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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:
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 2 of 23 Uncontrolled when printed
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?
REPORT OF ASSESSMENT CARRIED OUT AGAINST BS EN ISO 3834
Company Name: Project Number:
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 3 of 23 Uncontrolled when printed
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).
REPORT OF ASSESSMENT CARRIED OUT AGAINST BS EN ISO 3834
Company Name: Project Number:
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 4 of 23 Uncontrolled when printed
BS EN ISO 3834-2 QUESTIONNAIRE
Ref.
Requirement By the Manufacturer By the Assessor Yes No n/a Comments Yes No n/a Comments
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.
REPORT OF ASSESSMENT CARRIED OUT AGAINST BS EN ISO 3834
Company Name: Project Number:
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 5 of 23 Uncontrolled when printed
BS EN ISO 3834-2 QUESTIONNAIRE
Ref.
Requirement By the Manufacturer By the Assessor Yes No n/a Comments Yes No n/a Comments
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.
REPORT OF ASSESSMENT CARRIED OUT AGAINST BS EN ISO 3834
Company Name: Project Number:
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 6 of 23 Uncontrolled when printed
BS EN ISO 3834-2 QUESTIONNAIRE
Ref.
Requirement By the Manufacturer By the Assessor Yes No n/a Comments Yes No n/a Comments
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-
REPORT OF ASSESSMENT CARRIED OUT AGAINST BS EN ISO 3834
Company Name: Project Number:
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 7 of 23 Uncontrolled when printed
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?
BS EN ISO 3834-2 QUESTIONNAIRE
Ref.
Requirement By the Manufacturer By the Assessor Yes No n/a Comments Yes No n/a Comments
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
REPORT OF ASSESSMENT CARRIED OUT AGAINST BS EN ISO 3834
Company Name: Project Number:
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 8 of 23 Uncontrolled when printed
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?
REPORT OF ASSESSMENT CARRIED OUT AGAINST BS EN ISO 3834
Company Name: Project Number:
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 9 of 23 Uncontrolled when printed
BS EN ISO 3834-2 QUESTIONNAIRE
Ref.
Requirement By the Manufacturer By the Assessor Yes No n/a Comments Yes No n/a Comments
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.
REPORT OF ASSESSMENT CARRIED OUT AGAINST BS EN ISO 3834
Company Name: Project Number:
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 10 of 23 Uncontrolled when printed
BS EN ISO 3834-2 QUESTIONNAIRE
Ref.
Requirement By the Manufacturer By the Assessor Yes No n/a Comments Yes No n/a Comments
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.
REPORT OF ASSESSMENT CARRIED OUT AGAINST BS EN ISO 3834
Company Name: Project Number:
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 11 of 23 Uncontrolled when printed
BS EN ISO 3834-2 QUESTIONNAIRE
Ref.
Requirement By the Manufacturer By the Assessor Yes No n/a Comments Yes No n/a Comments
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.
REPORT OF ASSESSMENT CARRIED OUT AGAINST BS EN ISO 3834
Company Name: Project Number:
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 12 of 23 Uncontrolled when printed
BS EN ISO 3834-2 QUESTIONNAIRE
Ref.
Requirement By the Manufacturer By the Assessor Yes No n/a Comments Yes No n/a Comments
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.
REPORT OF ASSESSMENT CARRIED OUT AGAINST BS EN ISO 3834
Company Name: Project Number:
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 13 of 23 Uncontrolled when printed
BS EN ISO 3834-2 QUESTIONNAIRE
Ref.
Requirement By the Manufacturer By the Assessor Yes No n/a Comments Yes No n/a Comments
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?
REPORT OF ASSESSMENT CARRIED OUT AGAINST BS EN ISO 3834
Company Name: Project Number:
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 14 of 23 Uncontrolled when printed
BS EN ISO 3834-2 QUESTIONNAIRE
Ref.
Requirement By the Manufacturer By the Assessor Yes No n/a Comments Yes No n/a Comments
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?
REPORT OF ASSESSMENT CARRIED OUT AGAINST BS EN ISO 3834
Company Name: Project Number:
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 15 of 23 Uncontrolled when printed
BS EN ISO 3834-2 QUESTIONNAIRE
Ref.
Requirement By the Manufacturer By the Assessor Yes No n/a Comments Yes No n/a Comments
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?
REPORT OF ASSESSMENT CARRIED OUT AGAINST BS EN ISO 3834
Company Name: Project Number:
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 16 of 23 Uncontrolled when printed
BS EN ISO 3834-2 QUESTIONNAIRE
Ref.
Requirement By the Manufacturer By the Assessor Yes No n/a Comments Yes No n/a Comments
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.
REPORT OF ASSESSMENT CARRIED OUT AGAINST BS EN ISO 3834
Company Name: Project Number:
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 17 of 23 Uncontrolled when printed
BS EN ISO 3834-2QUESTIONNAIRE
Ref.
Requirement By the Manufacturer By the Assessor Yes No n/a Comments Yes No n/a Comments
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)
REPORT OF ASSESSMENT CARRIED OUT AGAINST BS EN ISO 3834
Company Name: Project Number:
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 18 of 23 Uncontrolled when printed
BS EN ISO 3834-2 QUESTIONNAIRE
Ref.
Requirement By the Manufacturer By the Assessor Yes No n/a Comments Yes No n/a Comments
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?
REPORT OF ASSESSMENT CARRIED OUT AGAINST BS EN ISO 3834
Company Name: Project Number:
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 19 of 23 Uncontrolled when printed
BS EN ISO 3834-2 QUESTIONNAIRE
Ref.
Requirement By the Manufacturer By the Assessor Yes No n/a Comments Yes No n/a Comments
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?
REPORT OF ASSESSMENT CARRIED OUT AGAINST BS EN ISO 3834
Company Name: Project Number:
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 20 of 23 Uncontrolled when printed
BS EN ISO 3834-2 QUESTIONNAIRE
Ref.
Requirement By the Manufacturer By the Assessor Yes No n/a Comments Yes No n/a Comments
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.
REPORT OF ASSESSMENT CARRIED OUT AGAINST BS EN ISO 3834
Company Name: Project Number:
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 21 of 23 Uncontrolled when printed
BS EN ISO 3834-2 QUESTIONNAIRE
Ref.
Requirement By the Manufacturer By the Assessor Yes No n/a Comments Yes No n/a Comments
Location of temporary attachments.
Traceability of fully mechanised and automated welding units to specific welds.
Traceability of welders and welding operators to specific welds.
REPORT OF ASSESSMENT CARRIED OUT AGAINST BS EN ISO 3834
Company Name: Project Number:
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 22 of 23 Uncontrolled when printed
BS EN ISO 3834-2 QUESTIONNAIRE
Ref.
Requirement By the Manufacturer By the Assessor Yes No n/a Comments Yes No n/a Comments
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.
REPORT OF ASSESSMENT CARRIED OUT AGAINST BS EN ISO 3834
Company Name: Project Number:
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 23 of 23 Uncontrolled when printed
BS EN ISO 3834-2 QUESTIONNAIRE
Ref.
Requirement By the Manufacturer By the Assessor Yes No n/a Comments Yes No n/a Comments
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?