GOST R 55143-2012

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  ГОСТ Р 55143-2012

GOST R 55143−2012/ISO/TR 3834−6:2007 Requirements for quality of fusion welding of metallic materials. Part 6. Guide to implementing ISO 3834

GOST R 55143−2012/ISO/TR 3834−6:2007

Group B09

NATIONAL STANDARD OF THE RUSSIAN FEDERATION

Requirements for quality of fusion welding of metallic materials

Part 6

Guide to implementing ISO 3834

Quality requirements for fusion welding of metallic materials. Part 6. Guidelines on implementing ISO 3834

OKS 25.160.01*
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* According to the official website of Rosstandart
OKS 25.160.40. — Note the manufacturer’s database.

Date of introduction 2014−01−01

Preface

1 PREPARED by the Federal state Autonomous institution «Scientific-educational center «welding and control» at MGTU im.N. Uh. Bauman (FGAU «NORSK» at Moscow state mining University them.N. Uh. Bauman) and the National Agency for Control of Welding (NAKS) on the basis of their own authentic translation into the Russian language of an international instrument referred to in paragraph 4

2 SUBMITTED by the Technical Committee for standardization TC 364 «welding and allied processes"

3 APPROVED AND put INTO EFFECT by the Federal Agency for technical regulation and Metrology, dated 22 November 2012 N 1013-St

4 this standard is identical to international ISO/TR 3834−6:2007* «Requirements for quality of fusion welding of metallic materials. Part 6. Guide to implementing ISO 3834» (ISO/TR 3834−6:2007 «Quality requirements for fusion welding of metallic materials — Part 6: Guidelines on implementing ISO 3834»).
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* Access to international and foreign documents referred to here and hereinafter, can be obtained by clicking on the link to the site shop.cntd.ru. — Note the manufacturer’s database.

In applying this standard it is recommended to use instead of the referenced international standards corresponding national standards, the details of which are given in Appendix YES

5 INTRODUCED FOR THE FIRST TIME

6 REISSUE. August 2014


Application rules of this standard are established in GOST R 1.0−2012 (section 8). Information about the changes to this standard is published in the annual (as of January 1 of the current year) reference index «National standards» and the official text changes and amendments — in monthly information index «National standards». In case of revision (replacement) or cancellation of this standard a notification will be published in the upcoming issue of the monthly information index «National standards». Relevant information, notification and lyrics are also posted in the information system of General use — on the official website of the Federal Agency for technical regulation and Metrology on the Internet (gost.ru)

Introduction

ISO/3834−6 developed by ISO/TC 44 «welding and allied processes», by the Subcommittee 10 «Unification of requirements in the field of welding of metals».

The series of standards ISO 3834 (hereinafter — ISO 3834) consists of the following parts, under the General title «Requirements for quality of fusion welding of metallic materials»:

— part 1. Selection criteria the appropriate level of quality requirements;

— part 2. Comprehensive quality requirements;

— part 3. Standard quality requirements;

— part 4. Elementary quality requirements;

— part 5. Documents, requirements of which have to be met in order to confirm compliance with the requirements of ISO 3834−2, ISO 3834−3 or ISO 3834−4;

— part 6. Guide to implementing ISO 3834 (Technical report).

Welding is a special process because the quality of welded joints can not only be confirmed by testing. The quality of the weld has to be in the product, not be the result of the test. This means that welding normally requires continuous control and the use of special procedures, or both. Reglamentary ISO 3834 quality requirements in welding and is designed to regulate the necessary control and required procedures.

ISO 3834 is not a management system standard that replaces ISO 9001, but it is a support tool in case of application by the manufacturer of ISO 9001. In this case, the requirements must be reflected in the relevant certificates and documentation. However, ISO 3834 can be used independently of ISO 9001.

ISO 3834 apply to fusion welding of metallic materials, and its application does not depend on the types of the manufactured product. The principles and many detailed requirements are nevertheless applicable to other welding processes and related welding processes.

One of the aims of ISO 3834 is setting requirements in the field of welding so that customers or supervising (supervising) bodies or individuals were not forced to do it yourself. Links to specific part of ISO 3834 should be sufficient to demonstrate the ability of the manufacturer to control welding activities for a specific type of work performed. This concept also applies to committees responsible for developing standards for products.

A reference to ISO 3834 does not require third-party assessment or certification. However, such assessment or certification by independent bodies is becoming a trend in commercial relationships and provides a basis for these goals, and for those manufacturers who use it to confirm the features of your welding production.

1 Scope

This standard provides guidance on the security requirements specified in other parts of the GOST R ISO 3834, and is intended to help manufacturers and users select the appropriate part of ISO 3834, containing the necessary level of quality requirements for welding. Selection of the necessary level of requirements to the quality of the weld is based on the knowledge of the manufacturer and the consumer of the standard GOST R ISO 3834 as a whole.

2 Normative references

This standard uses the regulatory references to the following international standards*. Subsequent amendments or modifications are valid for dated references of this standard only after the introduction of amendments and changes to it. For undated references the latest applicable edition of the referenced document (including amendments thereto).
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* The table of conformity of national standards international see the link. — Note the manufacturer’s database.

ISO 3834−1:2005 quality Requirements perform fusion welding of metallic materials. Part 1. Selection criteria the appropriate level of quality requirements (ISO 3834−1:2005 Quality requirements for fusion welding of metallic materials — Part 1: Criteria for the selection of the appropriate level of quality requirements)

ISO 3834−2 Requirements for quality of fusion welding of metallic materials. Part 2. Comprehensive quality requirements (ISO 3834−2, Quality requirements for fusion welding of metallic materials — Part 2: Comprehensive quality requirements)

ISO 3834−3 quality Requirements perform fusion welding of metallic materials. Part 3. Standard quality requirements (ISO 3834−3, Quality requirements for fusion welding of metallic materials — Part 3: Standard quality requirements)

ISO 3834−4 quality Requirements perform fusion welding of metallic materials. Part 4. Elementary quality requirements (ISO 3834−4, Quality requirements for fusion welding of metallic materials — Part 4: Elementary quality requirements)

ISO 3834−5 quality Requirements perform fusion welding of metallic materials. Part 5. Documents, requirements of which have to be met in order to confirm compliance with the requirements of ISO 3834−2, ISO 3834−3 or ISO 3834−4 (ISO 3834−5, Quality requirements for fusion welding of metallic materials — Part 5: Documents with which it is necessary to conform to claim conformity to the quality requirements of ISO 3834−2, ISO 3834−3 or ISO 3834−4)

3 Reduction

This standard applies the following abbreviations:

IWE — international welding engineer;

IWS — international welding specialist;

IWT — international welding technologist;

NDT — non-destructive testing;

PWHT — postweld thermal treatments;

pWPS — preliminary technical requirements for the welding procedure;

WI — work instruction;

WPQR Protocol of certification of welding procedures;

WPS technical requirements for the welding procedure.

4 Application of ISO 3834

4.1 General provisions

ISO 3834−1 establishes criteria for the selection of the appropriate level of quality requirements and application of ISO 3834 as a whole. The following sections set out various ways of selecting the manufacturer appropriate level of quality requirements for welding or application of GOST R ISO 3834 as a whole.

4.2 product Standards

If a product standard, provides control of fusion welding for the organization of welding engineering to apply the GOST R ISO 3834.

The standards provide for the application of ISO 3834 are YONG 1090, EN 12732, EN 12952, EN 13445 and EN 15085.

4.3 Customers and consumers

Customers and consumers of welded products can set in the contract or agreement a requirement that the confirmation of the manufacturer to the requirements of ISO 3834.

4.4 quality management System according to ISO 9001

Because ISO 9001 does not contain special requirements to the welding trade, you need to apply ISO 3834−2, ISO 3834−3 and ISO 3834−4.

4.5 Other system quality management than ISO 9001

Manufacturers of welded products with an excellent ISO 9001 quality management system, does not contain special requirements to the welding trade, you should apply ISO 3834−2, ISO 3834−3 and ISO 3834−4.

4.6 Manufacturers

If manufacturers want to confirm their competence in carrying out fusion welding, they must apply the appropriate part of ISO 3834.

5 Introduction the requirements of ISO 3834 in product standards

An important group of users, the ISO 3834 are standards committees that develop standards at the international, regional and national levels. ISO 3834−2, ISO 3834−3 and ISO 3834−4 set levels of requirements for quality of fusion welding. The committees that develop standards for products, should choose the part or parts of ISO 3834, which contain the relevant requirements for the quality of manufactured products, taking into account the selection criteria set ISO 3834−1:2005, section 5. Each part of ISO 3834 contains a complete set of quality requirements. Additional requirements for the welding quality can be established when there is good reason. In case of doubt as to the need to establish or set additional requirements it is recommended that consultation with ISO/TC 44/SC 10.

If the products are manufactured by welding, the standardization Committee may regulate used in the production of documents or select them from the list of ISO documents listed in ISO 3834−5. The standardization Committee must also determine the appropriate standards that regulate quality requirements, subject to application. If a series of standards listed in ISO 3834−5, contains requirements for the level of quality, for example for qualifications (certifications) welding procedures the Committee on standardization, it is sufficient to choose the most appropriate. Creating tables linking parts of ISO 3834 requirements to quality (with or without consideration of other quality standards such as ISO 9001), in addition to given in ISO 3834, is not recommended.

6 the Use of other documents in conjunction with ISO 3834

Full compliance with ISO 3834−2, ISO 3834−3 and ISO 3834−4 may be achieved by the use of documents given in ISO 3834−5 or by applying other documents containing equivalent technical conditions.

Standards that do not contain equivalent technical conditions, can be used if they are referenced in the applicable manufacturer’s standards for the products.

Product standards, compliance with which is confirmed by the results of operation may be applied by the manufacturer in conjunction with ISO 3834. If the manufacturer proves their compliance with ISO 3834 standards for products, the responsibility for the application of standards do not contain equivalent technical conditions, regardless of whether there are references to them or their requirements are included in the standard for products lies on the manufacturer. In the case of technical conditions established in the ISO documents given in ISO 3834−5, responsibility for the confirmation of equivalence of technical conditions fully lies with the manufacturer. The certificates issued on the results of the evaluation by independent certification or Declaration of conformity the manufacturer of any part of ISO 3834 should contain a list of the applicable manufacturer’s document and must contain or refer to equivalency of technical requirements.

7 Documentation and quality management system

7.1 Documentation

Any control system needs documentation. The term «documentation» includes a number of different types of documents such as procedures, reports, instructions and certificates (see table 1).


Table 1 — Examples of different types of welding technical documents

ISO 3834−2, ISO 3834−3 and ISO 3834−4 require the issuance of certain documents. Appendix A gives examples of typical documents that can be used by the manufacturers.

7.2 the quality management System

ISO 3834 does not require the mandatory application of the quality management system. However, ISO 3834−1:2005, section 6, defines the elements that can be considered as a complement to the ISO 3834 in the implementation of the quality management system. The most important of these is the management of documents, and the manufacturer shall implement a procedure for control of documents ensure:

— analysis and updating as necessary and re-approval of official documents;

— identification of user documents;

— availability of relevant versions of documents at the point of use;

— withdrawal from the use of invalid documents;

— archiving of records to ensure their preservation and possible re-treatment;

— preservation of the documents from destruction without reason.

Some of the reports that are generated as part of this system shall be periodically updated. These include reports of calibration/validation and qualification (certification) welders.

Manufacturers who have implemented quality management system according to ISO 9001, shall have a documented system, including elements contained in ISO 3834−1:2005, section 6.

The effectiveness of the system of control of welding production largely depends on participation of top management and its role in surveillance and implementation of actions in the detection of inconsistencies. Analysis from management and internal audit ensures the involvement of management in the control system of welding manufacture allows to supervise and to take measures on elimination of discrepancies. Figure 1 shows the system model and control of welding production, containing a list of actions aimed at ensuring the effectiveness of the system of control of welding production.

Figure 1 — Model of control system of welding production

Figure 1 — Model of control system of welding production

8 select the level of quality requirements

ISO 3834 establishes three levels of quality requirements that can be included in product standards, regulations and contracts or selected by the manufacturer. The requirement level is selected depending on kinds of manufactured production, conditions of its operation, nomenclature and applications. In ISO 3834−1 stated that the standard can be applied in welding conditions in the shop and/or outdoor (installation) sites. When choosing the appropriate level of requirements should be guided by the following criteria:

a) the degree of danger of the product;

b) difficulty of manufacture;

c) the range of products;

d) materials used;

e) the risk of defects associated to metallurgical processes;

f) the impact of manufacturing defects, such as displacement, deformation or defects in the weld on the performance and specifications of products.

In the standards for the products that require confirmation of compliance to ISO 3834, the most important when choosing the level of requirements relates to the degree of danger of the product and the presence of dynamic loads in service.

The standard level of quality requirements suitable for a wide range of products which should meet the usual safety requirements and which can be subjected to dynamic loading. Such products are made from normal materials of known weldability and documentation of measures taken to ensure mechanical performance and defect prevention. For products with limited security requirements and subjected to moderate static loads with minimal dynamic components typically have a basic level of quality requirements.

If there are high demands of safety products, operating under high static and dynamic loads and is made of materials used for highly loaded structures, should establish a comprehensive level of quality requirements. In the manufacture of new products, the use of new technological processes of welding also establish a comprehensive level of quality requirements is standard.

It is not possible to establish a correspondence between certain parts of ISO 3834 to specific products. This is due to the different complexity of design materials used and the complexity of the manufacturing processes for different types of products. Responsibility for the selection of the appropriate level of requirements imposed on technical standardization committees developing standards for products, or consumers, or manufacturers of specific types or groups of products.

The sequence of actions in establishing quality requirements for welding given in figure 2.

Figure 2 — Sequence of operations for establishing the quality requirements for welding

Figure 2 — Sequence of operations for establishing the quality requirements for welding

In ISO 3834−1 stated that if the compliance of the welding production to a certain level of quality, the production corresponds to lower levels of quality. Thus, the manufacturer who confirmed compliance with ISO 3834−2, is also consistent with ISO 3834−3 and ISO 3834−4. This has implications for the manufacturer, producing a large range of products, some of which may meet the comprehensive quality requirements, and other standard or elementary quality requirements. The manufacturer may apply comprehensive requirements for the quality of product to which is applicable this level, standard or basic levels of quality requirements for different products.

9 Implementation into production

9.1 General the implementation guide

9.1.1 General principles

ISO 3834 specifies requirements for many different types of activities, in particular to:

a) General management and the factory welding process as a special process;

b) manufacturing process instructions (e.g., instructions on the process of welding to ISO 3834−2 and ISO 3834−3);

c) confirmation of competence of personnel, its training, experience and skills (e.g. qualification, certification of welders).

The following provisions pertain to the organization of the manufacturer, the integration of ISO 9001 and specific controls.

9.1.2 Implementation

Many manufacturers apply requirements as to the procedures and instructions for production, and requirements for documenting the competence of personnel, its training, experience and skills. For manufacturers applying ISO 3834 does not lead to large changes in the management of production or costs. For some manufacturers this may mean an important change for the following reasons:

a) implementation of ISO 3834 coincides with the transition towards new national or international standards, which may require an attestation of welders and welding process, training or hiring of personnel to coordinate welding, to create the necessary knowledge base for various kinds of manufactured products;

b) requirement of the users confirm compliance with ISO 3834 manufacturers, who had previously used that have significantly different requirements;

c) existence of national or regional requirements of conformity manufacturer ISO 3834 in special sectors of industry to obtain permission for use of the products in this country or in this region. Such requirements may cause significant changes compared to previous practice.

If such actions are necessary, it should be noted that ISO 3834 reflects the good practice of manufacturing products for which welding is an important manufacturing process. Compliance with ISO 3834 gives confidence to the manufacturer and to the consumer that the products will be manufactured properly and will not be subject to premature destruction in the process of operation because of faulty manufacture, subject to appropriate technical supervision and maintenance.

9.1.3 welding Management

As welding is a special process and the consequences of poor welding can be critical, it is necessary to provide appropriate management to ensure that the welding is performed properly and the required inspections of manufactured products posted. Management includes:

— verification of welding procedures and welding personnel professionalism;

— availability, serviceability and maintenance of equipment;

— identification of production requirements;

— the conditions for the transfer of work subcontracted;

— the level of production planning;

— storage and handling of base metals and welding materials;

methods and inspections

— identification and traceability of products and works;

— correction of product non-compliance;

— the volume and retention of records confirming quality.

Welding management must regulate the objects and control methods (if necessary by reference to one or more procedures or standards), allocation of tasks and responsibilities, as well as to regulate the procedure of capturing and documenting certain aspects of the control system.

9.1.4 the Production process

9.1.4.1 Technical documentation

ISO 3834 defines a set of technical instructions, procedures, specifications and records in order to ensure the effectiveness of the system of welding control. Production activities that require technical documentation given in ISO 3834−1:2005, Annex A. If the activity is outside the specified, for example, heat treatment after welding (PWHT) shall be allowed to include it in the control system.

Examples of documentation used by the manufacturer in the control system are given in Appendix A.

9.1.4.2 the Certification of welding procedures

Technical requirements and certification of welding procedures are given in ISO 15607, ISO 15609 and contain five General methods, based on:

— tried and tested welding consumables (ISO 15610);

— previous welding experience (ISO 15611);

— standard welding procedure (ISO 15612);

— pre-production welding test (ISO 15613);

— testing of welding procedures (ISO 15614).

If the product standard is not reglamentary method according to ISO 15610, ISO 15614, then it needs to be regulated by the terms of the contract.

If test-welding (test welding procedures or test before production), the results should be entered into the Protocol of certification of welding procedures (WPQR). Documentation issued for certification of welding procedures are given in table 2.


Table 2 — Documentation, prepare for certification welding procedures

If you use standard welding procedures (see ISO 15612), pre-planning of certification of welding procedures is not required.

9.1.4.3 Other processes

The principles of certification of other production processes are largely comparable to the certification of technological processes of welding. General methods listed in 9.1.4.2, can also be applied to other production processes associated with the welding trade.

Examples of documentation for other processes is given below.

— Non-destructive testing

Non-destructive testing (NDT) of welds often regulated by product standards. A common practice is the use of standard test procedures for the applicable NDT method, has been prepared based on the relevant standards on NDT. The non-destructive test Protocol needs to include detailed test results and evaluation of the weld. This report usually contains data on critical parameters of NDT used in testing.

— Heat treatment after welding

The situation for heat treatment after welding (PWHT) is similar to that described above for NDT. You must have the process of heat treatment and Protocol with the parameters of heat treatment. Quality requirements for heat treatment are contained in ISO/TR 17663.

— Thermal cutting

Approved technological process for thermal cutting typically is not required, since typically rely on the skills and qualifications of the operator. However, it may be required in some cases, such as cutting heat sensitive material, for which there is only limited practical experience, or if there is a risk of occurrence of zones of high hardness in the cutting edge, which can have a negative impact on the final product.

9.2 Organization

The term «manufacturer» is widely used as a symbol of an organization that takes responsibility for coordinating welding operations. As a rule, management of welding fabrication within a single organization is a group of people under the control of the group of coordinators for welding (as specified in ISO 14731). Under «organization» in this context, but not always, refers to a legal entity. Some typical situations are presented in table 3.


Table 3 — Organization and objectives

The welding technology certified, for example, according to the norms of ISO 15614, in the same enterprise, may be applied at different enterprises of the same manufacturer, if the manufacturer are controlled by a common control system according to ISO 3834, including the same personnel for the coordination of welding works.

All organizations that do not meet the above requirement, within the framework of ISO 3834 defines as «subcontractor». If the subcontractor does not meet ISO 3834, a manufacturer should guarantee the fulfilment of the relevant requirements for each individual contract.

10 Interpretation of certain sections of ISO 3834

10.1 Analysis of contract specifications and technical requirements

The manufacturer must show compliance with the requirements of the relevant part of ISO 3834, for example, by providing a comprehensive checklist of technical requirements or by documented meeting minutes for contract or meeting technical requirements. This requirement cannot be considered as exhaustive; it is necessary to consider the conditions specific to the contract or to the requirements of the design.

The main challenge is to ensure that the manufacturer understands the technical requirements and the products can be manufactured in accordance with the contract.

For compliance must be provided for coordination of welding activities in accordance with ISO 14731.

10.2 Transfer, sub-contract

The manufacturer shall ensure that any associated with welding activities, which is transferred to the subcontract, including welding, NDT, supervision, heat treatment, equipment maintenance and calibration, meets the requirements of the contract and confirmed by the coordinator for welding, responsible in this area.

Subcontractors that perform welding or provide ancillary services can meet the same or higher level of requirements for ISO 3834 than the manufacturer. Depending on the conditions of the sub-Contracting of services or products for example a lower level.

It is not always possible to transfer to the subcontracting organizations that correspond to any level according to ISO 3834. The manufacturer is responsible for the fact that the welding or related processes are correctly controlled in accordance with ISO 3834. This may require auditing of subcontractors, including certified welders and welding process. If the manufacturer has the relevant technical requirements for the welding procedure, it may be appropriate to offer them to the subcontractors and to monitor their application. It is possible to organize acceptance of the products together with the representative of the manufacturer. Subcontractors providing services such as PWHT, NDT or inspection, can be audited if they held the appropriate certification for its activities in these areas. Extensive validation and control may be required in the case of the primary audit, significant inconsistencies.

If the requirements of the contract or the law of the necessity of compliance with specific parts of ISO 3834, sub-contractors must comply with the required or higher level. However, if you want compliance with ISO 3834−2 or ISO 3834−3, to perform work may be brought by the subcontractor meets the requirements of ISO 3834−4 to make simple welded constructions. This may require coordination with the customer or the authorised body.

In the absence of Treaty or legislative requirements, the manufacturer on its own initiative should ensure that the subcontractor required level according to ISO 3834 or to take measures to ensure the implementation of proper control over the work.

10.3 Coordination in welding

10.3.1 General provisions

Coordination in welding according to ISO 14731 is considered as management and execution of production and technical activities for the control of welding. It should be noted that coordination in welding are usually performed by different categories of staff, many of whom do not belong to the welding technology personnel. It is necessary to highlight the following aspects:

a) large organizations performing extensive and complex welding work, generally have several workers who are exclusively engaged in the control of welding. These employees hold positions of engineer, welding technologist or welding employment in full time coordination in welding;

b) in small organizations such duties may be transferred to the employees occupying other positions (e.g. production Manager or foreman) and perform other tasks in addition to coordination in welding (combining the duties of the coordinator in welding);

c) some activities related to the coordination in welding, typical examples of which are welding consumables storage and handling, maintenance and calibration of equipment can be sent to the workers occupying posts, not related to welding. These employees are often called upon to perform a few special tasks in the coordination of welding;

d) some manufacturers place the responsibility for performing certain work on welders or operators. In such cases, the manufacturer must ensure that the welders and operators have the necessary knowledge and competence;

e) management of monitoring activities and tests that also relate to coordination activities in welding, generally carried out by experts holding positions: controller of welding, engineer, NDT, head of the quality Department. In small enterprises this activity may be done by the master or other personnel.

10.3.2 the Coordinator of welding

ISO 3834−2 and ISO 3834−3 require application of ISO 14731, which establishes the staff requirements and is interrelated standard. Under the system, each associated with control activities such as monitoring (technical) maintenance welding of equipment is carried out by one or more employees are usually constantly working in the state of the manufacturer. ISO 3834 contains the requirements for each control welding. The allocation of these tasks and responsibilities the manufacturer shall:

a) install separate control elements and to prepare the lists with all the tasks and responsibilities and indicating the responsible;

b) to check all listed tasks and responsibilities to ascertain whether all actions contained in ISO 14731, were included in the control system, and properly assigned to the performers;

c) to establish criteria of competence, in terms of skills, experience and training for each coordinator in welding;

d) confirm the competence of the experts appointed to the post of coordinators in the welding, on the basis of their experience, education and (or) qualification in accordance with the prescribed duties.

It should be noted that the essential qualifications of the coordinator in welding is determined by its tasks and responsibilities established by the manufacturer in its organizational structure.

ISO 14731 uses the concept of «responsible welding coordinator» (to be documented) to witness one employee or more who possess the required level of technical knowledge for the spectrum manufactured products. All manufacturers should at least name one coordinator for welding. It is expected that a «responsible welding coordinator» is an employee of the manufacturer and competent for making decisions and signing documents that affect the quality of the product. Responsible welding coordinator has the overall responsibility for oversight of welding and technical activities, and can make decisions when the welding is performed properly.

ISO 14731:2006, Annex a makes reference to the training system, created by the international Institute of welding (MW). This system encourages clients and agencies to consider the responsible welding coordinator, with relevant diploma as «qualified by definition». This reference to the MW education and the diploma should be for clients and agencies is valid without verification. ISO 14731:2006, Annex a, does not prevent the manufacturer to refer to other qualifications for coordinators for welding. But from the manufacturer pending confirmation of compliance alternative qualifications for customers and superiors.

10.3.3 Interaction between knowledge in supervision of welding according to ISO 14731 and levels of quality according to ISO 3834

ISO 14731 contains two types of knowledge and experience that is required from the coordinator for welding:

a) overall technical knowledge;

b) specific technical knowledge on welding and related processes that relate to the intended objectives.

Additionally, this rule contains three levels of technical knowledge for coordinators welding:

— extensive technical knowledge;

— special technical knowledge;

— basic technical knowledge.

ISO 3834 reglamentary three levels of quality requirements for welding. Three levels in ISO 14731 and ISO 3834 for some but not all the requirements are interrelated.

The following paragraphs are significant for the degree of correlation:

a) because of the diversity of welding and technical operations, especially the basic weldability of metals;

b) diversity used in welding equipment (equipment such as devices with digital control and welding machines with a remote control, may require more production control than with manual arc welding);

c) the production volume (mass production requires accurate planning and production control to minimize costs).

d) evaluation group (more on the control of availability of surface and bulk defects, as well as more stringent eligibility criteria require a more strict control to avoid excessive repair or rejection).

Table 4 shows the relationship when the value of only one of the factors. It should be noted that many manufacturers have to consider more than one factor if the regulated required qualifications and experience of welding coordinators. The table is subject to compliance with the basic provisions. Additionally it is recommended that the welding coordinators have sufficient production experience.


Table 4 — Relationship between ISO 3834 and ISO 14731

It should be noted that the training requirements and the duration of the training course for diploma of International engineer specialist in welding (IWE) is stricter than for the diploma of International welding technologist (IWT) and the same difference between a diploma International welding technologist (IWT) and a diploma of International welding specialist (IWS). For IWE requires a University degree or comparable it, so manufacturers choose the qualification IWE is lower skill levels for both ISO 3834−2 and ISO 3834−3.

In defining the standards for the product shall indicate the levels of knowledge of the responsible supervising the welding of a person. In such cases, these requirements must be fulfilled by the manufacturer. Anyway, ISO 14731 allows you to transfer the supervision of the welding personnel, but the responsibility for compliance with ISO 14731 are the responsibility of the manufacturer.

10.4 Equipment

ISO 3834 requires compiling a list of critical equipment and installations and maintain the relevance of this list. For equipment and installations should be supervised to ensure that they can be used in the manufacture of the respective product.

It is expected that the manufacturer will have implemented the system for identification, control, maintenance and calibration (if relevant) of all production equipment, including the designated employees responsible for these actions, and detailed measures to prevent the use of defective equipment in production.

10.5 Welding-technical activities

Manufacturers through the availability of plans and other documents (drawings, instructions and specifications, etc.) must be able to show how it can be achieved and maintained compliance with the requirements for integrated production, NDT and other relevant activities.

10.6 Storage of basic metals

The manufacturer shall establish a system for storing base metals irrespective of, whether they purchased or provided by the client, including the components that should be included in the final product. It is expected that the methods and system specified.

10.7 Calibration and validation

Calibration and validation are very commonly used concepts, but not always properly interpreted. The principles are contained in ISO 17662.

Calibration is a process in which piece of equipment is regularly tested in comparison with measurement standards whose accuracy as to the conformity with the true result of the measurement is known. However, the precision of the tool can be determined by checking for a given level of error.

On the other hand, validation in connection with the measuring device is the process of confirming that the measurement result is satisfactory. This can be achieved through the application of the calibrated instrument or measurement standard to prove that the instrument under test gave a satisfactory result, based on the readings of the instruments and measurements tools.

Calibration of welding equipment is normally required only when the quality/stability (repeatability) of the weld depends on accurate and repeatable setting of parameters such as amperage, voltage, welding speed, gas flow, pulse characteristics etc. anyway, if the current source has calibrated readings for current and voltage, the manufacturer must have a calibrated tool that can be used to confirm that the welding parameters (amperage and voltage) meet the requirements of the WPS or work instruction.

While the number subjected to calibration and validation of equipment includes the equipment for heat treatment after welding and to control the conditions of storage electrodes, equipment for monitoring and testing such as NDT-instruments and apparatus for pressure test is not included. As a General rule, generally, devices for checking and measurement are always calibrated.

Usually calibration and validation are also required for devices to measure temperature, such as heat treatment, NDT-instruments and apparatus for pressure test. Some measuring instruments for measuring dimensions, such as sliding calipers, micrometers must be calibrated if the product requires this level of precision.

Therefore, clamp ammeter, which is used to check the amperage in the cable in those applications, when current is configured according to the installation deponirovannye specified parameters, or by using the ammeter in the instrument should be validated to show that the indication devices are satisfactory. In other cases, when the clamp ammeter is used as an indication for setting the right amperage on the unit for manual welding, clamp ammeter must be verified to ensure that there is proper level of amperage. In this case, the verification of the accuracy of the indications of the instrument are not possible. In this sense, the verification does not match the calibration or validation, as it is only the identity, whether a predetermined level of current.

It should be noted that when new welding processes and new sources of welding current, for example, for manual arc welding with pulse current, it is difficult or impossible to control the above without accurate measuring instruments and precise enough tools. Mechanized welding operation need precise control of heat and cause the need for accurate tools.

The manufacturer shall regulate and register what the instrument needs to be calibrated, and store the records of those calibrations.

10.8 Marking and traceability

ISO 3834 does not always require labelling and traceability. If a manufacturer entered into a contract or standing before entering into a contract, which requires traceability should be applied to the corresponding instruction.

This instruction should not cause any confusion with contracts that do not require backward traceability.

If you require traceability of the welding additive, it is expected that the various parties that apply when welding is logged, but is not required to fix the position of various parties admitted the welding additive with multiple connections.

11 Assessment and certification

ISO 3834 does not require assessment or certification. Manufacturer may, under his responsibility, to declare compliance with any part of ISO 3834. As part of this application, the manufacturer should clearly name the standards that were used in under control. If in ISO 3834−5 contains named ISO documents, a simple reference to ISO 3834−5. It may be the usual implementation of ISO 3834. Anyway, ISO 3834 can be used in order to assess the manufacturer from the customer (second party) or by the certifying institution (third party).

Annex a (informative). Examples of documents for control of welding related processes

Appendix A
(reference)

Table A. 1 contains documents that can be used by the manufacturer to control associated with welding activities.


Table A. 1 — Examples of documents for control of welding related processes

Numbers refer to the respective sections in the relevant parts of ISO 3834.

App YES (reference). Information about the compliance of the referenced international standards reference the national standards of the Russian Federation

App YES
(reference)

Table YES.1

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UDC 621.791.053:006.354 OKS 25.160.01 B09

Key words: quality requirements, quality level, fusion welding
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