Requirements ISO 3834

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Structure of EN ISO 3834  ISO 3834-1:2005, Criteria for the selection of the appropriate

level of quality requirements  ISO 3834-2:2005, Comprehensive quality requirements  ISO 3834-3:2005, Standard quality requirements  ISO 3834-4:2005, Elementary quality requirements  ISO 3834-5:2005, Applicable documentation (not full title)  ISO/TR 3834-6:2007, Guidelines on implementing ISO 3834

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ISO 3834-1 Clause-5 : Criteria for selection The extent and significance of safety-critical products The range of different materials used The range of products The complexity of manufacture The extent to which metallurgical problems may occur The extent to which manufacturing imperfections, e.g., misalignment, distortion, or weld imperfection, affect product performance

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Criteria for selection • Cotractual – Mutually agreed • Statutory – CE and similar product certifications • Regulatory – Product standards • Risk Management output

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Risk assessment  EWF Standard : Fundamentals of Risk Management

Failure mode effect analysis (FMEA) Fault tree analysis

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Likelihood of the event (Occurrence)

Risk Matrix

(Severity) 7

ISO 3834-1

Clause-6: Elements to consider for a QMS to complement ISO 3834: a) b) c) d) e) f) g) h) i) j) k) l) m)

control of documents & records (ISO 9001:2000, 4.2.3, 4.2.4) management responsibilities (ISO 9001:2000, Clause 5) provision of resources (ISO 9001:2000, 6.1) competence, awareness, training of personnel [ISO 9001:2000, 6.2.2, 7.5.2 (b)] planning of product realization (ISO 9001:2000, 7.1) determination of requirements related to the product (ISO 9001:2000, 7.2.1) review of requirements related to the product (ISO 9001:2000, 7.2.2) purchasing (ISO 9001:2000, 7.4) validation of processes (ISO 9001:2000, 7.5.2) customer property (ISO 9001:2000, 7.5.4) internal audit (ISO 9001:2000, 8.2.2) monitoring and measurement of product (ISO 9001:2000, 8.2.4). ISO 9004: guidance on the development & implementation of a QMS 8

ISO 3834-1 Annex-A Elements Contract review

ISO 3834-2

ISO 3834-3

Full documented review

Less extensive review

Design review

Design for welding to be confirmed

Subcontractor

Treat like a main fabricator

Welders, Operators Welding coordination Inspection personnel

Production equipment

Equipment maintenance Production plan

ISO 3834-4 Establish that capability and information is available Shall comply with all requirement

Approved in accordance with ISO 9606 Welding coordination personnel with appropriate technical knowledge Sufficient and competent personnel to be available Required to prepare, cut, weld, transport, lift, together with safety equipment and protective clothes

Shall be carried out, mtc. plan necessary Necessary

No specific requirements, Restricted plan necessary

Welding procedure specification WPS)

Instruction to make available to welder

Welding procedure approval

in accordance with the appropriate part of ISO 9956, approved as application standard or contract demands

Not required but personal responsibility of Mfg. Sufficient and competent third parties access are needed No specific requirement

No requirement No requirement No requirement

No specific requirement

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ISO 3834-1 Annex-A Elements Work instructions

ISO 3834-2

ISO 3834-3

ISO 3834-4

Welding procedure specification (WPS) or dedicated work instructions to be available

No requirement

Documentation

Necessary

Not specified

No requirement

Batch testing of consumables

Necessary

Not specified

No requirement

Storage and handling of welding consumables

According to supplier’s recommended minimum

Storage of parent materials

Protection required from influences by the environment, identifications to be maintained

No requirement

Post-weld heat treatment

Specification and complete record necessary

No requirement

Inspection before, during and after welding

Identification Traceability Quality records

Responsibilities as specified in contract

As required for specified operations

Non-conformances Calibration

Confirmation to specification necessary

Procedures shall be available Procedures shall be available Required when appropriate

Not specified Required when necessary

Shall be available to meet the rules for product liability

Not specified Not specified As reqd by contract

Retained for 5 years minimum 10

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ISO 3834-5 Reference Standards • • • • • • • • • •

Table 1 — Welders and welding operators qualification Table 2 — Welding coordination personnel qualification Table 3 — Non-destructive testing personnel qualification Table 4 — Welding procedure specifications Table 5 — Qualification of the welding procedures Table 6 — Post-weld heat treatment Table 7 — Inspection and testing during welding Table 8 — Inspection and testing after welding Table 9 — Calibration & validation of measuring, inspection, testing eqpt. Table 10 —Other fusion welding processes

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ISO 3834-6

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ISO 3834-6 Guidelines for implementation Clause 7.2, Quality System • Refers to clause-6 of 3834-1 for maintaining basic elements of quality system (ISO 9001 requirements)

• Manufacturer who already operates ISO 9001 are expected to have a documented system as referred in clause-6 of 3834-1

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ISO 3834-6 Clause-8 :

Criteria for selection

The extent and significance of safety-critical products The range of different materials used The range of products The complexity of manufacture The extent to which metallurgical problems may occur The extent to which manufacturing imperfections, e.g., misalignment, distortion, or weld imperfection, affect product performance

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ISO 3834-6 Guidelines for implementation 9.1.3 Control of welding Control is to be ensured by : ⎯ verification of welding procedures and the capabilities of welding personnel, ⎯ availability, suitability and maintenance of equipment, ⎯ identification of product requirements, ⎯ the manner in which sub-contracting is carried out, ⎯ the level of production planning, ⎯ storage and handling of parent metals and welding consumables, ⎯ operation and performance of inspection, ⎯ identification and traceability of product and work in progress, ⎯ correction of product non-conformance, and ⎯ the extent and storage of quality records. 17

ISO 3834-6

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5.2 Review of requirements 5.3 Technical review

Requirements are similar to enquiry & contract review in ISO 9001, but are much more specific.

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6 Sub-contracting • The subcontractor is treated as extension of manufacturers facility and shall fully comply with the relevant requirements of this part of ISO 3834. • The sub-contractor shall provide such records and documentation of his work as may be specified by the manufacturer. • Shall work under the order and responsibility of the manufacturer (WC). The manufacturer shall ensure that the sub-contractor can comply with the quality requirements as specified.

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7 Welding personnel 7.2 Welders and welding operators

• Welders and welding operators shall be qualified by an appropriate test according to : -ISO 3834-5, Table 1, for arc, electron beam, laser beam and gas welding 7.3 Welding coordination personnel • Manufacturer shall have at his disposal appropriate welding coordination personnel having responsibility for quality activities and sufficient authority to enable any necessary action to be taken. • Tasks and responsibilities shall be clearly defined. • The qualifications required shall be according to : -ISO 3834-5,Table 2, for arc, electron beam, laser beam and gas welding, 22

ISO 3834-5

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Adequacy of qualification • According to ISO 14731, a welding coordinator should be IWE/IWT. • Requirement is of competence, not paper qualification

Diploma = knowledge, not competence • WC must have, in addition to IWE/IWT, – current experience and competence in the job assigned, proven through extensive interview during audit or,

– A CIWE/CIWT certification on specific assignment 25

9 Equipment • power sources; mechanised or automatic welding equipment; • equipment for joint and surface preparation and for cutting, including thermal cutting; rolling, bending equipment. • equipment for preheating and post-heat treatment including temperature indicator; • jigs and fixtures; • cranes and handling equipment used for the production; • PPE and other safety equipment, • ovens, quivers, etc. used for treatment of welding consumables; • facilities for surface cleaning; • destructive and non-destructive testing facilities. 26

9 Equipment • New and repaired equipment are to be qualified by authorised person

• Maintenance – Documented plan, schedule – Items which controls variable essential for assuring quality must be included in schedule

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10.1 Production planning Production planning shall include at least: • sequence by which the construction shall be manufactured • identification of the individual processes • reference to appropriate procs. for welding & allied processes; • sequence in which the welds are to be made • order and timing in which individual processes are to be performed • Specs. for inspn/testing, involvement of any independent inspn. body • environmental conditions, e.g. protection from wind and rain • identification by batches, components or parts, as appropriate • allocation of qualified personnel • arrangement for any production test.

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10.3 Qualification of welding proc. • Welding procedures shall be qualified prior to production. • The method of qualification shall be in accordance with relevant product standards or as stated in the specification. • The ISO documents to which it is required to conform to are specified in : - ISO 3834-5:2005, Table 5, for arc welding, electron beam welding, laser beam welding and gas welding, 29

10.2 Welding-procedure specifications • The manufacturer shall prepare the welding-procedure specification (WPS) and shall ensure that these are used correctly in production. • The ISO documents to which it is required to conform are specified in : - ISO 3834-5:2005, Table 4, for arc, electron beam, laser beam and gas welding,

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ISO 3834-5

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10.5 Procedure for Preparation & Control of Documents – The procedure is identical with ISO 9001, 4.2.3.

– However, the standard specifies the main welding related document which must be maintained. – The documented procedures required by the standard are mentioned in respective sections.

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11 Welding consumables 11.1 General : Responsibilities & procedures for control of welding consumables shall be specified. 11.2 Batch testing Batch testing shall be required when specified. No specific requirement in ISO 3834-4 11.3 Storage and handling Procedures for storage, handling, identification & use of welding consumables which avoid moisture pick-up, oxidation, damage, etc. in accordance with the supplier‘s recommendations. 12 Storage of parent materials - materials should not be adversely affected. -Identification shall be maintained during storage. -Includes customer supplied materials 33

13 Post-weld heat treatment • The procedure shall be compatible with the parent material, welded joint, construction, etc. and shall be in accordance with the product standard and/or specified requirements. • Record of the heat treatment shall be made during the process. The record shall demonstrate that the specification has been followed and shall be traceable to the particular product. • The ISO documents to which it is required to conform to fulfil the quality requirements are specified in : - ISO 3834-5:2005, Table 6, for arc welding, electron beam welding, laser beam welding and gas welding, No specific requirement in ISO 3834-4 34

ISO 3834-5

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14 Inspection and testing 14.2 Inspection and testing before welding

⎯ suitability and validity of welders’ and welding operators’ certificates ⎯ suitability of WPS; joint preparation (e.g. shape and dimensions) ⎯ identity of parent material, identity of welding consumables ⎯ fit-up, jigging and tacking; special requirements in weldingproc. specs.(e.g. distortion prevention) ⎯ suitability of working conditions for welding, including environment. 36

14 Inspection and testing 14.3 Inspection and testing during welding Following shall be checked at suitable intervals/ by continuous monitoring: • essential welding parameters e.g. welding current, arc volts., travel speed • preheating/interpass temperature • cleaning and shape of runs and layers of weld metal • back gouging • welding sequence • correct use and handling of welding consumables • control of distortion • any intermediate examination (e.g. checking of dimensions) The ISO documents to which it is required to conform are specified in : - ISO 3834-5, Table 7, for arc, electron beam, laser beam and gas welding 37

14 Inspection and testing 14.4 Inspection and testing after welding Compliance with relevant acceptance criteria shall be checked: • by visual inspection; • by non-destructive testing; • by destructive testing; • form, shape and dimensions of the construction; • results and records of post-weld operations e.g. heat treatment, ageing The ISO documents to which it is required to conform are specified in : - ISO 3834-5, Table 8, for arc, electron beam, laser beam and gas welding 38

ISO 3834-5

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15 Non-conformance, corrective actions • Control of nonconforming products – Identification – Disposition – Notification

• Repair/rectification – WPS, Work instruction must be available – Re-inspection

• Corrective action – Ensure non-recurrence 40

16 Calibration & Validation • All equipment that contribute to the quality of the construction shall be suitably controlled and shall be calibrated or validated at specified intervals. • The ISO documents to which it is required to conform are specified in : – ISO 3834-5, Table-9, for arc, electron beam, laser beam and gas welding,

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ISO 3834-5

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ISO 17662

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17 Identification and traceability • identification of production plans, routing cards;

• identification of weld locations in construction; • identification of NDT procedures and personnel • identification of welding consumable (e.g. designation, trade name, manufacturer of consumables and batch or cast numbers) • identification &/or traceability of parent material e.g. type, cast number • identification of location of repairs;

• identification of location of temporary attachments; • Traceability for fully mechanised, automatic welding units to specific welds • traceability of welder and welding operators to specific welds • traceability of WPS to specific welds. 45

18 Quality records • • • • • •

Record of requirement/technical review; Material inspection & welding consumable documents; Welding-procedure qualification records - WPQR, WPS Eqpt. maintenance plan & records (including calibration records) Welder/operator qualification certificates; NDT personnel certificates Production plan; heat-treatment procedure specification and records; • NDT and DT procedures & reports; • Dimensional reports; • Records of repairs and non-conformance reports; • Other documents, if required. Quality records shall be retained for a minimum period of five years in the absence of any other specified requirements. 46

Summing up • basic elements of quality system (ISO 9001) may be implemented (refer to clause-6 of 3834-1), • Risk management to be addressed • Takes care of welding-specific processes, in-house or outsourced • Emphasis on Personnel competence and qualifications at all levels • Safety requirements (Occupational health safety, PPE, environment etc.) • Mandatory for supply of products to EU and many other countries • Many product standards call for the standard 47

Comparison: ISO 3834 vs 9001 ISO 3834 clause

Description of clauses of ISO 3834

ISO 9001clause

5.2

Review of requirements

5.3

Technical review

7.2.1, 7.2.2

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Sub-contracting

4.1, 7.4

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Qualification-Welding personnel

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Qualification-Inspection and testing personnel

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Equipment

9.1

Production and testing equipment: personal protective equipment, other safety equipment.

6.2 7.5.1

7.5.1, 6.4

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ISO 9001clause

9.5

Equipment maintenance

6.3

10.1

Production planning

7.5.1

10.2

Welding-procedure specifications

7.5.1

10.3

Qualification of the welding procedures

7.5.2

10.4

Work instructions

7.5.1

10.5

Procedures for preparation and control of documents

4.2.3

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Welding consumables

7.5.5 49



ISO 9001clause

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Storage of parent materials (including customer supplied material)

7.5.5, 7.5.4

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Inspection and testing

8.2.3, 8.2.4

14.5

Inspection and test status

7.5.3

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Non-conformance and corrective actions

8.3

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Calibration and validation of measuring, inspection and testing equipment

7.6

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Identification and traceability

7.5.3

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Quality records

4.2.4 50

Comparison: ISO 3834 vs 9001 • ISO 9001 allows scope for interpretation • ISO 3834 is more specific about welding process, goes into depth and does not leave much scope for interpretation • ISO 3834 is an additional tool to a QMS. ISO 9001 is the foundation.

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ISO 3834-5 Reference documents • Table 1 — Welders and welding operators qualification

• Table 2 — Welding coordination personnel qualification • Table 3 — Non-destructive testing personnel qualification • Table 4 — Welding procedure specifications

• Table 5 — Qualification of the welding procedures • Table 6 — Post-weld heat treatment • Table 7 — Inspection and testing during welding

• Table 8 — Inspection and testing after welding • Table 9 — Calibration & validation of measuring, inspection, testing eqpt. • Table 10 — Other fusion welding processes

• Annex A- Guidelines on qualification/education scheme for personnel dealing with welding coordination and inspection 54

Various Quality related Standards in Welding ISO 9001 General QMS Standard ISO 3834 QMS Standard for welding Welded Product

Personnel Qualification

EN 15085 EN 764 EN 1090

ISO 9606 ISO 14731 ISO 9712

Inspection & Testing ISO 17635-40 ISO 13916

Acceptance levels EN 12517 EN 1291

Examples only – not exhaustive 55

Various Quality related Standards in Welding ISO 9001 General QMS Standard ISO 3834 QMS Standard for welding Joint preparation

Process qualification

Materials standards

ISO 9692 ISO 9013

ISO 15607 ISO 15609

ISO 15608 ISO 20172

Consumables standards ISO 2560 ISO 14341


Various Quality related Standards in Welding ISO 9001 General QMS Standard ISO 3834 QMS Standard for welding Risk Management

Delivery conditions

Health Safety

Environment

EWF 644-08 ISO 14971

EN 13479

OHSAS 18001 ISO 11611 ISO 10882

ISO 14001 EN 14717 ISO 10882


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How to implement ISO 3834 ? • The very first step is to procure ISO 3834 standard (all parts) and related standards and study the requirements • You may consider an implementation package offered by IIW-ANBCC comprising of generic trainings on all aspects of ISO 3834 for different work groups, including a workshop. Training and certification of welders may also be included in the package. • IIW-ANBCC is not permitted to do consultancy since we are a certification body 59

Steps to Certification 1 Decide on applicable part of ISO 3834

 Contract requirements  Product standard  Statutory/regulatory requirements

 Risk management 60

Steps to Certification 2 Gap Analysis

 Audit by certification body to help you identify the gaps between requirement and existing practice.  A gap analysis audits are generic and no NC is given

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Steps to Certification 3 Awareness Training

 General understanding of the standard by all concerned

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Steps to Certification 4 Appointment of core team

A core team may be identified by you who will

have a deeper understanding and will actually effect the implementation/compliance in a planned and time bound manner

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Steps to Certification 5 Appointment of WC & RWC

←

 Internal appointment  Appoint from outside  Train your engineer

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Steps to Certification 6 Specific trainings to action groups ←

 Implementation

 Documentation  Related standards  Auditing

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Steps to Certification 7 Quality Manual and system documentation

 The core group shall identify the documentation

requirements specific to your organisation, and implement

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Steps to Certification

8 Training /certification of welders

←

 Make a scrutiny of all welders’ qualification

 Decide on appropriate training need  Get welders certified as per EN 287/ISO 9606

 Get welding operators certified as per ISO 14732 67

Steps to Certification

9 Implement and run – 3 months  This is required to generate sufficient records and evidence of compliances.  Compliances are verified through records, interviews, and observation  If you are already following a system and have records as required by the standard, you can go for certification before 3-months 68

Steps to Certification 10 Application for certification to IIW-India ANBCC ←

 This requires submission of various information in the application which is possible only after complete implementation

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Steps to Certification 11 Management Review  It is desirable to conduct internal auditing to verify the state of implementation, though it is not mandatory  A management review would be necessary to see the state or extent of compliance and if any additional/ corrective action is required.

 The management can assess and decide if CB should be called for audit. 70

Steps to Certification 12 Pre-assessment audit (optional) 13 Stage-1 audit 14 Stage-2 (Certification Audit) Note: Stage-1 and Stage-2 audit may be combined in one audit if client desires

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Application and Assessment • Application to ANBCC along with supporting documentation/manual • Pre assessment audit (Optional)

• Certification audit • Closure of NC (if any) to the satisfaction of the auditor, by the manufacturer within target time • Award of certificate to manufacturer

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Validity of Certificate • Certificate valid for 5 years subject to satisfactory surveillance.

• Surveillance audit once every year • Before end of 5-year validity period, recertification audit necessary for continued validity.

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Thank You www.iiwindia.com 76

Requirements ISO 3834

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