sc qual 145r4-10 combined document finnish proposal and checklist dvs-zert germany iso 3834.pdf

8/13/2019 SC Qual 145r4-10 Combined Document Finnish Proposal and Checklist DVS-Zert Germany ISO 3834.pdf

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International Institute of WeldingA world of jo in ing experience

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SC-Qual-145r4-10

Improving the quality and effectiveness of welding by utilizing the standard ISO3834

Objective

The objective of this publication is to provide companies intending to apply the standardISO 3834 dealing with the quality management of welding, advice on the kind ofprocedures and forms that might be beneficial to them and on the content of suchprocedures. This publication primarily deals with the adoption of ISO 3834-2, but much ofthe advice is also applicable to ISO 3834-3 and ISO 3834-4.

This publication does not mean that all the procedures presented in it are necessarilyrequired. Once the company has thoroughly considered its needs and has decided that itrequires a certain procedure, this publication can be used in order to find advice for thepreparation of the procedure. The publication should not be used as requirements forprocedures or check-lists in connection with audits.

Abst ract

This publication is primarily intended for people who are responsible for quality control inthe field of welding. Because the items presented in this publication may have asignificant impact on a companys business operations and their successful continuation,the publication will be a useful tool also for strategic and operational managers. Thispublication also deals with matters relating to the sale and marketing of products.Therefore the sales personnel of welded products shall understand, in order to ensurethat the products sold are manufactured in accordance with the designs, in a controlledmanner and with minimal risk.

ISO 3834-1 gives the instructions for the selection of the level of quality requirements,while ISO 3834-2, 3,and 4 present quality requirements of different levels. Manufacturersof certain welded products, such as pressure vessels, offshore structures and steelstructures, may need to comply with the quality requirements of ISO 3834 required byapplicable product standards. Foreign customers may also require compliance with theserequirements as well as major export companies of their own subcontractors. A companymay gain considerable benefit from applying these standards, even without third partycertification. It is possible to certificate the standard ISO 3834-2 as part of ISO 9001quality management system or ISO 3834-2, -3 and -4 can be certificated on their own.

ISO 3834 presents systematically and comprehensively the factors and measures having

an impact on the quality in welding, which a company can develop in order to improve themanageability of its production, the quality of its products and the reliability of its lead


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times as well as the cost-effectiveness of its manufacturing process. For the company it isimportant to identify properly those items that will be subject to the requirementspresented in ISO 3834-2, 3, and 4. The aim is to avoid unnecessary documentation andprocedures and ensure that the quality management is appropriate for the weldedproducts to be manufactured. This publication gives examples of the key procedures andthe related work instructions and forms.

The key issues to be taken into account in the quality management of welding:

Technical review verifies the companys capabilities for manufacturing the productthat has been ordered and identifies particular welding requirements related to thecontract. Only a correctly conducted technical review ensures well-managed, risk-free

and cost-effective production. Competence requirements specified for the welding personnelwill, in the case ofsome workshops, be clearly different from present practice. Product liability givesadditional emphasis on the responsibilities and role of the welding coordinationpersonnel. The requirements relating to qualification of welders and welding operatorsstrengthens the quality management of welding and can also reduce costs caused byerrors. The standard may not bring any significant changes to the current practiceregarding inspection personnel.

Production plan and qualified welding procedures assure that production iscarried out systematically and the characteristics of the welded joints meet the specified

requirements. There are several alternatives for the method of qualifying weldingprocedures and the company shall apply the one that is technically and economicallythe most appropriate for the product concerned.

Description of production and testing equipment used in connection with weldingallows the company to check the suitability of its equipment pool for the manufacturingand inspection of the product it sells. Acceptance tests of equipment, regularmaintenance and possible calibration or validation, in order to ensure that it will bepossible to follow the welding procedures sufficiently and that the inspection and testingresults are reliable.

Systematic dealing of non conformancesensures that a defective product is not putinto service by mistake. The reasons for non conformances are analysed and correctiveactions carried out in order to prevent similar non conformances in the future.

Adopting ISO 3834-2, 3, or 4 requires considerable time and effort by the company, withall the personnel being committing to the work and the additional activities required:developing work practices, performing new duties, ensuring the flow of information, etc.When the implementation starts it might be advantageous to engage external expertise inorder to obtain an objective picture of the starting point. The company may decide tofocus on reaching a point where the conditions are fit for certification by documentationand procedures for tasks and activities, but the real economic and technical benefit fromthe adoption of ISO 3834 will be achieved only when the activities and contentconcerning the welding work are developed. For this reason, ISO 3834-2, 3, and 4 should

be understood primarily as a tool for developing the welding activities in the company.


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Contents Page1. General 4

2. Reasons for using ISO 3834 4

3. Choice of quality requirement level 5

4. Procedures and forms 6

4.1 General 6

4.2 Purpose and content 7

4.3 Relevant procedures and forms/check lists 8

4.4 Review of requirements 104.5 Technical review 11

4.6 Sub-contracting 14

4.7 Welding and associated personnel 17

4.8 Inspection and testing personnel 19

4.9 Equipment 19

4.10 Welding and related activities 21

4.11 Storage and handling of welding consumables 22

4.12 Storage of parent material 23

4.13 Post- weld heat treatment 244.14 Inspection and testing 25

4.15 Non-conformance and corrective actions 27

4.16 Calibration and validation of measuring, inspection and testing equipment

4.17 Identification and traceability 29

4.18 Quality records 30

5. Need for certification 32

6. Adopting standard 3834 in a company 33

AnnexesA Example of check list for technical review 35

B Example of procedural guidelines for welders qualification test 37

1 General


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Welding is a general production method for manufacturing of metal products. Welding hasa considerable impact on both the products costs and quality. Consequently, it isimportant that the welding is carried out as efficiently as possible, meeting all specifiedquality requirements.

Weld quality is achieved by sound welding, not by inspection. Inspection, however,provides a check of the reliability of the product, but cannot improve poor quality. Weldingrequires continuous control and/or to follow documented procedures. On this basis, theISO 3834 series of welding standards has been prepared.

The purpose of the ISO 9000 series is that the company designates as a special processany work where the final quality of the product cannot be verified only by inspection. Ifquality requirements are specified for the welds in the product, it is appropriate to definewelding as a special process.

It shall be observed that ISO 3834 is not a quality control standard that replaces ISO9001, but more an auxiliary tool for applying ISO 9001 in companies which carry outwelding as a special process. In such a case, the additional compliance with ISO 3834will be included by a reference in the ISO 9001 quality system. It is also possible to obtaincertification under ISO 3834 without any linkage to the ISO 9001 quality system.

The standards are general and not fixed to any certain product. The series of standardsrefers to three different levels of quality requirements:

- ISO 3834-2 Comprehensive quality requirements- ISO 3834-3 Standard quality requirements- ISO 3834-4 Basic quality requirements.

Guidance for the choice of level of quality requirements is given in ISO 3834-1. ISO 3834-5 specifies documents and standards necessary to consider in order to claim conformityto ISO 3834-2, 3, or 4.

2 Reasons for using ISO 3834

Regulations

Regulations, eg, EU directives, define safety requirements on products and structures.Product standards present the technical solutions that serve to fulfil the safetyrequirements specified in the directives.

Product standards

Many European and some International product standards refer to the different parts ofISO 3834 regarding welding. For example, the standard concerning pressure vessels (EN13445) states that the manufacturer of the pressure vessel is obliged to fulfil as aminimum the welding quality requirements given in ISO 3834-3.

The European standard EN 1090-2, dealing with execution of steel structures, requiresthe use of quality requirements according to ISO 3834. The level of quality requirementsdepends on the execution class.


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CustomersOnce ISO 3834 is in use, companies could utilize it for marketing purposes andcustomers might require certification to ISO 3834.

The welding company(manufacturer)

The welding company wishes to improve its welding quality management system,increase productivity and, by applying quality control in welding, demonstrate to itscustomers to be a reliable supplier.

Main contractors

A subcontractor working to ISO 3834 can expect to have a significant advantage over itscompetitors, when a main contractor is outsourcing its welding or welding relatedactivities.

ISO 9001

ISO 9001 states that, where necessary, special processes shall be identified. Welding istypically considered as a special process. This requires that specific requirements, whichare specified in advance, are fulfilled. ISO 3834-2 is an excellent tool for doing this.

3 Choice of quality requirement level

ISO 3834-1 gives guidance on the choice of level of quality requirements.

When a welding company uses a quality control system conforming to ISO 9001, thecomprehensive quality requirements according to ISO 3834-2, 3, or 4 may all be selected.There are only small technical differences between ISO 3834-2 and ISO 3834-3. Themain difference is the level of documentation. ISO 3834-4, presenting basic qualityrequirements is the level of choice when the welded components have a low safety risk.Product standards and national codes may also give references to the different parts ofISO 3834. Table 1 gives a short summary of requirements for ISO 3834 in Europeanproduct standards.

Table 1 Selection of quality requirement level

Product or structure Requirements

Steel structures (EN 1090-2) Execution classes 3 and 4 ISO 3834-2Execution class 2 ISO 3834-3Execution class 1 ISO 3834-4

Pressure vessels (EN 13445) At least ISO 3834-3


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Railway vehicles (EN 15085) Certification level 1 ISO 3834-2Certification level 2 and 4 ISO 3834-3Certification level 3 ISO 3834-4

Off shore (NORSOK) ISO 3834-2

Water tube boilers (EN 12952-5) Recommends parts of ISO 3834-2

When applying ISO 3834, it should be noted that all of the items presented in thestandards do not need to be implemented, if they are not relevant. In such cases clearreasons shall be given for such a decision.

As a basis, it might be appropriate for a company to start applying the ISO 3834 byadopting the requirements of ISO 3834-2 and identifying those items that are relevantfrom the company's point of view. Care shall , however, be taken to ensure that thequality requirements specified are not lower than those presented in ISO 3834-4.

The company may also apply different levels of quality requirements for differentproducts. Although the company may have adopted the standard ISO 3834-2, it maydecide to apply lower quality requirements according to ISO 3834-3 or ISO 3834-4 inrespect of certain products or certain production lines.

4 Procedures and forms

4.1 General

Quality control may be described at three different levels:

At the general level, a description of the companys organisation, areas of responsibility,operation, equipment, personnel, etc. is given.

At the procedure level, the way in which the activity has to be performed is described aswell as responsible persons.

At the level relating to forms, the necessary forms, lists, reports, records, certificates and

detailed working instructions are prepared.Often the company is not familiar with preparing procedures. The procedures should beas simple as possible. A good procedure fits onto a single A4 sheet and is clear andconcise enough to be read without sitting down.

Not every item needs a procedure. Sometimes it is enough just to know how things haveto be done. It is often difficult to decide whether only knowing how to do things is enoughor whether written procedures are needed. Written procedures are needed, when peopleask a lot of questions, different people do the same task or when lots of mistakes aremade.

4.2 Purpose and contentThe purpose of procedure is to:


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ensure harmonised and effective working establish responsibilities in respect of tasks and work activities act as the practical starting point for preparatory work provide information act as a channel for exchanges of experience.

Procedures include e.g: purpose and scope of the work activity what is to be done and who does it (content of the procedure and the personresponsible for it) when, where and how the work activity is carried out (content of activity, person

responsible for it) materials, equipment and documents that are in use how the work activity is managed and documented.

4.3 Relevant procedures and forms/check lists

Table 2 gives procedures and forms that are appropriate according to different clauses ofISO 3834-2. Where necessary, they can also be used when applying ISO 3834-3 andISO 3834-4.

It may not be necessary to apply everything that is presented in Table 2; the companyhas fairly free hands to make the appropriate choices. Under no circumstances must the

table be used as audit requirements.The procedures provide examples of who could be the person responsible for certainwork activity. The examples are completely arbitrary. It is important to nominate theperson and ensure that the person is aware of his or her responsibilities and is also giventhe appropriate power to act.

Table 2 Useful procedures and forms/check lists

Clause in ISO

3834-2

Procedure Form/check list

5 Review ofrequirementreview andtechnical review

5.2 Procedure for requirementreview

5.3 Procedure for technicalreview 1)

5.2 Check list forassessment

5.2 Check list forassessment

6 Sub-contracting

6.1 Procedure for sub-contracting of welding works

6.2 Procedure forsubcontracting of heat

treatment6.3 Procedure for sub-

6.1 Form forordering/checking


6.3 Form for


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contracting of testing andinspection

6.4 Procedure forsubcontracting of maintenance

6.5 Procedure forsubcontracting of calibration

6.6 Procedure for acceptancetesting

ordering/checking



6.6 Form

7 Welding

personnel

7.2 Procedure for welders and

welding operators2)

7.3 Procedure for weldingcoordinators

7.4 Procedure for otherpersonnel

7.2 File with certificates

7.3 File with CV, copiesof diplomas etc.

7.4 File

8 Inspection andtesting personnel

8.2 Procedures for testing andinspection personnel

8.2 File with copies ofqualifications

9 Equipment 9.2. Procedure for capacityand capability of equipment

9.3 Procedure for acceptanceof equipment

9.4 Procedure for starting touse equipment and recording

9.5 Procedure for maintenanceof equipment

9.2 Capacity list

9.3 Acceptance reports

9.4 List of equipment

9.5 Maintenance anddimensional reports

10 Welding andrelated activities

10.1.1 Procedure forsubassemblies

10.1.2 Procedure for flow chart

10.2 Procedure for preparationof welding procedurespecifications

10.3 Procedure for qualificationof welding procedures

10.4 Procedure for preparationof work instructions

10.5 Procedure for weldingrelated maintenance and

support

10.1.1 Welding plan

10.1.2 Flow chart

10.2 Welding procedurespecifications

10.3 Welding procedurequalification record

10.4 Work instructions


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11 Weldingconsumables

11.3 Procedure for storage andhandling of weldingconsumables

11.3 Stock list

12 Storage ofparent materials

12 Procedure for storage ofparent materials

12 Stock list

13 Post-weldheat treatment

13 Procedure for preparationof heat treatment procedurespecifications

13.1 Het treatmentprocedure specifications

13.2 Heat treatmentrecords

14 Inspectionand testing

14.2 Procedure for activitiesprior to welding

14.3 Procedure for controlduring welding

14.4 Procedure for finalinspection

14.5 Procedure for preparationof an inspection plan

14.2 Check form

14.3 Check form

14.4 Check form

14.5 Inspection plan

15 Non-

conformance andcorrective actions

15.1 Procedure when the WPS

has not been used15.2 Procedure for non-conformances by inspection

15.3 Procedure for non-conformances found afterdelivery

15.1 Non-conformance

report15.2 Non-conformancereport

15.3 Non-conformancereport

16 Calibrationand validation ofmeasuring,inspection andtestingequipment

16.1 Procedures for calibrationand validation of thermometers

16.2 Procedures for calibration

and validation of electricalmeasuring devices

16.3 Procedures for calibrationand validation of measuringdevices

16.4 Procedures for calibrationand validation of flow meters

16.1 Calibration andvalidation report

16.2 Calibration and

validation report

16.3Calibration andvalidation report

16.4 Calibration andvalidation report

17 Identificationand traceability

17.1 Procedure for markings

17.2 Procedure for transfer of

markings17.3 Procedure for

17.1 Material card

17.2 Routing cards


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identification of welders17.4 Procedure for acceptancetests

18 Qualityrecords

18 Procedure for preparingand filing of quality records

18 Record forms

1)Example, see annex A2)Example see annex B

4.4 Review of requirements

The procedure for conducting the review of requirements concerns the part of thecontract that deals with welding. The purpose of the review is to ensure:

that the company is technically and otherwise capable (e.g. delivery schedule) tofulfil all the requirements and wishes presented by the customer and

to check that all the fundamental requirements relating to the welding of theproduct are recorded.

The review of requirements shall be conducted before any offer is submitted.

The review of requirements is the responsibility of the person, e.g. sales manager orproject manager, who goes through the orders and the proposed contract. It is important

for the welding coordinator to be present when matters concerning welding in the contractare dealt with.

If there are ambiguities in the order or in the proposed contract, the person in chargesolves them together with the other parties and with the customer.

In the review of requirements the relevant items presented in clause 5.2 in ISO 3834-2are reviewed. It is useful to draft a form for dealing with the matters below. If the companyhas previously supplied an identical or similar product, it is not essential to complete theform in respect of each individual contract.

a) Product standard to be used, together with any supplementary requirements: does the product relate to any directive? doesa productstandard exist (e.g. ISO-, EN- or national standard)? does the customer have an existing product standard? quality level and acceptance criteria? the mechanical, thermal and/or chemical characteristics set for the welded joints any additional requirements?

b) Statutory and regulatory requirements

does the product relate to any regulation?c) Any additional requirement determined by the manufacturer

any additional requirements?

d) The capability of the manufacturer to meet the prescribed requirements new project?


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review of resources?4.5 Technical review

The purpose of the procedure for the technical review is to look at the matters that shallbe taken into account when reviewing the contract. The procedure deals with mattersconcerning welding.

Each company has to nominate the person who will take responsibility for these matters.That person may be, for instance, the main project designer. The welding coordinatorshall be present whenever any welding matters are discussed.

The following issues should be resolved before the procedure is prepared:

has a technical review been conducted previously (have earlier experiences beentaken into account)? what are the differences in relation to previous requirements? (any fundamentalchanges?)

The technical review should cover at least the matters presented in clause 5.3 of ISO3834-2, as described in the list below. If the product in question has been manufacturedin the past, it is not always necessary to review these matters again.

a) Specification of parent material(s) and welded joint properties: weldability chemical composition

strength ductility (impact, tensile) thickness of material corrosion resistance wear resistance high temperature characteristics quality of parent material surface other characteristics

b) Quality and acceptance requirements for welds: quality level

acceptance level acceptance criteria for welding tests

c) Location, accessibility and sequence of welds, including accessibility for inspection andfor NDT:

appropriate welding positions welding equipment being used, including feasibility of automated welding significance of the welding sequence due to distortion of the work piece at which stage of manufacturing shall inspection be performed?

d1) Welding procedures: do all necessary welding procedure specifications exist?

are welding procedure specifications required for all the joints?


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d2) Written procedures for non-destructive testing (NDT): will non-destructive testing (NDT) be conducted? will the company perform the necessary non-destructive testing itself? do the necessary written procedures exist, e.g. NDT standards, for the NDT methodsto be performed?

d3) Heat-treatment procedures: are procedures needed for pre-heating and/or post-welding heat treatment? will the company perform the necessary pre-heating/heat treatment itself? are there appropriate procedures for pre-heating/heat treatment?

e) The approach to be used for the qualification of welding procedures:

how should the welding procedures be qualified (e.g. ISO 15607)? additional requirements (e.g. product standards)? acceptance criteria for the welding procedure test are there any appropriate qualification records available?

f) Qualification of personnel: is there a responsible welding coordinator? do the welders have valid certificates for the job in hand according to ISO 9606/EN287 or other applicable standards? Are additional requirements necessary (e.g. productstandards)? are the welding operators qualified according to ISO 14732/EN 1418 or other

applicable standards? are the NDT inspectors certified according to ISO 9712 or EN 473 are there any requirements for qualification of persons carrying out heat treatment?

g1) Selection of material, identification and/or traceability: what is the parent material?, availability?, weldability/special characteristics? supplier, approved?, known? how is the parent material identified (transfer of marking)? should the parent material used in the product be traceable? are material certificates required? (what level?) approved parent material/filler material filler material? (test reports?)

g2) Selection of welders: does the work require a welder who has a valid certificate for that particular weldingjob?

g3) Identification of welds: do the welds have to be identifiable? (to the welder?)

h) Quality control arrangements, including any involvement of an independent inspectionbody:

is external quality control required during manufacture?- customer?

- third party?- when?


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i) Inspection and testing: which parts will be inspected or tested?

- scope of inspection- inspection methods- inspection stages- reporting level (everything, deviations, errors)

j) Sub-contracting: welding work (required competences and licences) NDT testing post-weld heat treatment

does the customer approve the sub-contractor? how should sub-contractors be audited? previous experience of sub-contracting, approved suppliers

k) Post-weld heat treatment: has the company taken into account the quality requirements presented in ISO 17633concerning heat treatment in connection with welding?

l) Other welding requirements: production weld tests batch testing of welding consumables determination of ferrite content of weld metal

ageing hydrogen content sufficient information on permanent backing peening surface finish weld profile (undercuts, smooth transition, shape of root, convex weld (grinding) welding plan

m) Using special methods: root opening root gas buttering

n) dimensions and details of joint preparation on completed weld: type of joint type of joint preparation groove preparation tolerances

o) Welds which are to be made in workshop, or elsewhere: where final installation takes place (on site)? are the components produced in different workshops?

p) Environmental conditions relevant to the application of processes:

low temperature wind


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moisture lightening

q) Handling of non-conformances: how to act in case of a non conformance?

- additional inspections (can the number of inspections be reduced?)- alternative inspection methods

how to proceed if modifications are required after the contract stage?- who is authorised to approve the changes?- documentation of changes?

4.6 Sub-contractingIf the company intends to use sub-contracting services (e.g. in welding, inspection, NDT,heat treatment, calibration, maintenance), he shall provide the subcontractor with all therelevant specifications and requirements. The sub-contractor shall provide the documentsand records specified by the manufacturer concerning the sub-contracted work.

4.6.1 Sub-contracting of welding

The procedures on sub-contracting shall ensure that the sub-contractor has the technicaland qualitative capabilities (capacity and know-how) to manufacture the product such thatthe product meets the requirements specified by the actual customer, comply with the

appropriate items of ISO 3834 and that the timetable requirements will be met.The person responsible for the sub-contracting matters of the company has theresponsibility to ensure that the sub-contractor meets the technical preconditions requiredof manufacturing. This person should use experts in the company, e.g. the responsiblewelding coordinator.

Scope of sub-contractor assessment

Only the part of the subcontractor's technical know-how has to be assessed as requiredfor the sub-contracting work. The scope of the assessment depends on what kind of

quality system the sub-contractor has in use. If the subcontractor works according to acertified quality system including ISO 3834-2, it will be enough just to conform thetechnical competence (capacity) and to check the equipment. A sub-contractor withoutany documented quality system should be subjected to a separate quality auditconducted by the company.

Items to be addressed with the sub-contractor

Review of requirements

A review of requirements with the sub-contractor may be performed together with thetechnical review. A review of requirements may include the following.

a) Product standard and possible additional requirements to be applied:


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the sub-contractor needs to know what standard and requirements the product hasto fulfil.

Technical review

A technical review shall be performed with the sub-contractor wherein all the essentialaspects related to the sub-contractor's work will be addressed. Consideration should alsobe given to any earlier technical reviews or similar reviews. If there is significancedifferences or changes in resources of the sub-contractor an assessment is necessary. Atechnical review may include the following.

1) Welding procedure specifications: The sub-contractor's welding procedure specifications need to be checked. If theyare not suitable for the product to be welded, the sub-contractor shall qualify newwelding procedures to comply with the product and based on these qualifications newwelding procedure specifications shall be prepared. Assessment to be made whether it is possible to use the main company's weldingprocedure specifications (standard procedures)

2) Non destruct ive testing procedures: Will NDT be performed and if so, what is the extent? Will this be done:

- by the sub-contractor- by the company itself

- by a testing company chosen by the sub-contractor- by the testing company used by the main company, which will also inspect the maincompany's own manufacturing- for which authority shall the results be presented, and who will present them?

3) Heat-treatment procedures: Is heat treatment needed? Who will be the expert for heat treatment: The main company or the sub-contractor?

4) Qualification of welding procedures: The sub-contractor's welding procedures shall be qualified by the method required bythe quality requirements of the product to be manufactured

5) Qualification of personnel: Are the qualifications of personnel adequate or does the sub-contractors personnelneed new qualifications for the product to be manufactured, eg,welders and weldingoperators? Has a responsible welding co-ordinator been nominated and what is his task? Is the responsible welding co-ordinator employed by the sub-contractor?

6) Material

Does the main company deliver materials to the sub-contractor and how are theseidentified and separated from the subcontractor's own materials?

If the subcontractor buys the material, the following need to be specified:- Type of material (e.g. standard, composition, dimensional tolerances, etc.).


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- Quality requirements for materials- Approvals, material certificates required- Requirements for identification and traceability of the material

7) Selection and identification of welders: Where necessary, the same level as applied by the main company

8) Inspection and testing: The sub-contractor needs to be informed about what kinds of destructive and nondestructive testing is required and what the quality requirements are for the productmanufactured by the sub-contractor Customers inspections

Inspections performed by others (is there a quality plan?)

9) Post-weld heat treatment: If the product requires post-weld heat treatment, it is necessary to agree how the sub-contractor deals with post-weld heat treatment and on the quality requirements

10) Other requirements related to welding: The sub-contractor must be provided with all the necessary information in order to beable to do the required work

11) Handling of non-conformances:

What to do and who makes the decisions concerning non-conformances? Who conducts possible necessary negotiations with the main customer and asnecessary with the authorities (or equivalent)?

12) Other information

Design data

The sub-contractor shall be provided with clear workshop drawings and instructions, suchas the following:

material backing details and dimensions of joint preparations

permitted welding processes and consumables where necessary, welding sequence specification of parent material and characteristics of welded joints quality of the welds and acceptance requirements possible special instructions

Quality records

When required by the main company, the subcontractor shall provide or presentdocuments such as the following:

Welding procedure specifications Welding procedure qualification records Welders' qualification test certificates Measurement records


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Test reports from NDT and possible destructive testing Records of repairs and other non-conformance reports Documents related to the delivery

The quality documents to be filed either by the sub-contractor or by the main company asagreed.

4.6.2 Sub-contracting of heat treatment

An assessment of the sub-contractor will be performed during which the items listed inclause 4.13 will be checked.

4.6.3 Sub-contracting of inspection and testing

An assessment of the sub-contractors will be performed during which the items listedbelow will be checked.

a) Sub-contractors competence Are there any requirements for accreditation?

b) Inspection plan See clause 4.14.5

c) Qualification of NDT personnel (ISO 9712 or EN 473)

4.6.4 Sub-contracting of maintenance works

An assessment of the sub-contractor will be performed during which the items listed inclause 4.9.5 will be checked.

4.6.5 Sub-contracting of calibration

An assessment of the subcontractor will be performed during which the items listed inclause 4.16 will be checked.

4.7 Welding and the associated personnel

4.7.1 General

The purpose of the procedure is to ensure that the company has the required competentpersonnel capable to fulfil the tasks required by the contract, by the regulatoryrequirements, and by codes and orders of other bodies concerned.

The procedures apply to qualification of personnel and their various tasks.


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The responsibility for the skill of the personnel can, for example, be allocated to thecompanys HR manager or production manager. In the welding matters, the responsiblewelding co-ordinator will be contacted.

At technical reviews, personnel required for various projects are discussed along withtheir qualifications.

4.7.2 Welders and welding operators

Those doing welding work are required to be qualified according to the relevant part ofISO 9606-1 or EN 287, ISO 14732 or EN 1418 unless otherwise required by the productstandard or in the contract. The procedures show how qualifications and possible renewalincluding possible special requirements are to be dealt with. In some cases, a productiontest on site is required before the welder can start to work.

The welder's job description could also include the following activities: joint preparation (according to instructions) fitting (according to instructions) maintenance (according to instructions).

4.7.3 Welding coordinator

The company shall nominate at least one welding coordinator (responsible), who has the

overall welding responsibility and the necessary authorisations (e.g. to stop production). Itis possible for one responsible welding coordinator to be responsible for several sub-contractors.

If the field of activities of the company is broad, the tasks can be shared, e.g. between thelead welding coordinator and other welding coordinators or welding foremen. Wherenecessary, the welding coordinators and welding foremen report to the lead coordinator.The qualifications of the welding coordinators need to be demonstrated through sufficientexperience or training (e.g. IIW).

ISO 14731 shall be taken into consideration for the choice of welding coordinators' tasks.

Responsible welding coordinator(often the only welding coordinator in a company)

When defining tasks for the responsible welding coordinator, the following list can beused as guidance (see also ISO 14731):

Organising of welding quality management according to ISO 3834 Coordination of qualification of welding procedures Updating and distribution of files with welding procedure qualification records Preparation and signing of welding procedure specifications Publication of a table with qualified welding procedure specifications General instructions for welders' qualification Updating and publication of a centralised welder register Expert tasks connected to purchasing of welding equipment and materials

Coordination of welder's training Training of examiners for welder's qualification tests


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Technical welding expert services for different departments and units in thecompany (including the Design Department and Requirements Review).

Where necessary, a competence requirement may be specified for the responsiblewelding co-ordinator (e.g. IWE/IWT/IWS).

Welding coordinator(can also be responsible)

When preparing procedures for assisting welding coordinators, the following list can beused as guidance (see also ISO 14731):

Department-specific organising and preparation of procedures and forms concerningquality management in welding Acting as the responsible welding coordinator of various projects Having welding tests done according to the needs of the department Preparing and releasing of welding and heat-treatment procedure specifications tobe used Ensuring functioning of welders' qualification systems Welders training nominating of personnel for transfer marking on materials Controlling validity of welders' qualifications Controlling to ensure that transfer of markings takes place according to instructions Reserving of welding equipment Reserving of welding consumables

Where necessary, a competence requirement may be specified for the weldingcoordinator (e.g. IWT).

Welding foreman

A welding foremans tasks include: Work planning Organising and control of welding work Ensuring welding is carried out in accordance with WPS Organising and control of heat treatment

Organising and control of inspections.Where necessary, a competence requirement may be specified for the weldingcoordinator (e.g. IWS).

4.7.4 Other personnel

(not in ISO 3834)

Designer

Designers tasks include, e.g.: Preparation of manufacturing and welding drawings

Design of welded joints Preparation of prefabrication drawings


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Determination of manufacturing tolerances and appropriate choice of referencepoints and reference levels for dimensioning.

Heat-treatment personnel

The heat-treatment operators tasks include, e.g.: Heat treatment according to specifications Calibration of temperature measuring and recording equipment Validation of the furnace controlled temperature zone Control of temperatures Documentation of heat treatments Loading, supporting, protection, installation of measurement sensors, insulators, and

heating elements.

4.8 Inspection and testing personnel

The purpose of the procedure is to ensure that the qualifications of the NDT personnelare of a required level and in accordance with the ISO 9712 or EN 473 or as specified inthe product standard or contract.

4.9 Equipment

4.9.1 General

The purpose of the procedures is to ensure that the welding equipment can be used asrequired by the welding procedure specifications. Defective equipment shall not be used.

The procedures apply to description, acceptance, use and maintenance of equipment.Machine cards shall be kept of each equipment item showing the following:

Type and capacity Manufacturer and machine number Machine number used by the company or some other unique mark Acceptance tests Regular maintenance.

The responsibility for the maintenance of the equipment could be given to themaintenance manager or service manager. The responsibility may also be delegated tousers.

4.9.2 Procedure for capacity and capability of equipment

The procedure dealing with the description of the equipment shall specify what thecapacity list includes, e.g. number and capacity of welding equipment, such as maximumwelding current.


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4.9.3 Procedure for acceptance of equipment

Before equipments are accepted, it may be necessary to perform an acceptance test. Ifno acceptance standard is available, the necessary procedures may be preparedtogether with the equipment supplier.

4.9.4 Procedure for starting to use equipment and recording

Before the use of new or refurbished equipment, the following checks are necessary: External integrity Condition of cables

Operating functions.

Furthermore, a welding test should be performed to ensure that the equipment functionsnormally.

4.9.5 Procedure for maintenance of equipment

a) Maintenance interval, responsible person and the person performing the maintenance.

The maintenance report of a welding machine may show the following, for example: Inspections related to electrical safety Condition of welding cables

Condition of wire feeding devices Condition of welding gun or welding torch Output capacity Condition of measuring devices.

b) In daily maintenance of welding machines the following shall be observed: Condition of wire feed roller and correct compressive force Condition of current and gas nozzles Condition of insulator sleeve of gas nozzle Condition of protection hose of welding gun Condition of earthing

Gas flow of shielding gas Condition of valves.

4.10 Welding and related activities

The purpose of the procedures is to ensure that welding and the related activities takeplace as planned.

The responsibility for welding activities may be given to the responsible welding

coordinator, production manager, manufacturing manager or the welding foreman.


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The procedures may apply to the production plan, preparation and qualification of weldingprocedures, preparation of work instructions, maintenance work and auxiliary work, dailyplanning and performance of welding, maintenance or supporting activities.

4.10.1 Procedures for preparing the production plan

ISO 3834-2 can be applied as such for procedures concerning the production plan.Separate procedures could be prepared for individual work stages, e.g. cleaning, nestling,joint preparation, post-weld treatment and inspection of welds. A routing card can also beused to assist the preparation of the production plan.

4.10.2 Procedures for preparation of welding procedure specifications

The procedure for preparing of welding procedure specifications may include thefollowing:

Which items shall be included and to what degree of accuracy? Tolerances (for joint preparations; for welding parameters) For which products may the procedures be used? Method of qualification Choice of welding consumables (based on performed tests, experience orcustomer's requirements taking into account additional recommendations given by theconsumable manufacturer and possible authority requirements)

Who has the right to sign welding procedure specifications? Special procedures- Cleaning- tacking- buttering- root opening- pre-heating (measurement according to ISO 13916)?- repair welding.

4.10.3 Procedures for qualification of welding procedures

The preparation of welding procedure qualification records (WPQR) shall be included inthe procedure for qualification of welding procedures.

a) The WPQR for qualification by tested welding consumables (ISO 15610) may bebased on the following:

inspection body's (e.g. TTK, TV, DNV, Lloyds, etc.) lists of parent materials andfiller materials welding consumable manufacturers list (e.g. Esab, Elga, Bhler, etc.), which mayinclude filler material specific approvals.

b) The WPQR for qualification by previous experience (ISO 15611) may consist of the

following: Test reports and


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Customer's statement that the product has been in use the last five years without anyneed for weld repair. This statement may be done e.g. in connection with maintenanceat the customer.

c) Standard welding procedure (ISO 15612): WPQR prepared by the organisation which performed the welding procedure test (ifavailable).

d) Welding procedure tests (ISO 15614) and pre-production tests (ISO 15613): Procedures for examination of tests (what to do before, during test, and after thetests) Inspection and test reports.

The signatory of the qualification will be nominated in all cases.

4.10.4 Work instructions

The procedure for preparing of work instructions may include the following: Which items of the welding procedure specification and to what extent? Who has the right to sign the work instructions? Who may use work instructions?

4.10.5 Procedure for welding maintenance and supporting activities

The welder shall be able to understand the maintenance procedures (daily maintenanceand periodic maintenance) for the equipment and its parts. See clause 4.9.5.

4.11 Storage and handling of welding consumables

The purpose of the procedure is to ensure that the handling and storage of weldingconsumables has been sufficiently addressed in order to prevent them from becomingmoist, oxidised and damaged or mixed with one another. The procedure for storage,drying, baking and handling needs to comply with the recommendations of themanufacturer of welding consumables.

Responsibility

The person responsible for the storage and handling of the welding consumables is theperson in charge of welding in the company, e.g. responsible welding coordinator or aperson authorised by the coordinator, e.g. the stock keeper.

Contents

The procedure for storage of welding consumables may include the following:

a) Sufficiently detailed information for ordering welding consumables: Is it enough to use the classification and then choosing other welding consumableswith the same classification? Is it mandatory to purchase only welding consumables with specific trade names? Is, in special cases, a material certificate necessary?


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b) Acceptance of welding consumables: Conforming that the purchased welding consumable is what was ordered Check that sufficient markings are in place.

c) Storage of welding consumables: Temperature range in the storehouse shall be defined Existing maximum relative humidity in the storehouse shall be defined Where necessary, other conditions in the storehouse shall be reported Consumables to be stored in unopened original packages, and opened packagesalways to be used first Sequence of giving out of consumables from the storehouse: oldest consumables to

be used first (first in, first out) The number of consumables that can be given out from the storehouse for use at thework place shall be specified.

d) Handling of welding consumables: The consumables shall not become mixed up during use Where necessary, they shall be marked, e.g. with stickers or coloured markings Where necessary, the welding consumables shall be dried Where necessary, holding ovens or quivers shall be used Where necessary, the maximum storage time at the work place shall be specifiedafter which the consumables need to be re-dried or scrapped A minimum number of opened packages shall be permitted at the work place Proper discipline required on the work place: e.g. covered electrodes shall not be leftaround.

e) Drying and storage of welding consumables: Devices used for drying need to be available Consumable specific instructions for drying based on the consumablemanufacturer's instructions (temperature and drying time) shall be given The maximum holding time in holding oven shall be taken into account Mixing of welding consumables shall not be possible.

4.12 Storage of parent materials

The purpose of the procedure is to ensure that the parent materials used for weldedproducts meet the requirements specified for the product.

The procedure applies to the storage and handling of the parent materials.

The person responsible for manufacturing in the company is responsible for the storageof parent materials. The person responsible organises and ensures that the storage ofparent materials does not cause damage or that they become mixed during storage.

It is important to prevent wrong materials from being used.

Contents

The requirements specified for a product, or by a contract or a standard or the authoritiesshall be observed in the identification of materials.


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a) If the material supplier provides or is required to provide an order confirmation, thisshall be checked with care and expertise also in regard to its technical part.

b) Care shall be taken during acceptance inspections to ensure that all of therequirements in the order have been fulfilled and that all of the markings are as required.

c) Care shall be taken in the storage that the materials will not be damaged or mixed up.

d) In nestling, care shall be taken in marking to ensure that the materials will not becomemixed up. The marking system shall correspond to the product standards. Marks madeusing crayons, paint or stamps or batch-specific identifier cards may be used asnecessary. For example, the transfer of the markings of the pressure vessel materialsshall be made before nestling. A person appropriately trained will transfer the followingmarkings:

Material quality Cast and test numbers Stamp of the person transferring the markings.

Small parts may be marked using code markings.

e) During manufacturing care shall be taken to ensure that the identification of thematerials is retained.

f) Where necessary, and according to the product standard, the customer shall beprovided with information about the materials used, and as necessary also with material

certificates.

4.13 Post-weld heat treatment

The purpose of the procedure is to ensure that the welds are heat-treated in a specifiedmanner in order to fulfil the requirements of the welded product.

The procedure applies to the heat treatment after welding.

The responsibility for the heat treatment can be allocated to the person responsible formanufacturing or to the welding co-ordinator.

Contents

ISO 17663 describes heat treatment as a special process. It includes the following: Review of requirements and technical review Subcontracting Personnel Inspection and testing Equipment for heat-treatment Heat treatment activities Heat treatment records Non-conformance and corrective actions Quality records


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4.14 Inspection and testing4.14.1 Contents

The purpose of the procedure (Inspection and Testing Plan) is mainly to ensure thatquality control is in place before welding, during welding, and after welding.

Procedures are prepared for visual inspection and for both destructive and non-destructive testing.

The overall responsibility for inspections lies with a person who is independent ofproduction, e.g. the quality manager. The person or organisation performing theinspection is responsible for the actual inspection work and its results. The inspectors'

visual acuity should be checked at regular intervals. The majority of inspections do notrequire an outside inspector, e.g. a welder trained for inspection tasks can do the visualinspection of the welds he has made. The general principle is that the person doing thework is responsible for that work.

4.14.2 Inspection and testing before welding

The procedure may include:

a) Inspection of the welders qualifications:

Validity Suitability (range of qualification)

b) Welding procedure specifications/work instructions: Necessity Suitability Correct welding procedure specification Parent material and material thickness Identity of parent material Welding consumable(s) (marking, storage, and condition) Dimensions of joint preparations (method of preparation, bevel angle, gap, depth ofroot face) Fit-up, jigging and tacking Setting of welding parameters (welding current, voltage, wire feed rate) Measurement of preheating temperature Environmental conditions (e.g. temperature and draught)

c) Production tests: Extension parts to be welded for destructive testing

d) Non-conformances

4.14.3 Inspection during welding



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a) Control of welding parameters (that they are in use): Welding current Arc voltage Travel speed Gas flow rate Contact tube distance

b) Temperature measurements: ISO 13916 may be used when measuring the pre-heating temperature, the interpasstemperature, and preheat maintenance temperature.

c) Use and handling of welding consumables

d) Cleaning, shape and number of runs

e) Welding sequence

f) Back gouging

g) Control of distortion

h) Required intermediate examinations

i) Non-conformances

4.14.4 Inspection after welding


a) Implementation of the testing plan (destructive and non-destructive testing)

b) Checking of test reports: Written instructions (e.g. a specific standard) Acceptance levels Qualifications of inspection personnel

c) Checking the shape, profile and dimensions of the structure

d) Results of post-treatment:

Grinding Post-heating-treatment record Ageing

e) Non-conformances

Sometimes there could be a need to prepare testing plan (ITP). It might include: Test object Extent of testing Testing time Test methods/equipment Subcontracting

Test instructions Testing conditions (e.g. lighting, viewing angle, viewing distance)


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Acceptance levels (e.g. corresponding to quality levels) Recording instructions or report forms.4.14.5 Inspection and testing status

The inspection or test status of the welded structure is given in an appropriate manner,e.g. by means of a marking on the object itself or a traceability card.

4.15 Non-conformances and corrective actions

The purpose of procedures is to ensure that a nonconforming product does not go forward into production, for use or to bedelivered to the customer

correction is taken to correct the nonconformance corrective actions are taken to avoid repetition of the fault.

The procedures concern welding, inspection and non-conformances found after delivery.It is important to define what a non-conformance is.

All parties are obliged to report of any non-conformance they have noted. Depending onthe nature of the non-conformance, the welder shall have the right, if necessary, tointerrupt his/her work.

A designated person shall be given the responsibility for ensuring that thecorrections/repairs are made according to instructions and completed, and that therequired quality has been reached.

4.15.1 Procedures when the welding procedure specification has not been followed or is

impossible to follow

If the welding procedure specifications/work instruction was not followed, the welder shallinform e.g. the foreman/responsible welding coordinator about it. A non-conformancereport shall be made of this type of non-conformance.

The contents of the report should include e.g. of the following items: Description of the non-conformance Proposed action (correction of welding procedure specifications or workinstructions?) Decision Control of implementation Corrective action.

The procedure should describe how to proceed, e.g.

a) No action

b) Correction without permission

c) Correction with permission from a certain person

d) Classification for alternative use

e) Scrapping.


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Any repair welding shall be done according to the qualified welding procedures.4.15.2 Procedures for non-conformances found during inspection

The following may be mentioned in procedures for how to handle weld imperfectionsfound during inspection:

The way in which the imperfection has to be marked Acceptance of the non-conformance Increasing the extent of testing and additional test methods (see, technical review) corrective actions (see, technical review) reporting (see 4.15.1).

4.15.3 Procedures for non-conformances found after deliveryProcedures for dealing with non-conformances found after delivery may include thefollowing: