Company Certification Standards in Welding

SOME OF THE MANAGEMENT STANDARD.

ISO 900O -QMS ISO 14000 -EMS ISO 18000-Occupational Health and Safety Management System (OH& S MS) And International Standard OHSAS 18001:1999 ISO 27000-ISO/IEC 27002 provides best practice recommendations on IS security management systems (ISMS).

EMERGING STANDARDS
ISO-3834 Quality requirements for fusion welding of metallic materials. EN -15085- Welding of railway vehicles and components. IRIS- International Railway Industry Standard

Welding is a Special Process-Why

7 - Product realization 7.5 Production and service provision 7.5.2 Validation of processes for production and service provision The organization shall validate any processes for production and service provision where the resulting output cannot be verified by subsequent monitoring or measurement and as a consequence, deficiencies become apparent only after the product is in use or the service has been delivered.

What is ISO-3834&EN 15085

It is an international standard created by the welding professional ISO 9001 defines requirements for quality management system ISO 3834 also defines the quality requirements, only welded products. EN 15085 for railway applications.

What is ISO-3834&EN 15085(contd)

The standard specifies the requirements relating only to the welded structure. The standard can also be used as a production control system. ISO 3834 is not a product standard, but it is often cited as a requirement of various products to ensure good practice in the welding and to prevent premature failures.

What is ISO-3834&EN 15085(contd)

The standards provides details of how to control the various welding and weldingrelated operations to achieve the desired quality consistently The company that is certified according to this standard gains an advantage when competing with other companies in European and World wide markets.

ISO 3834 part-1 to 4

ISO 3834-1-General requirements ISO 3834-2- Comprehensive quality requirement ISO 3834-3- Standard quality requirement ISO 3834-4 -elementary quality requirement

ISO 3834-2- Comprehensive quality requirement

Constructions in which the failure of welds may lead to total product failure with significant financial consequences Major injury. The product may be subject to dynamic loading In addition to high static loading.

ISO 3834-3- Standard quality requirement

Constructions in which failure of welds
impair the intended use of construction. Normal safety risk Financial losses not extreme.

ISO 3834-4 elementary quality requirement

Constructions in which failure of welds Not fundamentally impair the intended use. No adverse effects on safety of people Minor financial consequences.

EN 15085 Railway applications Welding of railway vehicles and components

Part 1: General Part 2: Quality requirements and certification of welding manufacturer Part 3: Design requirements Part 4: Production requirements Part 5: Inspection, testing and documentation

REQUIREMENTS TO IMPLEMENT ISO 3834&EN 15085

MEN MATERIAL METHOD MACHINE MONEY

Welding personnel(Men)
Welders and welding operators Welding co-ordination personnel Inspection & testing personnel Welding inspection personnel Non-destructive testing personnel

Welder qualification standards

American standards ASME/Sec IX AWS D1.1 ISO/EURO BS EN 287 ISO 9606 INDIAN IS 817 IS 7318 IS7310

What is the main reason for carrying out a Welding Procedure Qualification Test ?

To show that following a given set of parameters will produce a welded joint that has the properties that satisfy the design requirements

Welder Qualification
What is the main reason for carrying out a Welder Qualification Test? To test the ability of a welder to follow verbal or written instructions and verification that the weld produced meets the required standard

Terminology
WPS - Weld Procedure Specification: Qualified instructions on how to complete the weld PQR - Procedure Qualification Record (ASME) & WPAR - Weld Procedure Approval Record: Record of the welding parameters and test results Welders Qualification Test Certificate & Welders Performance Qualification (ASME) Record of Welder test results and ranges of approval

Terminology
Essential Variable: A parameter that when changed outside its permitted range requires requalification Non Essential Variable
A parameter that when changed does not require requalification Supplementary Essential Variable Is an essential variable only when impact testing is required

Components of a welding procedure

Parent material

Type (Grouping) Thickness Diameter (Pipes) Surface condition

Components of a welding procedure

Welding process

Type of process (MMA, MAG, TIG, SAW etc) Equipment parameters Amps, Volts, Travel spee

Components of a welding procedure

Welding Consumables

Type of consumable/diameter of consumable Brand/classification Heat treatments/ storage

Components of a welding procedure

Joint design

Edge preparation Root gap, root face Jigging and tacking Type of baking

Welding Position

Location, shop or site Welding position e.g. 1G,2G, 3G etc Any weather precaution

Components of a welding procedure

Thermal heat treatments
Preheat, temps Post weld heat treatments e.g. stress relieving

EN 287-Part-1 -2011
QUALIFICATION TEST OF WELDERS FUSION WELDING PART-1- STEEL

Validity Of Approval

Valid for 2years, providing that the welders supervisor can confirm that at every six month period the welder has been working within his range of qualification.

Job knowledge for welders as per en 287

Job knowledge test shall comprise: identification of the range of qualification based on the current qualification test, properties and identification of parent materials within the material groups or sub-groups of the test pieces, properties and identification of parent materials within the material groups or sub-groups covered by the range of the qualification certificate to be issued, characteristic features of the welding process being the subject of the qualifica- tion test, properties and identification of welding consumables used for the particular welding process, the principles of edge preparation for welding and pre-welding assembly, the principles of selecting proper welding parameters, the principles of pre-heating and pre-heating control, proper interpass temperatures and their control, weld imperfections and their causes, method of repair of the welds below the acceptance level.

Visual Testing
Each test piece shall be subjected to visual testing (VT): after the root run of the butt weld has been performed in the test piece, after completion of the test piece. Visual testing and its recording shall comply with the guidelines contained in EN ISO 17637. The quality level of the test pieces, based on type and size of imperfections, shall be assessed in accordance with EN ISO 5817 for steel test pieces and EN ISO 10042 for the test pieces of aluminium or its alloys. Surface imperfections of the test piece shall be within quality level B. Only the following types of imperfections in quality level C are permitted: excess butt weld metal (502), excess fillet weld metal (503), excess throat of the fillet weld (5214), excessive penetration (504), incorrect weld toe (505), undercuts (501). The reference numbers given in brackets are in accordance with EN ISO 6520-1. In the assessment of the root run of the butt weld test piece welded from both sides, weld root removed, surface imperfections shall not exceed limits for imper fections within quality level D.

WELDER DESIGNATION
EN287-1-135-P-BW-1.1-S-t16-PA-ss nb.

Welder qualification designation

standard Welding Prod process uct type Weld type Material group Weldi Material ng thickness consu mable s Pipe out Welding Weld side position details diameter

EN 287 111 -1

BW

1.1

10 mm

D 60

PA

ss nb

1-Steel

SMAW

PLATE

Butt Weld

Steel with steel classified based on yield strength

Basic coated electro de.

plate thickness

out side dia

down hand

single side with no backing

BS EN ISO 5817 -2007

Welding-fusion welded joints in steel ,nickel,titanium and their alloys( beam welding excluded). Quality levels for imperfections

 Applicable above 0.5 mm parent metal thickness. Covers fully penetrated butt welded and all fillet welds. Principles of this standards can also be applied for partial penetration butt weld.

Different quality levels.

Three quality levels are given Quality level C -stringent Quality level C- Intermediate Quality level D- Moderate.

This International Standard applies to:

unalloyed and alloy steels; nickel and nickel alloys; titanium and titanium alloys; manual, mechanized and automatic welding; all welding positions; all types of welds, e.g. butt welds, fillet welds and branch connections; the following welding processes and their defined sub-processes in accordance with ISO 4063:

BS EN ISO 4063-2009
WELDING AND ALLIED PROCESSES NOMENCLATURE OF PROCESSES AND REFRENCE NUMBERS.

ISO 4063
Process number 1 arc 23- gas welding resistan weldin ce g welding 5 beam weldin g 8cutting &goug ing

52 81 oxy Laser fuel weldin cutting g

83 Plasm a cutting 833 air plasm

4063 classification
1 arc welding 111- SMAW/MMAW 12- Sub merged welding.(SAW) 121- sub merged arc welding with solid wire electrode. 13- GMAW 131- MIG welding with solid wire 135-MAG welding with solid wire 136- MAG welding with flux core wire.

14- GTAW. 141- TIG welding with solid filler material. 142- Autogenous welding. 15-PLASMA ARC WELDING

Resistance Welding
2- Resistance welding 21- resistance spot welding. 211- indirect spot welding 212- DIrect Spot Welding. 22 Resistance seam welding 225- foil butt seam welding

Beam welding
5- beam welding 52- laser beam welding 521- solid state laser welding 522-gas laser welding 523- diode laser welding

Gas cutting and gouging

81- oxy fuel/flame /oxygen cutting. 83- plasma cutting. 831- plasma cutting with oxidising gas. 832- plasma cutting with out oxidising gas. 833- air plasma cutting. 84-laser beam cutting 86- flame gouging

EN 287ESSENTIAL VARIABLES AND RANGE OF QUALIFICATION

the qualification of welders based on essential variables. each essential variable a range of qualification is required. all test pieces are to be welded within essential variable. any change in essential variable requires requalification.

List of essential variables

Welding process(es) Product type(plate and pipe) Type of weld(butt and fillet) Material group Filler material. Dimension(material thickness and outside pipe diameter) Welding position. Weld detail( backing, single side welding, both side welding, single layer, multi layer, leftward welding, rightward welding)

Welding processes
Each qualification test qualifies only one welding process. Change in welding process requires a new qualification. Exceptions. Change from solid wire electrode 135 to metal cored wire 138 does not require requalification.

Type of weld
But welds do not qualify fillet weld and vice versa.

What does not get measured What does not get Recorded What does not get monitored What does not get controlled

Cannot be Recorded Cannot be Monitored Cannot be Controlled Cannot be Improved

IMPROVEMENT IS THE HEART OF ANY STANDARD

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Equipment(machine)
Production and testing equipment
Description of equipment Suitability of equipment New equipment Equipment maintenance

Production planning(method)
Welding procedure specifications (WPS) Qualification of the welding procedures Work instructions Procedures for preparation and control of documents

Welding Consumables(material)
Batch testing Storage and handling

Materials
Storage of parent materials Post-weld heat treatment

Inspection & testing

Inspection & testing before welding Inspection & testing during welding Inspection & testing after welding Inspection & test status

OTHER REQUIREMENTS
Non-conformance and corrective actions Calibration and validation of measuring, inspection and testing equipment Identification & traceability Quality records

 Any questions