• Company CertificationStandards 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 welding-related 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 15085Railway 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

ISO/EURO INDIAN

ASME/Sec IXAWS D1.1

BS EN 287ISO 9606

IS 817IS 7318IS7310

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 resultsWelders 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 designationstandard Welding

processProduct type

Weld type

Material group

Welding consumables

Material thickness

Pipe out side diameter

Welding position

Weld details

EN 287 -1

111 P BW 1.1 B 10 mm D 60 PA ss nb

1-Steel SMAW PLATE Butt Weld

Steel with steel classified based on yield strength

Basic coated electrode.

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 4063Process number1 arc welding

2- resistance welding

3- gas welding

5 –beam welding

8- cutting &gouging

52Laser welding

81 oxy fuel cutting

83Plasma cutting

833 air plasma cutting84Laser beam welding

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.

48

What does not get measured

Cannot be Recorded

What does not get Recorded

Cannot be Monitored

What does not get monitored

Cannot be Controlled

What does not get controlled

Cannot be Improved

IMPROVEMENT IS THE HEART OF ANY STANDARD

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