Improving Quality of Welding with ISO 3834

International Institute of Welding
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Improving the quality and effectiveness of welding by utilizing the standard ISO 3834 Objective The objective of this publication is to provide companies intending to apply the standard ISO 3834 dealing with the quality management of welding, advice on the kind of procedures and forms that might be beneficial to them and on the content of such procedures. This publication primarily deals with the adoption of ISO 3834-2, but much of the 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 necessarily required. Once the company has thoroughly considered its needs and has decided that it requires a certain procedure, this publication can be used in order to find advice for the preparation of the procedure. The publication should not be used as requirements for procedures or check-lists in connection with audits.
Abstract
This publication is primarily intended for people who are responsible for quality control in the field of welding. Because the items presented in this publication may have a significant impact on a companys business operations and their successful continuation, the publication will be a useful 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 welded products shall understand, in order to ensure that the products sold are manufactured in accordance 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, while ISO 3834-2, 3, and 4 present quality requirements of different levels. Manufacturers of certain welded products, such as pressure vessels, offshore structures and steel structures, may need to 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 major export companies of their own subcontractors. A company may gain considerable benefit from applying these standards, even without third party certification. It is possible to certificate the standard ISO 3834-2 as part of ISO 9001 quality 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 the manageability 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 is important to identify 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 the quality management is appropriate for the welded products to be manufactured. This publication 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 companys capabilities for manufacturing the product that has been ordered and identifies particular welding requirements related to the contract. Only a correctly conducted technical review ensures well-managed, risk-free and cost-effective production. Competence requirements specified for the welding personnel will, in the case of some workshops, be clearly different from present practice. Product liability gives additional emphasis on the responsibilities and role of the welding coordination personnel. The requirements relating to qualification of welders and welding operators strengthens the quality management of welding and can also reduce costs caused by errors. The standard may not bring any significant changes to the current practice regarding inspection personnel. Production plan and qualified welding procedures assure that production is carried out systematically and the characteristics of the welded joints meet the specified requirements. There are several alternatives for the method of qualifying welding procedures and the company shall apply the one that is technically and economically the most appropriate for the product concerned. Description of production and testing equipment used in connection with welding allows the company to check the suitability of its equipment pool for the manufacturing and inspection of the product it sells. Acceptance tests of equipment, regular maintenance and possible calibration or validation, in order to ensure that it will be possible to follow the welding procedures sufficiently and that the inspection and testing results are reliable. Systematic dealing of non conformances ensures that a defective product is not put into service by mistake. The reasons for non conformances are analysed and corrective actions 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, with all 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 in order to obtain an objective picture of the starting point. The company may decide to focus on reaching a point where the conditions are fit for certification by documentation and procedures for tasks and activities, but the real economic and technical benefit from the adoption of ISO 3834 will be achieved only when the activities and content concerning 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
Page
1. General 2. Reasons for using ISO 3834 3. Choice of quality requirement level 4. Procedures and forms 4.1 General 4.2 Purpose and content 4.3 Relevant procedures and forms/check lists 4.4 Review of requirements 4.5 Technical review 4.6 Sub-contracting 4.7 Welding and associated personnel 4.8 Inspection and testing personnel 4.9 Equipment 4.10 Welding and related activities 4.11 Storage and handling of welding consumables 4.12 Storage of parent material 4.13 Post- weld heat treatment 4.14 Inspection and testing 4.15 Non-conformance and corrective actions 4.16 Calibration and validation of measuring, inspection and testing 4.17 Identification and traceability 4.18 Quality records 5. Need for certification 6. Adopting standard 3834 in a company Annexes A Example of check list for technical review B Example of procedural guidelines for welders qualification test
4 4 5 6 6 7 8 10 11 14 17 19 19 21 22 23 24 25 27 equipment 29 30 32 33
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1 General
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Welding is a general production method for manufacturing of metal products. Welding has a considerable impact on both the products costs and quality. Consequently, it is important that the 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 a check of the reliability of the product, but cannot improve poor quality. Welding requires continuous control and/or to follow documented procedures. On this basis, the ISO 3834 series of welding standards has been prepared. The purpose of the ISO 9000 series is that the company designates as a special process any work where the final quality of the product cannot be verified only by inspection. If quality requirements are specified for the welds in the product, it is appropriate to define welding as a special process. It shall be observed that ISO 3834 is not a quality control standard that replaces ISO 9001, but more an auxiliary tool for applying ISO 9001 in companies which carry out welding as a special process. In such a case, the additional compliance with ISO 3834 will be included by a reference in the ISO 9001 quality system. It is also possible to obtain certification 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 standards refers 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 38345 specifies documents and standards necessary to consider in order to claim conformity to 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 safety requirements specified in the directives. Product standards Many European and some International product standards refer to the different parts of ISO 3834 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. The European standard EN 1090-2, dealing with execution of steel structures, requires the use of quality requirements according to ISO 3834. The level of quality requirements depends on the execution class.
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Customers Once ISO 3834 is in use, companies could utilize it for marketing purposes and customers 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 its customers to be a reliable supplier. Main contractors A subcontractor working to ISO 3834 can expect to have a significant advantage over its competitors, 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 is typically considered as a special process. This requires that specific requirements, which are 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, the comprehensive 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 main difference is the level of documentation. ISO 3834-4, presenting basic quality requirements 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 of ISO 3834. Table 1 gives a short summary of requirements for ISO 3834 in European product standards.
Table 1 Selection of quality requirement level Product or structure Steel structures (EN 1090-2) Requirements
Execution classes 3 and 4 ISO 3834-2 Execution class 2 ISO 3834-3 Execution 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 3834-2 Certification level 2 and 4 ISO 3834-3 Certification level 3 ISO 3834-4 ISO 3834-2 Recommends parts of ISO 3834-2
Off shore (NORSOK) Water tube boilers (EN 12952-5)
When applying ISO 3834, it should be noted that all of the items presented in the standards do not need to be implemented, if they are not relevant. In such cases clear reasons shall be given for such a decision. As a basis, it might be appropriate for a company to start applying the ISO 3834 by adopting the requirements of ISO 3834-2 and identifying those items that are relevant from the company's point of view. Care shall , however, be taken to ensure that the quality requirements specified 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 apply lower quality requirements according to ISO 3834-3 or ISO 3834-4 in respect 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 as well 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 be as simple as possible. A good procedure fits onto a single A4 sheet and is clear and concise enough to be read without sitting down. Not every item needs a procedure. Sometimes it is enough just to know how things have to be done. It is often difficult to decide whether only knowing how to do things is enough or whether written procedures are needed. Written procedures are needed, when people ask a lot of questions, different people do the same task or when lots of mistakes are made. 4.2 Purpose and content
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The 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 person responsible 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 of ISO 3834-2. 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 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 certain work activity. The examples are completely arbitrary. It is important to nominate the person and ensure that the person is aware of his or her responsibilities and is also given the appropriate power to act.
Table 2 Useful procedures and forms/check lists Clause 3834-2 in ISO Procedure 5.2 Procedure for requirement review 5.3 Procedure for technical review 1) 6.1 Procedure for subcontracting of welding works 6.2 Procedure for subcontracting of heat treatment 6.3 Procedure for subForm/check list 5.2 Check list for assessment 5.2 Check list for assessment 6.1 Form for ordering/checking 6.2 Form for ordering/checking 6.3 Form for
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5 Review of requirement review and technical review 6 Subcontracting
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contracting of testing and inspection 6.4 Procedure for subcontracting of maintenance 6.5 Procedure for subcontracting of calibration 6.6 Procedure for acceptance testing 7 Welding personnel 7.2 Procedure for welders and welding operators 2) 7.3 Procedure for welding coordinators 7.4 Procedure for other personnel 8 Inspection and testing personnel 9 Equipment 8.2 Procedures for testing and inspection personnel 9.2. Procedure for capacity and capability of equipment 9.3 Procedure for acceptance of equipment 9.4 Procedure for starting to use equipment and recording 9.5 Procedure for maintenance of equipment 10 Welding and related activities 10.1.1 Procedure for subassemblies 10.1.2 Procedure for flow chart 10.2 Procedure for preparation of welding procedure specifications
ordering/checking 6.4 Form for ordering/checking 6.5 Form for ordering/checking 6.6 Form 7.2 File with certificates 7.3 File with CV, copies of diplomas etc. 7.4 File 8.2 File with copies of qualifications 9.2 Capacity list 9.3 Acceptance reports 9.4 List of equipment 9.5 Maintenance and dimensional reports 10.1.1 Welding plan 10.1.2 Flow chart 10.2 Welding procedure specifications
10.3 Procedure for qualification 10.3 Welding procedure of welding procedures qualification record 10.4 Procedure for preparation of work instructions 10.5 Procedure for welding related maintenance and support
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10.4 Work instructions

11 Welding consumables 12 Storage of parent materials 13 Post-weld heat treatment
11.3 Procedure for storage and 11.3 Stock list handling of welding consumables 12 Procedure for storage of parent materials 13 Procedure for preparation of heat treatment procedure specifications 14.2 Procedure for activities prior to welding 14.3 Procedure for control during welding 14.4 Procedure for final inspection 14.5 Procedure for preparation of an inspection plan 12 Stock list 13.1 Het treatment procedure specifications 13.2 Heat treatment records 14.2 Check form 14.3 Check form 14.4 Check form 14.5 Inspection plan 15.1 Non-conformance report 15.2 Non-conformance report 15.3 Non-conformance report 16.1 Calibration and validation report 16.2 Calibration and validation report 16.3Calibration and validation report 16.4 Calibration and validation report 17.1 Material card 17.2 Routing cards
14 Inspection and testing
15 Non15.1 Procedure when the WPS conformance and has not been used corrective actions 15.2 Procedure for nonconformances by inspection 15.3 Procedure for nonconformances found after delivery 16 Calibration and validation of measuring, inspection and testing equipment 16.1 Procedures for calibration and validation of thermometers 16.2 Procedures for calibration and validation of electrical measuring devices 16.3 Procedures for calibration and validation of measuring devices 16.4 Procedures for calibration and validation of flow meters 17 Identification and traceability 17.1 Procedure for markings 17.2 Procedure for transfer of markings 17.3 Procedure for
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identification of welders 17.4 Procedure for acceptance tests 18 Quality records

1) 2)
18 Procedure for preparing and filing of quality records
18 Record forms
Example, see annex A Example see annex B
4.4 Review of requirements The procedure for conducting the review of requirements concerns the part of the contract that deals with welding. The purpose of the review is to ensure: that the company is technically and otherwise capable (e.g. delivery schedule) to fulfil all the requirements and wishes presented by the customer and to check that all the fundamental requirements relating to the welding of the product 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 or project 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 contract are dealt with. If there are ambiguities in the order or in the proposed contract, the person in charge solves 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 3834-2 are reviewed. It is useful to draft a form for dealing with the matters below. If the company has previously 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? 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?
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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 shall be taken into account when reviewing the contract. The procedure deals with matters concerning 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 coordinator shall 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 been taken into account)? 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 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 and for 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 methods to 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/EN 287 or other applicable standards? Are additional requirements necessary (e.g. product standards)? 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 welding job? g3) Identification of welds: do the welds have to be identifiable? (to the welder?) h) Quality control arrangements, including any involvement of an independent inspection body: 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 17633 concerning 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-contracting If 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 the relevant specifications and requirements. The sub-contractor shall provide the documents and 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 technical and qualitative capabilities (capacity and know-how) to manufacture the product such that the 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 the responsibility to ensure 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 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 a certified quality system including ISO 3834-2, it will be enough just to conform the technical competence (capacity) and to check the equipment. A sub-contractor without any documented quality system should be subjected to a separate quality audit conducted 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 the technical 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 has to fulfil. Technical review A technical review shall be performed with the sub-contractor wherein all the essential aspects related to the sub-contractor's work will be addressed. Consideration should also be given to any earlier technical reviews or similar reviews. If there is significance differences or changes in resources of the sub-contractor an assessment is necessary. A technical review may include the following. 1) Welding procedure specifications: The sub-contractor's welding procedure specifications need to be checked. If they are not suitable for the product to be welded, the sub-contractor shall qualify new welding procedures to 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 welding procedure specifications (standard procedures) 2) Non destructive 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 the quality requirements of the product to be manufactured 5) Qualification of personnel: Are the qualifications of personnel adequate or does the sub-contractors 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 these identified 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 non destructive testing is required and what the quality requirements are for the product manufactured 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 subcontractor 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 able 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 as necessary with the authorities (or equivalent)? 12) Other information Design data The sub-contractor shall be provided with clear workshop drawings and instructions, such as 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 present documents 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 as agreed. 4.6.2 Sub-contracting of heat treatment An assessment of the sub-contractor will be performed during which the items listed in clause 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 listed below 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 in clause 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 in clause 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 competent personnel 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.
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The responsibility for the skill of the personnel can, for example, be allocated to the companys HR 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 their qualifications. 4.7.2 Welders and welding operators Those doing welding work are required to be qualified according to the relevant part of ISO 9606-1 or EN 287, ISO 14732 or EN 1418 unless otherwise required by the product standard or in the contract. The procedures show how qualifications and possible renewal including possible special requirements are to be dealt with. In some cases, a production test 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). It is possible for one responsible welding coordinator to be responsible for several subcontractors. If the field of activities of the company is broad, the tasks can be shared, e.g. between the lead welding coordinator and other welding coordinators or welding foremen. Where necessary, the welding coordinators and welding foremen report to the lead coordinator. The qualifications of the 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 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 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 as guidance (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 Preparing and releasing of welding and heat-treatment procedure specifications to be 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 welding coordinator (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 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
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Determination of manufacturing tolerances and appropriate choice of reference points 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 personnel are of a required level and in accordance with the ISO 9712 or EN 473 or as specified in the 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 as required 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 the maintenance manager 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 list includes, e.g. number and capacity of welding equipment, such as maximum welding 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. If no acceptance standard is available, the necessary procedures may be prepared together 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 functions normally. 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 take place 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 welding procedures, preparation of work instructions, maintenance work and auxiliary work, daily planning 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 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's requirements 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 - 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 the procedure for qualification of welding procedures. a) The WPQR for qualification by tested welding consumables (ISO 15610) may be based on the following: inspection body's (e.g. TTK, TV, DNV, Lloyds, etc.) lists of parent materials and filler materials welding consumable manufacturers list (e.g. Esab, Elga, Bhler, etc.), which may include 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 any need for weld repair. This statement may be done e.g. in connection with maintenance at the customer. c) Standard welding procedure (ISO 15612): WPQR prepared by the organisation which performed the welding procedure test (if available). 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. 4.11 Storage and handling of welding consumables
The purpose of the procedure is to ensure that the handling and storage of welding consumables 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, baking and handling needs to comply with the recommendations of the manufacturer of welding consumables. Responsibility The person responsible for the storage and handling of the welding consumables is the person in charge of welding in the company, e.g. responsible welding coordinator or a person 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 consumables with 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 packages always 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 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 after 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 left around. e) Drying and storage of welding consumables: Devices used for drying need to be available Consumable specific instructions for drying based on the manufacturer'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
consumable
The purpose of the procedure is to ensure that the parent materials used for welded products 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 storage of parent materials. The person responsible organises and ensures that the storage of parent 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 authorities shall 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, this shall 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 the requirements 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 become mixed up. 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, the transfer of the markings of the pressure vessel materials shall be made before nestling. A person 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 is retained. f) Where necessary, and according to the product standard, the customer shall be provided 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 specified manner 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 for manufacturing 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 testing
4.14.1 Contents The purpose of the procedure (Inspection and Testing Plan) is mainly to ensure that quality control is in place before welding, during welding, and after welding. Procedures are prepared for visual inspection and for both destructive and nondestructive testing. 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 responsible for the actual inspection work and its results. The inspectors' visual acuity should be checked at regular intervals. The majority of inspections do not require an outside inspector, e.g. a welder trained for inspection tasks can do the visual inspection of the welds he has made. The general principle 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 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 of root 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 The procedure may include:
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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 interpass temperature, 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 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 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 be delivered 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 on the nature of the non-conformance, the welder shall have the right, if necessary, to interrupt his/her work. A designated person shall be given the responsibility for ensuring that the corrections/repairs are made according to instructions and completed, and that the required 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 shall inform e.g. the foreman/responsible welding coordinator about it. A non-conformance report 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 instructions?) 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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work
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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 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 procedure specification really meet the requirements for the work to be done? Has the welding procedure specification been wrongly prepared? Has the welding procedure specification been qualified by previous welding experience according EN ISO 15611 (the qualification of WPS to be withdrawn?) What method has to be followed in corrective and preventive actions? Reporting Others 4.16 Calibration and validation of measuring, inspection and testing equipment The purpose of the procedures is to ensure that the measurement instruments and equipment in use meet the required technical and other criteria for fulfilling the requirements specified by the customer. Requirements for calibration and validation of equipment used for welding, including ancillary activities are given in ISO 17662. The procedures refer to the measurement instruments and equipment used in manufacture and inspection. The company shall nominate a person responsible for calibration and validation. The company is responsible for the appropriate calibration or validation of inspection, measurement and testing equipment for welded products. The extent and level of accuracy of the calibration or validation and the interval between these activities shall be defined by the company according to required product standards. It shall be observed that tight production tolerances cause a greater need for accuracy of calibrated or validated equipment. Generally, calibration concerns instruments and equipment (master instruments) used for validation of instruments used in testing the final properties of a product. For products requiring great accuracy, the degree of measurement uncertainty (accuracy) shall be known and it is necessary to ensure the companys own measurement equipment is traceable to international measurement standards.
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The company shall prepare the necessary calibration or validation procedures for instruments and equipment. The most common objects of calibration or validation in the welding industry include: a) The equipment required for inspection by measuring of finished products or, if necessary, parts, e.g.: measuring tapes for final inspections caliper gauges and micrometers gauge blocks dial indicators angle gauges measuring instruments for throat thicknesses rulers matrices thickness gauges theodolites and measuring machines b) c) Gauges and meters used in welding and flame cutting, e.g.: ammeters and voltmeters tachometers gas flow meters (rotameter) wire feed regulator measurement equipment required in heat treatment and pre-heating, e.g.: plotters regulators thermoelements thermometers pyrometers
d) Equipment used in non-destructive testing, e.g.: magnetization equipment magnetic field gauge light intensity meters X-ray equipment viewing devices densitometers ultrasonic equipment and calibration blocks e) Destructive testing: The equipment should be subject to official calibration inspection, e.g. hardness, tensile testing machines and impact hammers. 4.17 Identification and traceability
The purpose of the procedures is to ensure that the identification and traceability of the welded product or its parts are maintained throughout the whole manufacturing process.
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The procedures concern organizing and documenting the identification and traceability of welding and related activities. The company is responsible for planning, managing and documenting identification and traceability at the product level. Identification and traceability relating to welding should include, if necessary, depending on the structure and its application: identification of production plans (see also clause 4.10.1) identification of routing cards or a list identification of weld locations, e.g. by a drawing of the actual situation identification of non-destructive testing procedures and personnel (for which object?) identification of welding consumables, e.g. designation, trade name,, manufacturer of welding consumables and batch or cast number, if required identification and/or traceability of parent material, e.g. type, cast number, if required identification of location of weld repairs identification of location of temporary attachments traceability for fully mechanized or automatic welding units to specific welds traceability of welders and welding operators to specific welds . traceability of welding procedure specifications to specific welds. 4.18 Quality records
4.18.1 General
The quality records are an essential part of the companys quality assurance system. They provide the basis for its quality policy, quality objectives and working methods and they ensure the repeatability of procedures. With the help of the quality records and systematic working methods, it is possible to get customers and possible third parties, already interested at the first contact. At the same time they may also be convinced of the companys ability to manufacture and deliver the required product. The records should be used by all those whose work is affected by the document in question. The quality records can be divided into two groups: 1) The documents relating to the companys own activities e.g. operational and work instructions for the organization, distribution of responsibilities and operations of the company. 2) Quality files derived from the documents, reports and check lists (forms) on actions relating to the product and documents delivered to the customer together with the product. 4.18.2 Records relating to the companys own operations In a welding company records are, for example, the organizational description/chart, responsibilities and authorizations within the organization, the equipment list and documents specified in ISO 3834-2.
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These include instructions relating to document management and procedures for: how perform certain operations references to standards, if possible the person performing the operation the timing of the operation signing the completion of operation.
In addition to table 2 the following records may be useful: correspondence with the customer, inquiries, offers/tenders, orders, confirmations of orders documents and confirmations of orders relating to purchasing drawings approved subcontractors non-destructive and destructive testing procedures and reports procedures for acceptance of parent materials and transfer of marks material certificates 4.18.3 Quality files regarding a specific product A contract, product standard or law may require that certain quality records have to be delivered together with the product to the purchaser and in some cases also to the relevant authorities. Quality files should also be retained in order to demonstrate the achievement of the required quality and the efficient functioning of the quality procedures. The documents should be prepared at the stage of manufacture or inspection concerned and collected so that they can be collected immediately when the product has been completed. The welding coordinator or the person responsible for quality should check and approve the documents before sending them to the customer. The documents should be sufficiently clear, accurate and easily identifiable as belonging to a specific product, so that it can be proved afterwards that the requirements of manufacture and inspections have been fulfilled. The manufacturer files the documents in accordance with its own archiving procedures. Another way of ensuring that the necessary documents are created on schedule is to have a production or quality plan covering the stages and operations involved in the products manufacture and inspection, signed by the responsible person when the required actions have been completed. The documents specified in the contract shall be submitted together with the product. The documents to be delivered may include the following: records of requirement/technical reviews production/quality plan material certificates information on welding consumables
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reports of material testing routing cards relating to inspection measurement and other test reports list of welding procedure specifications used list of qualified welders used heat treatment procedure specifications and reports records of repairs and non-conformance reports.
The periods for retention of individual records shall be defined and documented and the record holders identified. 4.18.4 Document management The manufacturer should create an easily usable list-based or other equivalent procedure for document control, in order to verify their validity and to prevent the use of invalid and/or outdated documents. The documents shall be provided with an identification number, a revision number, signature and date of approval. The persons to whom the documents have been delivered to shall be listed, and at the same time it is ensured that all have the latest revised version at their disposal. The documents may be filed as a hard copy or in an electronic format, for example for 10 years. The person who has approved the original document should also approve any changes made. The points changed are to be marked in a suitable manner. 5 Need for certification
Fulfillment of the requirements of ISO 3834 can be demonstrated in different ways. Often the requirement may be a certification of the system. The company should be able to choose itself whether it wants certification to promote marketing, to improve overall quality and efficiency and to increase the credibility of its operations from the customers or stakeholders perspective.
There are several ways of showing the customer or a potential customer that the companys welding quality requirements have been met. These are: a method bilaterally agreed on between the customer and the company auditing by the customer auditing by a third party chosen by the customer. Quality is always a question of agreement between the customer and the supplier, which does not necessarily require certification. 6 Adoption of ISO 3834 in a company The adoption of ISO 3834 in a company may, for example, be carried out in as a project in three stages. AT the first stage the company has to carry out a survey of the current situation. This stage should be performed with great care and sufficient time should be spent on it, as it forms the basis for the success of the whole project. The current situation should be
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examined as thoroughly and as truthfully as possible. It is human at this stage to embellish the actual situation in the company. Such embellishment, however, makes the actual advantage gained from the project smaller than expected. Very often only the requirements of the standard will be met, but the possibilities for improving the quality and efficiency of the production will be lost already at the beginning of the project. In many cases the examination of the initial situation is useful, if consultation with an outside expert is used, because the expert has no need to describe the situation as better than it actually is. Neither is an outside expert subject to workplace blindness, which is only human for people who have worked for a long time at the same workplace. When real quality improvement is defined as the goal, it is important to gain the commitment of personnel at all levels in the companys hierarchy to the project. The executive management of the company shall give and demonstrate its full support for the project from the beginning to the end. This is supported by informing and training the personnel at the earliest possible stage. It has been found useful to arrange training of the stuff in connection with the survey of the current situation. The number of companys staff, products and company culture are important factors making the organizing of a training event beneficial. Separate training events can be organized for clerical staff and welding personnel, or all personnel groups can be gathered together in one event. The advantage of the first alternative is that the content of the training can be tailored accurately to meet the needs of target group. For example, for welders, the items of the standard on Equipment, Welding activities and Welding consumables can be highlighted. For the clerical staff it would be useful to concentrate, for example, the item Requirement and technical reviews. The advantage of a common training event organized for the whole personnel would be that it would be possible to examine matters from different perspectives. The various personnel groups would gain an overall picture of all the operations affecting quality management in welding as required by the standard. The personnel groups would get knowledge of items dealt with in other groups areas of responsibility and understand the actions required by themselves and others and the linkages and dependencies between them. The number of participants in the training events should be restricted to enable an open and controlled discussion of matters. In large enterprises it is better to arrange several events than to bring together the whole personnel or personnel group in one training event. There is no reason to underestimate the importance of training or information events, because the basic requirement for a successful project is that the whole personnel is involved in developing the activities. The main objective of the first stage is to identify and record items needing improvement. After this stage it is often useful to update the project plan, in order to ensure a realistic schedule for implementation. At the second stage, on the basis of the initial survey, an action plan shall be prepared for addressing the items needing development and the planned actions shall be performed. These actions may be split into separate tasks, for example, according to the
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list of contents in the standard or to the companies own quality manual. Chronologically the separate tasks may be carried out either simultaneously or successively. The method of implementation depends on the resources available for the project and how responsibilities are assigned in the company. At latest at this stage of the project, it is recommended to nominate a responsible person(s) for each item to be developed. Training of the companys personnel continues at this stage. While the first stage mainly gives information on the content of ISO 3834 and the actions regarding needed procedures and documentation to meet the requirements, at this stage the objective is focused on the technical content of actions and procedures. Activities and training given at this stage are to a large extent decisive as regards the technical and economic benefits that adopting ISO 3834 will bring the company. When the items according to ISO 3834 are used as a tool for measuring the quality producing capacity of the company, and the weaknesses and disadvantages found as a result of using the standard are addressed properly, the productivity of welding can be improved and quality costs cut, so that the expenditure and effort put into the ISO 3834 project will be found as an excellent investment. The duration of the second stage depends very much on the size and initial situation of the company. If the company has a certified ISO 9001 quality system in place and it has, for example, successfully manufactured standardized products, it has in practice already had to operate according to many of the items of ISO 3834-2. Readiness for certification can in this case be achieved quite quickly and with a very reasonable amount of work. The additional work may be limited to revising of a few operational procedures to bring them into the form required by ISO 3834. The work is considerably more demanding if the company does not have a certified quality system, or a well documented quality management system has not been required for the products it manufactures, especially as regards welding. The work of preparing procedures is in any case quite extensive even though an effort is made to minimize the number of procedures to what is appropriate. Time and resources shall also be reserved for understanding the purpose of the procedures and for learning the tasks involved in practice and establishing them on all levels of production. Typically, 618 months shall be reserved for the second stage. In order to achieve a timetable of 6 months, the ISO 3834 work shall be done by teams of several (> 3) people simultaneously in the different areas of operations. If the implementation of the standard will be done in a team, as small as possible, (e.g. in addition to normal workload), the project will easily take more than a year. The estimates above mainly concern companies with a wide production program. If the company manufactures a clearly limited range of products, where the welding work is similar, and the requirements are clearly established, the timetable for adopting ISO 3834 may be much shorter. The third stage involves checking the functional effectiveness of the quality management system for welding and its compliance with standards, so that any remaining disadvantages are found before the real audit by an external party. This pre-audit could
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be carried out by an expert in the project, who has not participated in developing the procedures of the company concerned. The pre-audit could also be done by an outside expert familiar with ISO 3834. The idea here is to avoid a situation where a person could assess the results of his or her own work. Any disadvantages found will, of course, be corrected, after which the company can ask for an audit by an accredited certificating body. The end goal is an effectively functioning quality management system for welding, and at this stage all the procedures will comply with the appropriate requirements according to ISO 3834. Problems The most common problems occurring with the implementation of ISO 3834 are: purchasing or ordering status of the responsible welding coordinator in the company handling of welding consumables following the welding procedure specifications validation of ammeters and voltmeters range of qualifications.
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Annex A: Questionnaire for Audits according to EN ISO 3834-2:

Note: The reduced requirements according to EN ISO 3834-3 and -4 shall be taken into consideration accordingly. In case of a certification according to EN ISO 3834-4 the addressed documents in this questionnaire do not need to be submitted with the application. Number of registration: Name of company: Address: _____________________________________ _____________________________________ _____________________________________ _____________________________________ Audit team leader: Auditor: Reference documents (Status): Date of audit: _____________________________________ _____________________________________ _____________________________________ _____________________________________ Type of audit: Audit Preliminary audit Follow-up audit Surveillance audit Re-Audit
_________________________ Signature (Audit team leader)
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Paris Nord 2 - 90 rue des Vanesses - BP 51362 - VILLEPINTE - 95942 ROISSY CH DE GAULLE Cedex FRANCE Phone : + 33 1 49 90 36 08 Fax : + 33 1 49 90 36 80
Eleme nt numb er acc. to Referencen umber acc. to
+ 33 1 49 90 36 79 Email : iiwceo@wanadoo.fr
+ 33 1 49 90 36 15 WEB Site : http://www.iiw-iis.org
To be completed by the company
To be completed by the auditor Result of the audit R2)
ISO ISO 3834 38341) 2 -1
Questions to the quality requirements according to ISO 3834-2

REVIEW OF REQUIREMENTS AND TECHNICAL REVIEW
Confirmation Remarks, if required
5.2
Are the following technical aspects considered? Product standards Statutory and regulatory requirements Any additional requirement determined by the manufacturer Any additional requirement determined by the customer The capability of the manufacturer to meet the prescribed requirements Is the check of the requirements indicated and appropriately documented, if necessary?
e.g..
Yes No Remarks:
Checklist Description Records

2 5.3 Are the following technical requirements checked? Yes No
Parent material(s) Remarks: specification, welded joint properties Quality and acceptance requirements for welds Location, accessibility, weld sequence (Welding, NDT) Welding procedures, nondestructive testing procedures, heat treatment Qualification of welding procedures Qualification of personnel Selection, identification, traceability
1) 2) Graduation: part 2, 3 and 4 see table A of ISO 3834-1 R = Result, 0 = not applicable , 1 = met, 2 = partly met, but still acceptable, 3 = partly met, but not acceptable, 4 = not acceptable
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ISO ISO 3834 38341) 2 -1
Questions to the quality requirements according to ISO 3834-2 Quality-control Inspection, testing Sub-contracting Post-weld heat treatment Specific welding requirements Specific welding procedures Specifications regarding joint preparation and completed weld Environmental conditions Handling of non-conformances
1, 2, 22
18
Is the check of the requirements indicated and appropriately documented, if necessary?

e.g..
Yes No Remarks:
3 3
6 6
Checklist Description Records SUB-CONTRACTING Are sub-contractings performed? Sub-contracting of welding works Yes / No Sub-contracting of inspection Yes / No Sub-contracting of NDT Yes / No Sub-contracting of heat treatment Yes / No Others:
Are the followings items considered by sub-contracting?
Yes No
1) 2)
Graduation: part 2, 3 and 4 see table A of ISO 3834-1 R = Result, 0 = not applicable , 1 = met, 2 = partly met, but still acceptable, 3 = partly met, but not acceptable, 4 = not acceptable
39
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ISO ISO 3834 38341) 2 -1
Definition of preconditions and Remarks: criterias of selection of subcontractors Ensuring of the necessary documents to the subcontractor Observance of the relevant requirements according to ISO 3834 by the sub-contractor Fulfilling of the quality requirements by the subcontractor Is the check of the requirements indicated and appropriately documented, if necessary?
e.g..
Sub-contractor list Subcontractor audit plan Audit report undertaken by the manufacturer
4 4 4, 22 7 7.2 7.2 18
WELDING PERSONNEL Welder and operators Is a sufficient number of welders/operators available and qualified by suitable qualification tests? Welding coordination personnel Is the welding coordination personnel competent and authorized to enable any necessary action to be?
e.g.
Yes No Submit certificates or present them during the audit. Remarks:
Is the number of qualified welders/operators sufficient? Are the qualifications suitable?
5 5
7.3 7.3
Yes No
Remarks:
Organisation chart Appointment

1) 2) Graduation: part 2, 3 and 4 see table A of ISO 3834-1 R = Result, 0 = not applicable , 1 = met, 2 = partly met, but still acceptable, 3 = partly met, but not acceptable, 4 = not acceptable
40
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ISO ISO 3834 38341) 2 -1
7.3
Are the tasks and responsibilities Yes No defined?

e.g.
Are the determinations suitable?
7.3
7.3
Matrix of responsibilities Description of position Are the competences for the review of requirements defined and is the welding coordinator integrated in the sense of EN ISO 14731? Organisation chart Description of position Matrix of competence Other proof (Nomination, bulletin) Is a sufficient number of competent welding coordination personnel according to the designated production range available?
Remarks
Yes No
Remarks:
DVS-SFI/IWE/EWE, number: DVS-ST/IWT/EWT, number: DVS-SFM/IWS/EWS, number: Other qualifications, number: Submit certificates or present them during the audit.
Is the number sufficient? Yes No Are the qualification suitable? Yes No In case of other qualifications (DVSSFI/EWE/IWE, DVSST/EWT/IWT, DVSSFM/EWS/IWS): a separate professional interview is necessary covering the following items: Welding Processes Welding Consumables Materials Construction Calculation Manufacturing Examination Classification to DIN EN
1) 2)
41
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ISO ISO 3834 38341) 2 -1
ISO 14731: C: S: B:
6 8
INSPECTION AND TESTING

PERSONNEL
Yes Is a sufficient number of No competent personnel for planning, performing, supervising and testing of the welding Remarks: production available? Are (additional to the direct visual Yes, which? testing) testing methods used? Visual testing using devices (VT) Penetrant testing (PT) Magnetic particle testing (MT) Radiographic testing (RT) Ultrasonic testing (UT) Others No Yes Is the personnel sufficient No qualified to perform nonSubmit certificates or present destructive testing? them during the audit. (see EN ISO 3834-5: 2005, tables 3 and 10) EQUIPMENT Is an actual list of essential equipment used for production and testing available? Power sources and other machines Equipment for joint and surface preparation as well as for cutting, including thermal cutting. Yes No Submit the list or present it during the audit with details to: Maximum capacity of crane(s) Size of components that the workshop is able to
42
6, 22
8.2 18
7, 8, 9 7, 8, 9
9.2
1) 2)
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ISO ISO 3834 38341) 2 -1
7, 8, 9
9.3
7, 8, 9
9.4
handle Equipment for preheating and post-heat treatment including Capability of mechanised temperature indicator or automatic welding Jigs and fixtures equipment Cranes and handling Dimensions and equipment used for the maximum temperature of production furnaces for heat Personal protective equipment treatment and other safety equipment, directly associated with the Capacities of rolling, applicable manufacturing bending and cutting process equipment Ovens, quivers etc. used for treatment of welding Facilities for surface cleaning Destructive and nondestructive facilities Is the equipment adequate to the Yes welding application concerned? No (Proof of suitability only if specified) Yes Is the correct function of new or No refurbished equipment verified before the initial operation? Remarks: Yes Are documented plans for the No maintenance of equipment available, including control of maintenance of the facilities used Remarks: for checking the relevant parameters of the welding specifications? Yes Do the plans cover all equipment, which are essential No for the quality of the components? Remarks: Condition of guides in equipment for thermal cutting,
43
7, 8, 9, 22
9.5, 18
7, 8, 9, 22
9.5, 18
1) 2)
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ISO ISO 3834 38341) 2 -1
Questions to the quality requirements according to ISO 3834-2 mechanised fixtures etc. Condition of ammeters, voltmeters, flow meters etc, used for the operation of the welding equipment Condition of cables, hoses, connectors, etc. Condition of control system in mechanised and/or automatic welding unit Condition of temperaturemeasurement instruments Condition of wire feeders and conduits Is guaranteed that defective equipment is not used?
7, 8, 9
9.6
Yes No Remarks:
10, 11, 12 10, 11, 12
10
WELDING AND RELATED

ACTIVITIES
10.1
Is a production planning carried out, including the equipment foresight for use of manufacturing and testing Specification of the sequence by which the component/construction shall be manufactured Identification of the individual processes required to manufacture the component/construction Reference to the appropriate procedure specifications for welding and allied processes Sequence in which the welds are to be made
Yes No Remarks:
1) 2)
44
SIRET : 422 335 901 00019 - APE 524R - TVA : FR20422335901


ISO ISO 3834 38341) 2 -1
Questions to the quality requirements according to ISO 3834-2 Order and timing in which the individual processes are to be performed Specification for inspection and testing, including the involvement of any independent inspection body Environmental conditions (e.g. protection from wind and rain) Identification by batches, components or parts Allocation of qualifies personnel Arrangement for any production test
10, 11, 12, 22
10.1, 18
Are the production plans suitable Yes No for the relevant application and do they contain all necessary information? Remarks: Are welding procedure specifications (WPS) for the welding procedures in use available? Arc welding (EN ISO 15609-1) Gas welding (EN ISO 15609-2) Electron beam welding (EN ISO 15609-3) Laser beam welding (EN ISO 15609-4) Arc stud welding (EN ISO 14555) Others: By which method are these welding procedures qualified? Qualification by a welding procedure test (EN ISO 15614) Yes No Present examples during the audit
.
10, 11, 12, 22
10.2, 18
10, 11, 12, 22
10.3, 18
Yes No Remarks:
1) 2)
45
SIRET : 422 335 901 00019 - APE 524R - TVA : FR20422335901


ISO ISO 3834 38341) 2 -1
Questions to the quality requirements according to ISO 3834-2 Qualification based on tested consumables (EN ISO 15610) Qualification based on previous experience (EN ISO 15611) Qualification by adoption of a standard welding procedure (EN ISO 15612) Qualification based on preproduction welding test (EN ISO 15613) Others: Are additional to the welding procedures specifications also work instructions used? Is a procedure for establishing and control of relevant quality documents available? Procedure for establishing and controlling of e.g.: - WPS - WPQR - Inspection documents WELDING CONSUMABLES
10, 11, 12
10.4
Yes No Remarks: Yes No Remarks:
10, 11, 12
10.5
13, 14 14, 22
11 11.1, 18
13
11.2
Yes Are responsibilities and procedures for control of welding No consumables specified? Remarks: e.g: Conformity certificate Inspection document Yes Is batch testing of welding No consumables required? Remarks:
1) 2)
46
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ISO ISO 3834 38341) 2 -1
Questions to the quality requirements according to ISO 3834-2 Are procedures for storage, handling and use of welding consumables produced and implemented? Moisture pick-up Oxidation Damage Recommendations of supplier STORAGE OF PARENT MATERIALS Is the storage of the parent material (including material supplied by the customer) performed in such a way, that they are not be adversely affected? Are measures and plans available for environmental influences? Are tasks and responsibilities for control of the storage of parent material specified and implemented in production (identification, storage and handling)?
Confirmation Remarks, if required Yes No Remarks:
14
11.3
15 15
12 12
Yes No Remarks: Yes No Remarks: Yes No Remarks: Yes No Remarks:
15, 22
12 18
Is the marking/identification during the time of storing guaranteed? Type of marking Inspection documents POST-WELD HEAT TREATMENT Is post-weld heat treatment performed? (also subcontracting)? Are the responsibilities for the performance of post-weld heat treatment specified?
16 16
13 13
16
13
Yes No (Further questions are not applicable) Yes No
1) 2)
47
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ISO ISO 3834 38341) 2 -1
Confirmation Remarks, if required Remarks:
16, 22
13, 18
16, 22
13, 18
17 17, 22
14 14.2, 18
Is post-weld heat treatment performed according to written instructions? Related to e.g.: Parent material Welded joint Component Product standards/specifications Can, on the basis of the record, the traceability of the performance of the post-weld heat treatment to the particular component be demonstrated? Recording of the process parameter (e.g. heat treatment record) Size of the furnace Conditions of supporting in the furnace INSPECTION AND TESTING
Yes No Remarks:
Yes No Remarks:
Are inspection and testing before Yes welding performed in accordance No with the contact/rules? Remarks: Suitability and validity of welders and operators qualification certificates Suitability of the welding procedure specification Identity of parent material Identity of welding consumables Joint preparation Fit-up, jigging and tacking Any special requirements in
48
1) 2)
SIRET : 422 335 901 00019 - APE 524R - TVA : FR20422335901


ISO ISO 3834 38341) 2 -1
Questions to the quality requirements according to ISO 3834-2 the welding procedure specification Suitability of working conditions, including environment Are inspection and testing during welding performed in accordance with the contract/rules? Essential welding parameters Preheating/interpass temperature Cleaning and shape of runs and layers of weld metal Back gouging Weld sequence Correct use and handling of welding consumables Control of distortion And intermediate examination (e.g. checking of dimensions) Are inspection and testing after welding performed in accordance with the contact/rules? By visual testing By non-destructive testing By destructive testing Form, shape and dimension of the component/construction Results and records of postweld operations
Is the status of inspection and testing given, as appropriate? e.g..
17, 22
14.3, 18
Yes No Remarks:
17, 22
14.4, 18
Yes No Remarks:
17, 22
14.5, 18
At the component In the routing cards
Yes No Remarks:
18
15
NON-CONFORMANCE AND CORRECTIVE ACTIONS
1) 2)
49
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ISO ISO 3834 38341) 2 -1
Questions to the quality requirements according to ISO 3834-2 Are measures implemented to handle items, which are not conform to specified requirements? Identification Responsibilities Repair specification/repair Re-inspection Measures for avoiding recurrence Are non-conformance records maintained? CALIBRATION AND VALIDATION OF MEASURING, INSPECTION AND TESTING EQUIPMENT Are measuring, inspection and testing equipment calibrated and validated? Equipment Procedure Responsibilities Check list (see EN ISO 3834-5: 2005, Tables 9 and 10) IDENTIFICATION AND
TRACEABILITYI
Confirmation Remarks, if required Yes No Remarks:
18, 22
15, 18
19
16
19
16
Yes No Submit a list or present it during the audit
20, 21 20, 21
17
17
Are rules for identification and traceability during the manufacturing process available? e.g. it can be required: Identification of production plans Identification by routing cards Identification of weld locations in the component/construction
Yes No Remarks:
1) 2)
50
SIRET : 422 335 901 00019 - APE 524R - TVA : FR20422335901


ISO ISO 3834 38341) 2 -1
Questions to the quality requirements according to ISO 3834-2 Identification of non-destructive testing procedures and personnel Identification of welding consumables Identification and/or traceability of the parent material Identification of location of repairs Identification of location of temporary attachments Traceability of fully mechanised and automatic welding units to specific welds Traceability of welder and operators to specific welds Traceability of welding procedure specifications to specific welds QUALITY RECORDS
22 22
18 18
Are quality records available and Yes No for which time period are they retained? Remarks: Time period 5 years Record of requirement/technical review Material inspection documents Welding consumables inspection documents Welding procedure specifications (WPS) Equipment maintenance records Welding procedure qualification records (WPQR) Welder or welder operator qualification Production plan Non-destructive testing
1) 2)
51
SIRET : 422 335 901 00019 - APE 524R - TVA : FR20422335901


ISO ISO 3834 38341) 2 -1
Questions to the quality requirements according to ISO 3834-2 personnel certificates Heat treatment specifications and records Non-destructive and destructive testing procedures reports Dimensional reports Records of repairs and nonconformance reports Other documents, if required USE OF STANDARDS NOT COVERED IN ISO 3834-5 Does the manufacturer specify the use of standards different than those referred in ISO 38345? USE OF THE CERTIFICATE
---
---
---
---
Yes No Remarks:
-----
-----
Does the use of the certificate by Yes the manufacturer give a true and No accurate image of the Remarks: manufacturers capability covered by the certification?
1) 2)
52
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Annex B: Example of a simple procedure for qualification of welders

Scope This procedure ensures that the welders have the required qualification Field of application This procedure concerns qualification of welders according to ISO 9606/EN 287-1. Qualification testing of welders and examination All welders perform qualification tests according to ISO 9606/EN 287-1. Annex A includes a list of the qualification tests to be performed. For examination check list C 6.2 will be used. Testing The welding co-ordinator performs the visual testing according to ISO 17637. After acceptance the test pieces will be sent to testing laboratory (Inspection Ltd) for radiographic testing. (see procedure B 5.3j). Quality records The responsible welding co-ordinator files a data base including all welders' certificates. The data base includes a list of welders, their qualification and validity. Validity The welding co-ordinator signs the certificates every six months. For signing the welding foreman provides the welding co-ordinator with all necessary information concerning welding work. Every two years new qualification tests are carried out.
3) 4)
53
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Improving Quality of Welding with ISO 3834

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International Institute of Welding

A world of joining experience

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Pressure vessels (EN 13445)

At least ISO 3834-3

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Railway vehicles (EN 15085)

Off shore (NORSOK) Water tube boilers (EN 12952-5)

The purpose of procedure is to:

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5 Review of requirement review and technical review 6 Subcontracting

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10.4 Work instructions

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11 Welding consumables 12 Storage of parent materials 13 Post-weld heat treatment

14 Inspection and testing

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International Institute of Welding

identification of welders 17.4 Procedure for acceptance tests 18 Quality records

18 Procedure for preparing and filing of quality records

Example, see annex A Example see annex B

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International Institute of Welding

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International Institute of Welding

International Institute of Welding

International Institute of Welding

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International Institute of Welding

Welding and related activities

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International Institute of Welding

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Inspection and testing

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Acceptance levels (e.g. corresponding to quality levels)

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International Institute of Welding

Annex A: Questionnaire for Audits according to EN ISO 3834-2: