ISO 3834 Questinaire - TUV NORD Worldwide · PDF fileAGAINST BS EN ISO 3834 Prepared by: S Brown Reviewed by: P Ward Authorised by: ... Specification of welding procedures, NDT procedures

REPORT OF ASSESSMENT CARRIED OUT AGAINST BS EN ISO 3834

Prepared by: S Brown

Reviewed by: P Ward

Authorised by: R Thomsen

Document ID: QA021F002

Date: 20/06/2012

Revision: 1

© 2011 TÜV UK Ltd. Page 1 of 23 Uncontrolled when printed

REPORT OF AN ASSESSMENT CARRIED OUT AGAINST

BS EN ISO 3834-2:2005

Quality requirements for fusion welding of metallic materials – Part2: Comprehensivequality requirements

Company Report No.

Address

Tel:

Description of Business

Quality Related Welding Personnel

Welding Coordination Personnel

Personnel Involved in Assessment Process

Assessment carried out by

Date of Assessment

Signature and Date:

REPORT OF ASSESSMENT CARRIED OUT AGAINST BS EN ISO 3834 Company Name: Project Number:


Reviewed by: P Ward



Date: 20/06/2012

Revision: 1


BS EN ISO 3834-2 QUESTIONNAIRE

Ref.

Requirement By the Manufacturer By the Assessor Yes No N/a Comments Yes No N/a Comments

5 Review of Requirements & Technical Review

5.1 General

a) Are the contractual requirements and technical data, provided by the purchaser or in-house, reviewed by competent staff?

b) Does the manufacturer affirm its capability to meet all the requirements?

c) Does the manufacturer verify that the work content is within its capability?

d) Does the manufacturer identify variations between the contract and previous quotations, and notify the purchaser of any resulting programme, cost or engineering changes?


Company Name: Project Number:


Reviewed by: P Ward



Date: 20/06/2012

Revision: 1


BS EN ISO 3834-2QUESTIONNAIRE

Ref.

Requirement By the Manufacturer By the Assessor Yes No n/a Comments Yes No n/a Comments

5.2 Review of Requirements Are the following considered?

a) The product standard to be used and any supplementary requirements.

b) Statutory and regulatory requirements.

c) Additional requirements determined by the manufacturer.

d) The capability of the manufacturer to meet the prescribed requirements.

5.3 Technical Review Are the following considered?

a) Parent material specifications and welded joint properties.

b) Quality and acceptance requirements for welds.

c) Location, access and sequence of welds, including access for inspection and non-destructive testing (NDT).




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Date: 20/06/2012

Revision: 1



Ref.


d) Specification of welding procedures, NDT procedures and heat treatment procedures.

e) Means of qualifying welding procedures.

f) Qualification of personnel.

g) Selection, identification and traceability of materials, welds etc.

h) Quality control arrangements, including independent inspection body involvement.

i) Inspection and testing.

j) Sub-contracting.

k) Post weld heat treatment.

l) Welding requirements e.g. consumable batch testing, hydrogen content, backing, surface finish, weld profile etc.




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Ref.


m) Special welding methods.

n) Details of joint preparations and completed welds.

o) Location at which welds are to be made.

p) Environmental conditions E.g. low ambient temperature.

q) Handling of non-conformances.




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Revision: 1



Ref.


6 Sub-contracting

a) Are any activities sub-contracted by the manufacturer?

b) Are sub-contractors provided with the necessary information to meet the applicable requirements?

c) Does the sub-contractor provide records and manufacturing documentation to the manufacturer?

d) Does the manufacturer ensure that the sub-contractor can comply with the specified quality requirements?

e) Is the sub-contractor provided with the results of any reviews carried out by the manufacturer?

f) If the design of the product is sub-contracted are supplementary requirements (if necessary) specified to the sub-contractors?

g) Has the manufacturer a written procedure, which describes how the sub-




Reviewed by: P Ward



Date: 20/06/2012

Revision: 1


contracted activities comply with the requirements of the contract/design specification?

h) Does the procedure above define the tasks and responsibilities of the welding co-ordinator?

7 Welding personnel

7.1 General

Does the manufacturer have sufficient competent personnel for the planning, performing and supervising of the welding production according to specified requirements?


Ref.


7.2 Welders and welding operators

Are welders and welding operators qualified by appropriate tests? Please quote standards being used in the comment collum.

7.3 Welding coordination personnel

a) Does the manufacturer have sufficient appropriate welding coordination personnel at his disposal?

b) Do welding coordination personnel have sufficient




Reviewed by: P Ward



Date: 20/06/2012

Revision: 1


authority to enable necessary actions to be taken?

c) Are the tasks and responsibilities of welding coordination personnel clearly defined?

8 Inspection and testing personnel

8.1 General

Does the manufacturer have sufficient competent personnel for the planning, performing and supervising the inspection and testing of the welding production according to specified requirements?




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Ref.


8.2 Non-destructive testing personnel

Are NDT personnel suitably qualified?

9 Equipment

9.1 Production and testing equipment The following equipment shall be available, as necessary -

a) Power sources and other machines.

b) Equipment for joint and surface preparation and cutting, including thermal cutting.

c) Preheating and post weld heat treatment equipment, including temperature indicators.

d) Jigs and fixtures.

e) Cranes and handling equipment.




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Ref.


f) Personal protective equipment and other safety equipment associated with the manufacturing process.

g) Ovens, quivers etc. for treatment of welding consumables.

h) Surface cleaning equipment.

i) Destructive and non-destructive testing facilities.

9.2 Description of equipment

The manufacturer shall maintain a list of essential equipment used for manufacturing production, typically -

a) Maximum capacity of crane(s).

b) Maximum size of components that can be handled.

c) Capability of mechanised or automated welding equipment.




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d) Size and temperature capability of furnaces for post-weld heat treatment.

e) Capacity of rolling, bending and cutting equipments.

9.3 Suitability of equipment

The manufacturer shall ensure that the equipment is adequate for the intended application.

9.4 New equipment

Are appropriate tests carried out and documented following the installation of new or refurbished equipment?

9.5 Equipment maintenance

a) Does the manufacturer have documented plans for the maintenance of equipment, ensuring checks of those items which control variables listed in the relevant procedure specifications e.g.

b) Condition of guides in thermal cutting equipment, mechanised fixtures etc.

c) Condition of ammeters, voltmeters, flow meters etc. used with welding equipment.




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Ref.


d) Condition of cables, hoses, connectors etc.

e) Condition of control systems in mechanised/automated welding units.

f) Condition of temperature measurement instruments.

g) Condition of wire feeders and conduits.

h) Procedure which prevents the use of defective equipment.

10 Welding and related activities

10.1 Production planning

Does the manufacturer carry out adequate production planning and consider, as a minimum -

a) Sequence of fabrication.

b) The individual processes required for manufacture.

c) Appropriate procedure specifications.




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Ref.


d) Inspection and testing requirements, including independent inspection body requirements.

e) Environmental conditions.

f) Batch/component/part identification.

g) Production test requirements.

10.2 Welding procedure specifications

a) Are procedures prepared in accordance with BS EN ISO 15609-1?

b) Is the correct use of welding procedures verified in production?

10.3 Qualification of welding procedures

Are welding procedures qualified prior to use in production? Please quote relevant standards being used.

10.4 Work instructions

Are work instructions/welding procedure specifications used for instruction?




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Ref.


10.5 Procedures for preparation and control of documents Does the manufacturer have procedures for the preparation and control of the following?

a) Welding procedure specifications.

b) Welding procedure qualification records.

c) Welder/welding operator qualification certificates.

11 Welding consumables

11.1 General

Are responsibilities and procedures for control of welding consumables specified?

11.2 Batch testing

Is batch testing of welding consumables specified?

11.3 Storage and handling

a) Are procedures in place for the storage, handling, identification and use of welding consumables?




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Ref.


b) Are these procedures in accordance with the supplier’s recommendations?

12 Storage of parent materials

Are all materials, including those supplied by the client, stored and identified in a satisfactory manner?

13 Post weld heat treatment

a) Where appropriate, are procedures in place, which are compatible with the parent materials, welded joints and application standards/requirements?

b) Does the manufacturer maintain adequate and traceable post weld heat treatment records?

14 Inspection and testing

14.1 General

a) Are inspections and tests scheduled for appropriate points in the manufacturing process to assure conformity with specified requirements?




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Revision: 1



Ref.


14.2 Inspection and testing before welding Are the following checked before welding commences?

b) Suitability/validity of welder/welding operator approval certificates.

c) Suitability of welding procedure specification.

d) Identity of parent material(s).

e) Identity of welding consumables(s).

f) Joint preparation.

g) Fit-up, jigging and backing.

h) Special requirements from the welding procedure specification.

i) Suitability of working conditions including environment.




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Date: 20/06/2012

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BS EN ISO 3834-2QUESTIONNAIRE

Ref.


14.3 Inspection and testing during welding During welding the following should be checked at suitable intervals or by continuous monitoring.

EN ISO 3834-5:2005 Table 7 refers. .

a) Essential welding parameters e.g. current, voltage, travel speed.

b) Preheat/interpass temperatures.

c) Cleaning, shape of weld beads and layers of weld metal.

d) Back gouging.

e) Welding sequence.

f) Correct use and handling of welding consumables.

g) Control of distortion.

h) Intermediate examination (i.e. checking of dimensions)




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Ref.


14.4 Inspection and testing after welding Compliance with the relevant acceptance criteria shall be checked by -

EN ISO 3834-5:2005 Table 8 refers.

i) Visual inspection

j) Non-destructive testing

k) Destructive testing.

l) Form, shape and dimensions of the construction.

m) Results and records of post-weld operations e.g. post weld heat treatment, ageing etc.

14.5 Inspection and test status

Are measures taken, as appropriate, to indicate the status of inspection and test during manufacture of the construction?




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Ref.


15 Non-conformances and corrective actions

a) Are measures in place to prevent non-conforming items from being used?

b) Are suitable procedures available at workstations for repair/rectification?

c) Following repair/rectification, are items re-inspected and tested in accordance with original requirements?

d) Are procedures in place to avoid recurrence of non-conformances?

16 Calibration

Does the manufacturer have appropriate procedures for the calibration/validation of measuring, inspection and testing equipment?




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Date: 20/06/2012

Revision: 1



Ref.


17 Identification and traceability

Where appropriate, is identification and traceability maintained during the manufacturing process?

Do documented systems include, if necessary, reference to the following?

Production plans.

Routing cards.

Weld locations.

NDT procedures and personnel.

Welding consumables.

Parent material.

Location of repairs.




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Ref.


Location of temporary attachments.

Traceability of fully mechanised and automated welding units to specific welds.

Traceability of welders and welding operators to specific welds.




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Date: 20/06/2012

Revision: 1



Ref.


18 Quality records These shall include, when applicable -

Record of requirement and technical reviews.

Material inspection documents.

Welding consumable inspection documents.

Welding procedure specifications.

Equipment maintenance records.

Welding procedure qualification records.

Welder and welding operator qualification certificates.

Production plan.




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Ref.


18 NDT personnel certificates.

Heat treatment procedure specifications and records.

NDT testing and destructive testing procedures and reports.

Dimensional reports.

Records of repairs and non-conformance reports.

Other documents as required.

Are quality records retained for a minimum period of 5 years, or longer if specified?

Documents

ISO 3834 Questinaire - TUV NORD Worldwide · PDF fileAGAINST BS EN ISO 3834 Prepared by: S Brown Reviewed by: P Ward Authorised by: ... Specification of welding procedures, NDT procedures