pipe to Pipe WPS Test: The plates are like this
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Based on ASME SEC-IX the above test divided into two parts
a) Less than 10mm or equal to 10 mm plate thickness
b) Greater than 10 mm plate thickness
The below diagrams shown how to mark the samples on BUTT WELD coupon for plates
and pipes
The standard size of the WPS plate is 300 mm length X 250 mm Wide
Figure-1 Figure-2
Figure-3 Figure-4
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The above figures (1, 2) discard portion of the sample is 25 mm
1) Transverse Tensile Test - 2 No’s - Marking for this test is 35 mm for gas cut
2) Face bend Tests - 2 No’s - Marking for this test is 40 mm for gas cut
3) Root Bend Tests - 2 No’s - Marking for this test is 40 mm for gas cut
1) Transverse Tensile Test - 2 No’s -Marking for this test is 35 mm for gas cut
2) Side Bend Tests - 4 No’s -Marking for this test is 15 mm for gas cut
Sample preparation
Transverse Tensile Test: - Standard Specimen as Per ASME SEC-IX
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1) When you choose gas cutting the tensile sample marking on the plate or pipe shall be 35 mm
why because after gas cutting will do milling of tensile specimen total width, the width shall
be 31 mm, reduced section shall be 19 mm and radius is R25mm
2) In Transverse tensile test specimen is like as a tensile test and find out the tensile strength
3) The tensile strength meets the specified value of parent metal Tensile strength
4) Some cases the transverse tensile test broken inside the weld, in those cases also
compares the specified value of parent metal tensile strength. The tensile strength
meets the specified value then the tensile test sample is satisfactory and the
transverse tensile test is acceptable
5) In ASME SEC-IX if the specimen breaks in the base metal outside of the weld or
weld interface, the test shall be accepted as meeting the requirements, provided the
strength is not more than 5% below the minimum specified tensile strength of the
base metal.
6) In case of thickness is greater than 38 mm then it will take multiple Transverse
tensile specimens
7) Multiple tensile specimens are also follow same diagram as shown above QW
462.1(a) in ASME SEC-II
8) Transverse Tensile Test specimen dimensions (Diagram) are same at any Plate
thickness. As given above two figures for Plate QW 462.1(a) and for Pipe QW
462.1(b).
Face Bend and Root Bend tests:
As shown in below figures
88
1) The Plate or Pipe thickness less than or equal to 10 mm then only we take Face &
Root bend specimens
2) 2 No’s Root bends & 2 No’s Face bends samples are taken in WPS Test.
3) When you choose gas cutting the face bend and Root bend samples mark on the
plate or pipe shall be 40 mm why because after gas cutting will do milling of
bend specimen total width is 38 mm as per standard.
4) In face & Root bend specimens use the mandrel size is 4T,and bend an angle of
180°
5) The length of the specimen is 150 mm (min) or as required for bend test.
6) You are doing Face bend test the mandrel is put on the root side of the weld then
only face side of the weld comes outer surface as well as Root bend also the
mandrel put on the face side of the weld then only Root side of the weld comes
outer surface
7) Distance between the rollers = mandrel +2xT
8) After test will have to observer any cracks on the weld and corners also.
9) The Acceptance of cracks is not over the 3mm on the weld curved surface.
In Pipe Face bend and Root bend test specimen width is vary at lower diameters in that
cases will take the width of the bend specimens is like as follows
Note:
1) If the pipe being tested has a diameter of NPS 4 (DN 100) or less, the width of the bend specimen
may be 3/4 in. (19 mm)
2) For pipe diameters NPS 2 (DN 50) to and including NPS 4 (DN 100). The bend specimen width may be
3/8 in. (10 mm)
3) for pipe diameters less than NPS 2 (DN 50) down to and including NPS 3/8 (DN 10) and as an
alternative, if the pipe being tested is equal to or less than NPS 1 (DN 25) pipe size, the width of the
bend specimens may be that obtained by cutting the pipe into quarter sections, less an allowance for
saw cuts or machine cutting. These specimens cut into quarter sections are not required to have one
surface machined flat as shown in QW-462.3(a). Bend specimens taken from tubing of comparable
sizes may be handled in a similar manner.
89
Side bend Tests:
1) The Plate or Pipe thickness greater than 10 mm then only we take Side bend
specimens
2) 4 No’s Side bends samples are taken in WPS Test.
3) When you choose gas cutting the Side bend samples mark on the plate or pipe
shall be 15 mm why because after gas cutting will do milling of bend specimen
total width is 10 mm as per standard.
4) In Side bend specimens use the mandrel size is 4T or Ø40 ,and bend an angle of
180°
5) The length of the specimen is 150 mm (min) or as required for bend test.
6) Why the mandrel is 40 mm Dia for all thickness is the side bend specimen width
taken as 10 mm as per standard and will apply the load on the sample is side of
the weld in that cases the width is converted into thickness and the thickness is
converted into width. So width =10 mm converted into thickness that’s why will
choose a mandrel size is 40 Dia for thickness greater than 10 mm plates or pipes.
7) You are doing side bend test the mandrel is put on the side of the weld then only
total surface of the weld comes outer surface
8) Distance between the rollers = mandrel +2xT
9) If the plate or Pipe thickness above 38 mm will do multiple Side bend Specimens.
10)After test will have to observer any cracks on the weld and corners also.
Observation: The Acceptance of cracks is not over the 3mm on the weld curved surface.
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WPQ
WPS Tests to be conducted on Weld Plate or Pipe
1) Face Bend Test - 1 No
2) Root Bend Test - 1 No
3) Side Bend Tests - 2 No’s
Based on ASME SEC-IX the above test divided into two parts
c) Less than 10mm or equal to 10 mm plate thickness
d) Greater than 10 mm plate thickness
The below diagrams shown how to mark the samples on BUTT WELD coupon for plates
and pipes
Figure-5 Figure-6
Figure-7 Figure-8
91
The above figures (5, 6) discard portion of the sample is 25 mm
1) Face bend Test - 1 No - Marking for this test is 40 mm for gas cut
2) Root Bend Test - 1 No - Marking for this test is 40 mm for gas cut
3) Side Bend Tests - 2 No’s -Marking for this test is 15 mm for gas cut
1) The Plate or Pipe thickness less than or equal to 10 mm then only we take Face &
Root bend specimen
2) 1 No’s Root bend & 1 No’s Face bend samples are taken in WPQ Test.
3) When you choose gas cutting the face bend and Root bend samples mark on the
plate or pipe shall be 40 mm why because after gas cutting will do milling of
bend specimen total width is 38 mm as per standard.
4) In face & Root bend specimens use the mandrel size is 4T,and bend an angle of
180°
5) The length of the specimen is 150 mm (min) or as required for bend test.
92
6) You are doing Face bend test the mandrel is put on the root side of the weld then
only face side of the weld comes outer surface as well as Root bend also the
mandrel put on the face side of the weld then only Root side of the weld comes
outer surface
7) Distance between the rollers = mandrel +2xT
8) After test will have to observer any cracks on the weld and corners also.
9) The Acceptance of cracks is not over the 3mm on the weld curved surface.
In Pipe Face bend and Root bend test specimen width is vary at lower diameters in that
cases will take the width of the bend specimens is like as follows
Note:
1) If the pipe being tested has a diameter of NPS 4 (DN 100) or less, the width of the bend specimen
may be 3/4 in. (19 mm)
2) For pipe diameters NPS 2 (DN 50) to and including NPS 4 (DN 100). The bend specimen width may be
3/8 in. (10 mm)
3) for pipe diameters less than NPS 2 (DN 50) down to and including NPS 3/8 (DN 10) and as
an alternative, if the pipe being tested is equal to or less than NPS 1 (DN 25) pipe size, the
width of the bend specimens may be that obtained by cutting the pipe into quarter sections,
less an allowance for saw cuts or machine cutting. These specimens cut into quarter
sections are not required to have one surface machined flat as shown in QW-462.3(a). Bend
specimens taken from tubing of comparable sizes may be handled in a similar manner.
1) The Plate or Pipe thickness greater than 10 mm then only we take Side bend
specimens
2) 2 No’s Side bends samples are taken in WPQ Test.
3) When you choose gas cutting the Side bend samples mark on the plate or pipe
shall be 15 mm why because after gas cutting will do milling of bend specimen
total width is 10 mm as per standard.
4) In Side bend specimens use the mandrel size is 4T or Ø40 ,and bend an angle of
180°
5) The length of the specimen is 150 mm (min) or as required for bend test.
6) Why the mandrel is 40 mm Dia for all thickness is the side bend specimen width
taken as 10 mm as per standard and will apply the load on the sample is side of
the weld in that cases the width is converted into thickness and the thickness is
converted into width. So width =10 mm converted into thickness that’s why will
choose a mandrel size is 40 Dia for thickness greater than 10 mm plates or pipes.
93
7) You are doing side bend test the mandrel is put on the side of the weld then only
total surface of the weld comes outer surface
8) Distance between the rollers = mandrel +2xT
9) If the plate or Pipe thickness above 38 mm will do multiple Side bend Specimens.
10)After test will have to observer any cracks on the weld and corners also.
Observation: The Acceptance of cracks is not over the 3mm on the weld curved surface.
94
WELD TEST PROCEDURE FOR WELD
COUPON AS PER AWS D1.1/1.1M-2015
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WORK INSTRUCTION FOR WELD TEST FOR WELD COUPON AS PER AWS D1.1/1.1M-2015
1) Plate to Plate
2) Pipe to Pipe
WPS
WPS Tests to be conducted on Weld Plate or Pipe
1) Transverse tensile test - 2 No’s
2) Face Bend Tests - 2 No’s
3) Root Bend Tests - 2 No’s
4) Side Bend Tests - 4 No’s
Supplementary test
5) Charpy Impact tests - 2 Sets(one set is WELD other one is HAZ)
Plate to Plate and Pipe to Pipe WPS Test: The plates are like this
96
Based on AWS D1.1/1.1 M the above test divided into two parts ON PLATES,
PIPES, and TUBES
a) Less than 10mm or equal to 10 mm plate thickness
b) Greater than 10 mm plate thickness
The below diagrams shown how to mark the samples on BUTT WELD coupon for plates
The standard size of the WPS plate is 380 mm length X 360 mm Wide
Figure-1 Figure-2
The below diagrams shown how to mark the samples on BUTT WELD coupon for Pipes
Figure-3 Figure-4
97
Figure-5
1) Transverse Tensile Test - 2 No’s - Marking for this test is 35 mm for gas cut
2) Face bend Tests - 2 No’s - Marking for this test is 30 mm for gas cut
3) Root Bend Tests - 2 No’s -Marking for this test is 30 mm for gas cut
4) Charpy Impact Test(if Reqd) - 2 sets - Marking for this test is 100x100 mm for gas cut
Note: If Pipe O.D is >100 mm & the pipe wall thickness is <10 mm the face bend and Root
bend specimens width is 42 mm for gas cut why because the width of the specimen is 40
mm as per standard
1) Transverse Tensile Test - 2 No’s -Marking for this test is 35 mm for gas cut
2) Side Bend Tests - 4 No’s -Marking for this test is 15 mm for gas cut
3) Charpy Impact Test(if Reqd) - 2 sets - Marking for this test is 100x100 mm for gas cut
1) Transverse Tensile Test - 2 No’s -Marking for this test is 35 mm for gas cut
2) Side Bend Tests - 4 No’s -Marking for this test is 15 mm for gas cut
Or
3) Face bend Tests - 2 No’s - Marking for this test is 42 mm for gas cut
4) Root Bend Tests - 2 No’s - Marking for this test is 42 mm for gas cut
5) Charpy Impact Test(if Reqd) - 2 sets -Marking for this test is 100x100 mm for gas cut
Note: If TUBE or PIPE thickness <10 mm the face bend and Root bend specimens width is
42 mm for gas cut why because the width of the specimen is 40 mm as per standard
Note: If TUBE or PIPE thickness >10 mm the side bend specimens width is 15 mm for gas
cut why because the width of the specimen is 10 mm as per standard
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Sample preparation
Transverse Tensile Test: - Standard Specimen as Per AWS D 1.1/1.1M
1) When you choose gas cutting the tensile sample marking on the plate or pipe shall
be 35 mm why because after gas cutting will do milling of tensile specimen total
width, the width shall be 32 mm, reduced section shall be 20 mm and radius is
R25mm & Smaller diameters like 50 mm & 75 mm diameter the reduced section
shall be 12 mm and width of grip section shall be 24 mm but radius is same.
2) In Transverse tensile test specimen is like as a tensile test and find out the tensile
strength
3) The tensile strength meets the specified value of parent metal Tensile strength
4) Some cases the transverse tensile test broken inside the weld, in those
cases also compares the specified value of parent metal tensile strength.
The tensile strength meets the specified value then the tensile test sample
is satisfactory and the transverse tensile test is acceptable
5) In case of thickness is greater than 38 mm then it will take multiple
Transverse tensile specimens
6) Multiple tensile specimens are also follow same diagram as shown above
Figure
7) Transverse Tensile Test specimen dimensions (Diagram) are same at
any Plate or Pipe or Tube any thickness except for smaller diameter
of Pipe
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Face Bend and Root end tests:
As shown in below figures
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Side bend Tests:
1) The Plate or Pipe or Tube thickness greater than 10 mm then only we take
Side bend specimens
2) 4 No’s Side bends samples are taken in WPS Test.
3) When you choose gas cutting the Side bend samples mark on the plate or pipe
shall be 15 mm why because after gas cutting will do milling of bend specimen
total width is 10 mm as per standard.
4) In Side bend specimens use the mandrel size is depend upon the
yield stress of the parent metal please see below and bend an angle
of 180°
Yield stress Dia of the mandrel
Under 345 Mpa 38.1 mm
345 MPa to 620 MPa 50.8 mm
Over 620 MPa 63.5 mm
5) The length of the specimen is 150 mm (min) or as required for bend test.
6) You are doing side bend test the mandrel is put on the side of the weld then only
total surface of the weld comes outer surface
7) Distance between the rollers = mandrel +2xT
8) If the plate or Pipe thickness above 38 mm will do multiple Side bend Specimens.
10) After test will have to observer any cracks on the weld and corners also.
Observation: The Acceptance of cracks is not over the 3mm on the weld curved surface
and not more than 6 mm on corner cracks.
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WPQ
WPS Tests to be conducted on Weld Plate or Pipe
1) Face Bend Test - 1 No
2) Root Bend Test - 1 No
3) Side Bend Tests - 2 No’s
Based on AWS D 1.1/1.1 M the above test divided into two parts
c) Less than 10mm or equal to 10 mm plate thickness
d) Greater than 10 mm plate thickness
The below diagrams shown how to mark the samples on BUTT WELD coupon for plates,
pipes, Tubes
Figure-5 Figure-6
Figure-7 Figure-8
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Figure-9
The above figures (5, 6) discard portion of the sample is 25 mm
1) Face bend Test - 1 No - Marking for this test is 42 mm for gas cut
2) Root Bend Test - 1 No - Marking for this test is 42 mm for gas cut
3) Side Bend Tests - 2 No’s -Marking for this test is 15 mm for gas cut
1) Face bend Test - 1 No - Marking for this test is 42 mm for gas cut
2) Root Bend Test - 1 No - Marking for this test is 42 mm for gas cut
Or
3) Side Bend Tests - 2 No’s -Marking for this test is 15 mm for gas cut
Based on that AWS D 1.1 says take the samples into three positions there are
1) Center weld V-Notch( 3 specimens)
2) Fusion line +1 mm V-Notch (3 specimens)
3) Fusion line +5 mm V-Notch (3 specimens)
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As per weld joint will take the samples.
106
107
WELD TEST PROCEDURE FOR WELD
COUPON AS PER BS EN ISO 15614-
1-2004+A2-2012
BS EN ISO 15614-1-2004+A2:2012Specification
and Qualification of welding procedures for Metallic
Materials-Welding Procedure Test-Part: 1-Arc and
Gas welding of steels and Arc welding of Nickel and
Nickel alloys
108
WORK INSTRUCTION FOR WELD TEST FOR WELD COUPON AS PER BS EN ISO 15614
Based on BS EN ISO 15614 the above test divided into two parts
a) Less than 12mm
b) Greater than and equal to 12 mm plate thickness
The below diagrams shown how to mark the samples on BUTT WELD coupon for plates
and pipes
Figure-1
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Figure-2
110
Sample preparation
111
1) When you choose gas cutting the tensile sample marking on the plate or pipe shall
be 40,30,20 mm why because after gas cutting will do milling of tensile specimen
total width, the width shall be 37, 24,12 mm, reduced section shall be 25,12,6 mm
respectively and radius is R25mm
2) In Transverse tensile test specimen is like as a tensile test and find out the tensile
strength
3) The tensile strength meets the specified value of parent metal Tensile strength
4) Some cases the transverse tensile test broken inside the weld, in those
cases also compares the specified value of parent metal tensile strength.
The tensile strength meets the specified value then the tensile test sample
is satisfactory and the transverse tensile test is acceptable
5) In case of thickness is greater than 30 mm then it will take multiple
Transverse tensile specimens
6) Multiple tensile specimens are also follow same diagram as shown
above figures
7) Transverse Tensile Test specimen dimensions (figure 1 & 2) are
same at anyPlate thickness. As given above two figures for Plate and
for Pipe.
8) In Case for dissimilar metal joints the Tensile Strength shall not be
less than the minimum value specified for the parent metal having
the lowest Tensile Strength.
1) The Plate or Pipe thickness less than 12 mm then only we take Face &
Root bend specimens
2) 2 No’s Root bends & 2 No’s Face bends samples are taken in WPS Test.
3) When you choose gas cutting the face bend and Root bend samples
mark on the plate or pipe shall be 25 mm why because after gas
cutting will do milling of bend specimen total width is 20 mm as per
standard.
4) In face & Root bend specimens use the mandrel size is 4T,and bend
an angle of 180°
5) The length of the specimen is 150 mm (min) or as required for bend test.
For example Plate thickness is 10 mm = The Mandrel used is 4T =4x10=40 mm Dia
For example Plate thickness is 8 mm = The Mandrel used is 4T = 4x8=32 mm Dia
For example Plate thickness is 6 mm = The Mandrel used is 4T = 4x6=24 mm Dia
For example Plate thickness is 3 mm = The Mandrel used is 4T = 4x3=12 mm Dia
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6) You are doing Face bend test the mandrel is put on the root side of the
weld then only face side of the weld comes outer surface as well as Root
bend also the mandrel put on the face side of the weld then only Root
side of the weld comes outer surface
7) Distance between the rollers = mandrel +2xT
8) After test will have to observer any cracks on the weld and corners also.
9) The Acceptance of cracks is not over the 3mm on the weld curved surface and the
corner cracks are ignored.
1) The Plate or Pipe thickness greater than and equal to 12 mm then only we
take Side bend specimens
2) 4 No’s Side bends samples are taken in WPS Test.
3) When you choose gas cutting the Side bend samples mark on the plate or pipe
shall be 15 mm why because after gas cutting will do milling of bend specimen
total width is 10 mm as per standard.
4) In Side bend specimens use the mandrel size is 4T or Ø40 ,and bend an angle of
180°
5) The length of the specimen is 150 mm (min) or as required for bend test.
For example Plate thickness is 16 mm = The Mandrel used is 4T = 4x10=40 mm Dia
For example Plate thickness is 28 mm = The Mandrel used is 4T = 4x10=40 mm Dia
For example Plate thickness is 60 mm = The Mandrel used is 4T = 4x10=40 mm Dia
For example Plate thickness is 100 mm = The Mandrel used is 4T = 4x10=40 mm Dia
6) Why the mandrel is 40 mm Dia for all thickness is the side bend specimen width
taken as 10 mm as per standard and will apply the load on the sample is side of
the weld in that cases the width is converted into thickness and the thickness is
converted into width. So width =10 mm converted into thickness that’s why will
choose a mandrel size is 40 Dia for thickness greater than 10 mm plates or pipes.
7) You are doing side bend test the mandrel is put on the side of the weld then only
total surface of the weld comes outer surface
8) Distance between the rollers = mandrel +2xT
9) If the plate or Pipe thickness above 40 mm will do multiple Side bend Specimens.
10) After test will have to observer any cracks on the weld and corners also.
Observation: The Acceptance of cracks is not over the 3mm on the weld curved surface.
113
Charpy Impact Tests: As Per EN 875
Charpy V-Notch angle 45° and Notch Depth 2 mm
Different types of weld shapes and samples taken as shown in above figure
Important:
Specification
114
Hardness Test (Vickers) : As Per EN 1043-1
115
Macroscopic Examination Test: As Per EN 1321
The examination of the test piece by naked eye, under low magnification, with or without
etching.
Abbreviations.
Purpose of Test
116
Removal of Test Piece
Etching Methods
Report
117
WELD TEST PROCEDURE FOR WELD
COUPON AS PER API 1104 - 2014
118
WORK INSTRUCTION FOR WELD TEST FOR WELD COUPON AS PER API 1104
This standard covers the gas and arc welding of butt, fillet, and socket welds in carbon
and low-alloy steel piping used in the compression, pumping, and transmission of crude
petroleum, petroleum products, fuel gases, carbon dioxide, nitrogen, and where applicable,
covers welding on distribution systems. It applies to both new construction and in service
welding. The welding may be done by a shielded metal arc welding, submerged arc welding, gas
tungsten arc welding, gas metal arc welding, flux-cored arc welding, plasma arc welding,
oxyacetylene welding, or flash butt welding process or by a combination of these processes
using a manual, semiautomatic, mechanized, or automatic welding technique or a combination
of these techniques. The welds may be produced by position or roll welding or by a
combination of position and roll welding.
This standard also covers the procedures for radiographic, magnetic particle, liquid
penetrant, and ultrasonic testing, as well as the acceptance standards to be applied to
production welds tested to destruction or inspected by radiographic, magnetic particle, liquid
penetrant, ultrasonic, and visual testing methods.
1) Pipe to Pipe
WPS
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Based on API 1104 the above test divided into two parts
a) Less than 12.7 mm Wall thickness
b) Greater than 12.7 mm Wall thickness
The below diagrams shown how to mark the samples on BUTT WELD coupon pipes
120
The below table shows how many samples and what types of tests to be conducted in WPS
Sample preparation
Transverse Tensile Test: - Standard Specimen as Per API 1104-2014
OR
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1) When you choose gas cutting the tensile sample marking on the pipe shall be 30 mm why
because after gas cutting will do milling of tensile specimen total width, the width shall be
25 mm (Figure (a)). OR The Tensile specimen preparation as shown in above figure (b).
2) In Transverse tensile test specimen is like as a tensile test and find out the tensile strength
3) The tensile strength meets the specified value of parent metal Tensile strength
4) Some cases the transverse tensile test broken inside the weld, in those cases also
compares the specified value of parent metal tensile strength. The tensile strength
meets the specified value then the tensile test sample is satisfactory and the
transverse tensile test is acceptable
5) In API 1104 if the specimen breaks in the base metal outside of the weld or weld
interface, the test shall be accepted as meeting the requirements, provided the
strength is not more than 5% below the minimum specified tensile strength of the
base metal.
6) Thickness is as Material thickness.
1) The Pipe Wall thickness less than 12.7 mm then only we take Face & Root bend
specimens
2) Root bends & Face bends samples are taken in WPS Test follow above table.
3) When you choose gas cutting the face bend and Root bend samples mark on the
Pipe shall be 30 mm why because after gas cutting will do milling of bend
specimen total width is 25 mm as per standard.
4) In face & Root bend specimens use the mandrel size is 90 mm, Distance
between the rollers is 120 mm and bend an angle of 180°
5) The length of the specimen is 230 mm (min) or as required for bend test.
6) You are doing Face bend test the mandrel is put on the root side of the weld then
only face side of the weld comes outer surface as well as Root bend also the
mandrel put on the face side of the weld then only Root side of the weld comes
outer surface
7) Distance between the rollers = 120 mm
8) After test will have to observer any cracks on the weld and corners also.
9) The Acceptance of cracks is not over the 3mm on the weld curved surface and not more
than 6 mm at corner radius cracks.
122
Side bend Tests:
As shown in below figure
1) The Pipe wall thickness greater than 12.7 mm then only we take Side bend
specimens
2) Side bends samples are taken in WPS Test as shown above table.
3) When you choose gas cutting the Side bend samples mark on the plate or pipe
shall be 19 mm why because after gas cutting will do milling of bend specimen
total width is 13 mm as per standard.
4) In Side bend specimens use the mandrel size is 90 mm, Distance between the
rollers is 120 mm and bend an angle of 180°
5) The length of the specimen is 230 mm (min) or as required for bend test.
6) You are doing side bend test the mandrel is put on the side of the weld then only
total surface of the weld comes outer surface
7) Distance between the rollers = 120 mm
8) After test will have to observer any cracks on the weld and corners also.
Observation: The Acceptance of cracks is not over the 3mm on the weld curved surface
and not more than 6 mm on corner radius cracks.
123
Nick Break Test:
As Shown in below figure
1) When you choose gas cutting the Nick Break sample marking on the pipe shall be
30 mm why because after gas cutting will do milling of Nick Break specimen total
width, the width shall be 25 mm (Figure (5)).
2) The Nick Break test specimen is like as a tensile test Procedure and find out the
defects inside the weld.
3) The Nick Break sample preparation is shown in above figure, cut 3 mm groove one
side of the sample,3 mm groove cut another side of the sample in the pipe thickness
& 1.6 mm groove cut top and 1.6 mm groove cut on bottom of the sample along the
weld after will do Nick break test.
Acceptance
124
Bend Set up Diagram
125
REPAIR PROCEDURE FOR WPS TEST
Qualification
The above three test already discussed in WPS test. Dimensions are same in Repair
procedure also.
In repair procedure additional tests are added there are
126
1) Macro Test
2) Hardness Test
3) Charpy Impact Test
Macroscopic Examination
Hardness Test
127
128
Charpy Impact Test
Charpy Impact Testing shall be performed at locations in the weld as specified company
Acceptance
129
WPQ
WPS Tests to be conducted on Weld Pipe Only
1) Transverse tensile test
2) Face Bend Tests
3) Root Bend Tests
4) Side Bend Tests
5) Nick Break Tests
Based on API 1104 the above test divided into two parts
c) Less than 12.7 mm Wall thickness
d) Greater than 12.7 mm Wall thickness
The below diagrams shown how to mark the samples on BUTT WELD coupon pipes
130
1) The above tests are already discussed in WPS
2) All tests dimensions are same as WPS test
3) Based on above table will take the samples and tests to be conducted
Based on above table -7 take the sample and conduct test on welded pipe
131
TMT BARS TEST PROCEDURE
132
WORK INSTRUCTION FOR TMT BARS AS PER IS 1786-2008
REFERENCE: IS 1786-2008
Procedure:
1) Take the sample 1 meter length of TMT bar
2) Put the sample on weighing machine and take the weight in terms of kgs
3) Note down the reading and compare the value to standard weight in specification.
4) Based on that confirm TMT bar is Acceptable or Not.
in
133
Tensile Test:
134
Bend Test:
Re-bend Test:
135
Ar value of TMT bar:
Ar means The mean projected rib area per unit length(sq mm/mm)
Calculation of Ar is
Ar=A x N x sin θ / S
A= Area of rib (sq mm)
N=Number of transverse ribs
First calculate A i.e.
136