ISO 3834 Guife for Implementation IIW SC Qual 145r4-10 Final 2011-03-13

8/16/2019 ISO 3834 Guife for Implementation IIW SC Qual 145r4-10 Final 2011-03-13

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International Inst itute of Welding A wor ld of jo in ing experience

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“To act as the world-wide network for knowledge exchange of joining technologiesto improve the global quality of life.”

SC-Qual-145r4-10

Improving the quality and effectiveness of welding by utilizing the standardISO 3834 – Guideline for company implementation

IIW Keywords: ISO 3834, Company Certification, Quality Management, Checklist,

Questionnaire

ObjectiveThe objective of this publication is to provide companies intending to apply the standard ISO3834 dealing with the quality management of welding, advice on the kind of procedures andforms that might be beneficial to them and on the content of such procedures. This publicationprimarily deals with the adoption of ISO 3834-2, but much of the advice is also applicable toISO 3834-3 and ISO 3834-4.

This publication does not mean that all the procedures presented in it are necessarily required.

Once the company has thoroughly considered its needs and has decided that it requires acertain procedure, this publication can be used in order to find advice for the preparation of theprocedure. The publication should not be used as requirements for procedures or check-lists inconnection with audits.

Abst ract

This publication is primarily intended for people who are responsible for quality control in thefield of welding. Because the items presented in this publication may have a significant impacton a company’s business operations and their successful continuation, the publication will be auseful tool also for strategic and operational managers. This publication also deals with matters

relating to the sale and marketing of products. Therefore the sales personnel of weldedproducts shall understand, in order to ensure that the products sold are manufactured inaccordance with the designs, in a controlled manner and with minimal risk.

ISO 3834-1 gives the instructions for the selection of the level of quality requirements, whileISO 3834-2, 3, and 4 present quality requirements of different levels. Manufacturers of certainwelded products, such as pressure vessels, offshore structures and steel structures, may needto comply with the quality requirements of ISO 3834 required by applicable product standards.Foreign customers may also require compliance with these requirements as well as majorexport companies of their own subcontractors. A company may gain considerable benefit fromapplying these standards, even without third party certification. It is possible to certificate thestandard ISO 3834-2 as part of ISO 9001 quality management system or ISO 3834-2, -3 and -4can be certificated on their own.


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ISO 3834 presents systematically and comprehensively the factors and measures having animpact 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 times aswell as the cost-effectiveness of its manufacturing process. For the company it is important toidentify properly those items that will be subject to the requirements presented in ISO 3834-2,3, and 4. The aim is to avoid unnecessary documentation and procedures and ensure that thequality management is appropriate for the welded products to be manufactured. Thispublication gives examples of the key procedures and the related work instructions and forms.

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

• Technical review verifies the company’s capabilities for manufacturing the product that has

been ordered and identifies particular welding requirements related to the contract. Only acorrectly conducted technical review ensures well-managed, risk-free and cost-effectiveproduction.

• Competence requirements specified for the welding personnel will, in the case of someworkshops, be clearly different from present practice. Product liability gives additionalemphasis on the responsibilities and role of the welding coordination personnel. Therequirements relating to qualification of welders and welding operators strengthens the qualitymanagement of welding and can also reduce costs caused by errors. The standard may notbring any significant changes to the current practice regarding inspection personnel.

• Production plan and qualified welding procedures assure that production is carried outsystematically and the characteristics of the welded joints meet the specified requirements.There are several alternatives for the method of qualifying welding procedures and thecompany shall apply the one that is technically and economically the most appropriate for theproduct concerned.

• Descript ion of production and testing equipment used in connection with welding allowsthe company to check the suitability of its equipment pool for the manufacturing andinspection of the product it sells. Acceptance tests of equipment, regular maintenance andpossible calibration or validation, in order to ensure that it will be possible to follow thewelding procedures sufficiently and that the inspection and testing results are reliable.

• Systematic dealing of non conformances ensures that a defective product is not put intoservice by mistake. The reasons for non conformances are analysed and corrective actionscarried 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, with all thepersonnel being committing to the work and the additional activities required: developing workpractices, performing new duties, ensuring the flow of information, etc. When theimplementation starts it might be advantageous to engage external expertise in order to obtainan objective picture of the starting point. The company may decide to focus on reaching a pointwhere the conditions are fit for certification by documentation and procedures for tasks andactivities, but the real economic and technical benefit from the adoption of ISO 3834 will beachieved only when the activities and content concerning the welding work are developed. Forthis 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 Page

1. 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 7

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 20

4.9 Equipment 20

4.10 Welding and related activities 21

4.11 Storage and handling of welding consumables 23

4.12 Storage of parent material 24

4.13 Post- weld heat treatment 254.14 Inspection and testing 25

4.15 Non-conformance and corrective actions 27

4.16 Calibration and validation of measuring, inspection and testing

equipment 28

4.17 Identification and traceability 30

4.18 Quality records 30

5. Need for certification 32

6. Adopting standard 3834 in a company 33Annexes

A Example of check list for technical review 36

B Example of procedural guidelines for welders’ qualification test 52


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1 General

Welding is a general production method for manufacturing of metal products. Welding has aconsiderable impact on both the product’s costs and quality. Consequently, it is important thatthe welding is carried out as efficiently as possible, meeting all specified quality requirements.

Weld quality is achieved by sound welding, not by inspection. Inspection, however, provides acheck of the reliability of the product, but cannot improve poor quality. Welding requirescontinuous control and/or to follow documented procedures. On this basis, the ISO 3834 seriesof welding standards has been prepared.

The purpose of the ISO 9000 series is that the company designates as a special process anywork where the final quality of the product cannot be verified only by inspection. If qualityrequirements are specified for the welds in the product, it is appropriate to define welding as aspecial process.

It shall be observed that ISO 3834 is not a quality control standard that replaces ISO 9001, butmore an auxiliary tool for applying ISO 9001 in companies which carry out welding as a specialprocess. In such a case, the additional compliance with ISO 3834 will be included by areference in the ISO 9001 quality system. It is also possible to obtain certification under ISO3834 without any linkage to the ISO 9001 quality system.

The standards are general and not fixed to any certain product. The series of standards refersto 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 3834-5specifies documents and standards necessary to consider in order to claim conformity to ISO3834-2, 3, or 4.

2 Reasons for using ISO 3834Regulations

Regulations, eg, EU directives, define safety requirements on products and structures. Productstandards present the technical solutions that serve to fulfil the safety requirements specified inthe directives.

Product standards

Many European and some International product standards refer to the different parts of ISO3834 regarding welding. For example, the standard concerning pressure vessels (EN 13445)states that the manufacturer of the pressure vessel is obliged to fulfil as a minimum the welding

quality requirements given in ISO 3834-3.


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The European standard EN 1090-2, dealing with execution of steel structures, requires the useof quality requirements according to ISO 3834. The level of quality requirements depends onthe execution class.

Customers

Once ISO 3834 is in use, companies could utilize it for marketing purposes and customersmight require certification to ISO 3834.

The welding company (manufacturer)

The welding company wishes to improve its welding quality management system, increaseproductivity and, by applying quality control in welding, demonstrate to its customers to be areliable 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 related activities.

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, which arespecified 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. The maindifference is the level of documentation. ISO 3834-4, presenting basic quality requirements isthe level of choice when the welded components have a low safety risk. Product standards andnational codes may also give references to the different parts of ISO 3834. Table 1 gives a

short summary of requirements for ISO 3834 in European product standards.


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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

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

Certification level 3 ISO 3834-4Off 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 the standards donot need to be implemented, if they are not relevant. In such cases clear reasons shall be givenfor such a decision.

As a basis, it might be appropriate for a company to start applying the ISO 3834 by adoptingthe requirements of ISO 3834-2 and identifying those items that are relevant from thecompany's point of view. Care shall , however, be taken to ensure that the quality requirementsspecified are not lower than those presented in ISO 3834-4.

The company may also apply different levels of quality requirements for different products.Although the company may have adopted the standard ISO 3834-2, it may decide to applylower quality requirements according to ISO 3834-3 or ISO 3834-4 in respect of certainproducts or certain production lines.

4 Procedures and forms

4.1 GeneralQuality control may be described at three different levels:

At the general level, a description of the company’s 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 as well asresponsible persons.

At the level relating to forms, the necessary forms, lists, reports, records, certificates anddetailed working instructions are prepared.

Often the company is not familiar with preparing procedures. The procedures should be as

simple as possible. A good procedure fits onto a single A4 sheet and is clear and conciseenough to be read without sitting down.


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Not every item needs a procedure. Sometimes it is enough just to know how things have to bedone. It is often difficult to decide whether only knowing how to do things is enough or whetherwritten procedures are needed. Written procedures are needed, when people ask a lot ofquestions, different people do the same task or when lots of mistakes are made.

4.2 Purpose and content

The purpose of procedure is to:• 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 person responsible forit)• when, where and how the work activity is carried out (content of activity, person responsiblefor 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 of ISO3834-2. Where necessary, they can also be used when applying ISO 3834-3 and ISO 3834-4.

It may not be necessary to apply everything that is presented in Table 2; the company has fairlyfree hands to make the appropriate choices. Under no circumstances must the table be usedas audit requirements.

The procedures provide examples of who could be the person responsible for certain workactivity. The examples are completely arbitrary. It is important to nominate the person andensure that the person is aware of his or her responsibilities and is also given the appropriate

power to act.


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Table 2 – Useful procedures and forms/check lists

Clause in ISO3834-2

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 works6.2 Procedure forsubcontracting of heattreatment

6.3 Procedure for sub-contracting of testing andinspection

6.4 Procedure forsubcontracting of maintenance

6.5 Procedure forsubcontracting of calibration

6.6 Procedure for acceptancetesting

6.1 Form for

ordering/checking6.2 Form forordering/checking

6.3 Form forordering/checking



6.6 Form

7 Weldingpersonnel

7.2 Procedure for welders andwelding operators 2)

7.3 Procedure for weldingcoordinators

7.4 Procedure for other

personnel

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


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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 preparation

of work instructions10.5 Procedure for weldingrelated maintenance andsupport

10.1.1 Welding plan

10.1.2 Flow chart

10.2 Welding procedurespecifications

10.3 Welding procedurequalification record

10.4 Work instructions

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 final

inspection14.5 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 WPShas not been used

15.2 Procedure for non-conformances by inspection

15.3 Procedure for non-conformances found afterdelivery

15.1 Non-conformancereport



16 Calibrationand validation of

16.1 Procedures for calibrationand validation of thermometers

16.1 Calibration andvalidation report


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measuring,inspection andtestingequipment

16.2 Procedures for calibrationand validation of electricalmeasuring devices

16.3 Procedures for calibrationand validation of measuringdevices

16.4 Procedures for calibrationand validation of flow meters


16.3Calibration andvalidation report


17 Identificationand traceability

17.1 Procedure for markings

17.2 Procedure for transfer ofmarkings

17.3 Procedure foridentification of welders

17.4 Procedure for acceptancetests

17.1 Material card

17.2 Routing cards

18 Qualityrecords

18 Procedure for preparingand filing of quality records

18 Record forms

1) Example, see annex A

2) Example see annex B4.4 Review of requirements

The procedure for conducting the review of requirements concerns the part of the contract thatdeals with welding. The purpose of the review is to ensure:

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

• to check that all the fundamental requirements relating to the welding of the product arerecorded.

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 or projectmanager, who goes through the orders and the proposed contract. It is important for thewelding coordinator to be present when matters concerning welding in the contract are dealtwith.

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

In the review of requirements the relevant items presented in clause 5.2 in ISO 3834-2 arereviewed. It is useful to draft a form for dealing with the matters below. If the company haspreviously supplied an identical or similar product, it is not essential to complete the form in

respect of each individual contract.a) Product standard to be used, together with any supplementary requirements:

• does the product relate to any directive?


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• does a product standard 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?• review of resources?

4.5 Technical review

The purpose of the procedure for the technical review is to look at the matters that shall betaken into account when reviewing the contract. The procedure deals with matters concerningwelding.

Each company has to nominate the person who will take responsibility for these matters. Thatperson may be, for instance, the main project designer. The welding coordinator shall bepresent 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 been taken intoaccount)?• what are the differences in relation to previous requirements? (any fundamental changes?)

The technical review should cover at least the matters presented in clause 5.3 of ISO 3834-2,as described in the list below. If the product in question has been manufactured in the past, it isnot 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


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c) Location, accessibility and sequence of welds, including accessibility for inspection and forNDT:• 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?

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 methods to beperformed?

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/EN 287 orother applicable standards? Are additional requirements necessary (e.g. product standards)?• are the welding operators qualified according to ISO 14732/EN 1418 or other applicablestandards?• 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 welding job?g3) Identification of welds:

• do the welds have to be identifiable? (to the welder?)


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h) Quality control arrangements, including any involvement of an independent inspection body:• is external quality control required during manufacture?- customer?- third party?- when?

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 planm) 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?


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p) Environmental conditions relevant to the application of processes:• low temperature• wind• 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-contracting

If the company intends to use sub-contracting services (e.g. in welding, inspection, NDT, heattreatment, calibration, maintenance), he shall provide the subcontractor with all the relevantspecifications and requirements. The sub-contractor shall provide the documents and recordsspecified 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 technical andqualitative capabilities (capacity and know-how) to manufacture the product such that theproduct meets the requirements specified by the actual customer, comply with the appropriateitems of ISO 3834 and that the timetable requirements will be met.

The person responsible for the sub-contracting matters of the company has the responsibility toensure that the sub-contractor meets the technical preconditions required of manufacturing.This person should use experts in the company, e.g. the responsible welding coordinator.

Scope of sub-contractor assessment

Only the part of the subcontractor's technical know-how has to be assessed as required for thesub-contracting work. The scope of the assessment depends on what kind of quality systemthe sub-contractor has in use. If the subcontractor works according to a certified quality systemincluding ISO 3834-2, it will be enough just to conform the technical competence (capacity) andto check the equipment. A sub-contractor without any documented quality system should besubjected to a separate quality audit conducted by the company.

Items to be addressed wi th the sub-contractor

Review of requirements

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

a) Product standard and possible additional requirements to be applied:• the sub-contractor needs to know what standard and requirements the product has to fulfil.


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Technical reviewA technical review shall be performed with the sub-contractor wherein all the essential aspectsrelated to the sub-contractor's work will be addressed. Consideration should also be given toany earlier technical reviews or similar reviews. If there is significance differences or changes inresources of the sub-contractor an assessment is necessary. A technical review may includethe following.

1) Welding procedure specifications:• The sub-contractor's welding procedure specifications need to be checked. If they are notsuitable for the product to be welded, the sub-contractor shall qualify new welding proceduresto comply with the product and based on these qualifications new welding 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 main

company'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 by thequality requirements of the product to be manufactured

5) Qualification of personnel:• Are the qualifications of personnel adequate or does the sub-contractor’s personnel need

new qualifications for the product to be manufactured, eg, welders and welding operators?• 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.).- Quality requirements for materials- Approvals, material certificates required

- Requirements for identification and traceability of the material7) Selection and identification of welders:

• Where necessary, the same level as applied by the main company


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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• Customer’s 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 be ableto 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 as necessarywith the authorities (or equivalent)?

12) Other information

Design data

The sub-contractor shall be provided with clear workshop drawings and instructions, such asthe 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 present documentssuch as the following:

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


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4.6.2 Sub-contracting of heat treatment

An assessment of the sub-contractor will be performed during which the items listed in clause4.13 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 listed below willbe checked.

a) Sub-contractor’s 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 in clause4.9.5 will be checked.

4.6.5 Sub-contracting of calibration

An assessment of the subcontractor will be performed during which the items listed in clause4.16 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 regulatory requirements,and by codes and orders of other bodies concerned.

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

The responsibility for the skill of the personnel can, for example, be allocated to the company’sHR manager or production manager. In the welding matters, the responsible welding co-ordinator will be contacted.

At technical reviews, personnel required for various projects are discussed along with theirqualifications.

4.7.2 Welders and welding operators

Those doing welding work are required to be qualified according to the relevant part of ISO9606-1 or EN 287, ISO 14732 or EN 1418 unless otherwise required by the product standard


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or in the contract. The procedures show how qualifications and possible renewal includingpossible special requirements are to be dealt with. In some cases, a production test on site isrequired 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). It ispossible 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 the leadwelding coordinator and other welding coordinators or welding foremen. Where necessary, thewelding coordinators and welding foremen report to the lead coordinator. The qualifications ofthe welding coordinators need to be demonstrated through sufficient experience 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 be used asguidance (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• Technical welding expert services for different departments and units in the company(including the Design Department and Requirements Review).

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

Welding coordinator (can also be responsible)

When preparing procedures for assisting welding coordinators, the following list can be used asguidance (see also ISO 14731):

• Department-specific organising and preparation of procedures and forms concerning

quality management in welding• Acting as the responsible welding coordinator of various projects• Having welding tests done according to the needs of the department


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• Preparing and releasing of welding and heat-treatment procedure specifications to beused• 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 welding coordinator(e.g. IWT).

Welding foreman

A welding foreman’s 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 welding coordinator(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

• Determination of manufacturing tolerances and appropriate choice of reference points andreference levels for dimensioning.

Heat-treatment personnel

The heat-treatment operator’s 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, andheating elements.


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4.8 Inspection and testing personnel The purpose of the procedure is to ensure that the qualifications of the NDT personnel are of arequired level and in accordance with the ISO 9712 or EN 473 or as specified in the productstandard 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. Machinecards 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 the maintenancemanager or service manager. The responsibility may also be delegated to users.

4.9.2 Procedure for capacity and capability of equipment

The procedure dealing with the description of the equipment shall specify what the capacity listincludes, e.g. number and capacity of welding equipment, such as maximum welding current.

4.9.3 Procedure for acceptance of equipment

Before equipments are accepted, it may be necessary to perform an acceptance test. If noacceptance standard is available, the necessary procedures may be prepared together with theequipment 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


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• 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 take place asplanned.

The responsibility for welding activities may be given to the responsible welding coordinator,production manager, manufacturing manager or the welding foreman.

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. Separateprocedures could be prepared for individual work stages, e.g. cleaning, nestling, jointpreparation, post-weld treatment and inspection of welds. A routing card can also be used 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 the following:• 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 or customer'srequirements taking into account additional recommendations given by the consumable

manufacturer and possible authority requirements)• Who has the right to sign welding procedure specifications?• Special procedures


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- 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 in theprocedure for qualification of welding procedures.

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

• inspection body's (e.g. TTK, TÜV, DNV, Lloyds, etc.) lists of parent materials and fillermaterials• welding consumable manufacturer’s list (e.g. Esab, Elga, Böhler, etc.), which may includefiller material specific approvals.

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

• Test reports and

• Customer's statement that the product has been in use the last five years without any needfor weld repair. This statement may be done e.g. in connection with maintenance at thecustomer.

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 the tests)• 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 maintenance and

periodic maintenance) for the equipment and its parts. See clause 4.9.5.


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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 becoming moist,oxidised and damaged or mixed with one another. The procedure for storage, drying, bakingand handling needs to comply with the recommendations of the manufacturer of weldingconsumables.

Responsibility

The person responsible for the storage and handling of the welding consumables is the personin charge of welding in the company, e.g. responsible welding coordinator or a personauthorised 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 consumables withthe same classification?• Is it mandatory to purchase only welding consumables with specific trade names?• Is, in special cases, a material certificate necessary?

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 packages alwaysto be used first• Sequence of giving out of consumables from the storehouse: oldest consumables to beused first (first in, first out)• The number of consumables that can be given out from the storehouse for use at the work

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 specified afterwhich 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 left

around.e) Drying and storage of welding consumables:

• Devices used for drying need to be available


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• Consumable specific instructions for drying based on the consumable manufacturer'sinstructions (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 welded productsmeet 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 storage ofparent materials. The person responsible organises and ensures that the storage of parentmaterials 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 authorities shallbe observed in the identification of materials.

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

b) Care shall be taken during acceptance inspections to ensure that all of the requirements inthe 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 become mixedup. The marking system shall correspond to the product standards. Marks made using crayons,paint or stamps or batch-specific identifier cards may be used as necessary. For example, thetransfer of the markings of the pressure vessel materials shall be made before nestling. Aperson appropriately trained will transfer the following markings:

• 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 the materials isretained.

f) Where necessary, and according to the product standard, the customer shall be providedwith 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 specified

manner in order to fulfil the requirements of the welded product.The procedure applies to the heat treatment after welding.


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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

4.14 Inspection and testing

4.14.1 Contents

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

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

The overall responsibility for inspections lies with a person who is independent of production,e.g. the quality manager. The person or organisation performing the inspection is responsiblefor the actual inspection work and its results. The inspectors' visual acuity should be checked atregular intervals. The majority of inspections do not require an outside inspector, e.g. a weldertrained for inspection tasks can do the visual inspection of the welds he has made. The generalprinciple is that the person doing the work is responsible for that work.

4.14.2 Inspection and testing before welding

The procedure may include:

a) Inspection of the welder’s 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 of rootface)


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• 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

The procedure may include: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 consumablesd) 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

The procedure may include:

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


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e) Non-conformancesSometimes 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)• 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. bymeans 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 be delivered tothe 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 isimportant to define what a non-conformance is.

All parties are obliged to report of any non-conformance they have noted. Depending on thenature of the non-conformance, the welder shall have the right, if necessary, to interrupt his/herwork.

A designated person shall be given the responsibility for ensuring that the corrections/repairsare made according to instructions and completed, and that the required quality has beenreached.

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-conformance reportshall 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 work instructions?)• Decision• Control of implementation

• Corrective action.The procedure should describe how to proceed, e.g.


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a) No actionb) Correction without permission

c) Correction with permission from a certain person

d) Classification for alternative use

e) Scrapping.

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 imperfections found

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 delivery

Procedures for dealing with non-conformances found after delivery may include the following:

• Classification of the non-conformance

• NDT• Heat treatment• Does the welding procedur