Implementing ISO 3834 for Welding Quality

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Improving the quality and effectiveness of welding by utilizing the standard
ISO 3834 Guideline for company implementation
IIW Keywords: ISO 3834, Company Certification, Quality Management, Checklist,
Questionnaire
Objective
The objective of this publication is to provide companies intending to apply the standard ISO
3834 dealing with the quality management of welding, advice on the kind of procedures and
forms that might be beneficial to them and on the content of such procedures. This publication
primarily deals with the adoption of ISO 3834-2, but much of the advice is also applicable to
ISO 3834-3 and ISO 3834-4.
This publication does not mean that all the procedures presented in it are necessarily required.
Once the company has thoroughly considered its needs and has decided that it requires a
certain procedure, this publication can be used in order to find advice for the preparation of the
procedure. The publication should not be used as requirements for procedures or check-lists in
connection with audits.
Abstract
This publication is primarily intended for people who are responsible for quality control in the
field of welding. Because the items presented in this publication may have a significant impact
on a companys business operations and their successful continuation, the publication will be a
useful tool also for strategic and operational managers. This publication also deals with matters
relating to the sale and marketing of products. Therefore the sales personnel of welded
products shall understand, in order to ensure that the products sold are manufactured in
accordance with the designs, in a controlled manner and with minimal risk.
ISO 3834-1 gives the instructions for the selection of the level of quality requirements, while
ISO 3834-2, 3, and 4 present quality requirements of different levels. Manufacturers of certain
welded products, such as pressure vessels, offshore structures and steel structures, may need
to comply with the quality requirements of ISO 3834 required by applicable product standards.
Foreign customers may also require compliance with these requirements as well as major
export companies of their own subcontractors. A company may gain considerable benefit from
applying these standards, even without third party certification. It is possible to certificate the
standard ISO 3834-2 as part of ISO 9001 quality management system or ISO 3834-2, -3 and -4
can be certificated on their own.
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ISO 3834 presents systematically and comprehensively the factors and measures having an
impact on the quality in welding, which a company can develop in order to improve the
manageability of its production, the quality of its products and the reliability of its lead times as
well as the cost-effectiveness of its manufacturing process. For the company it is important to
identify properly those items that will be subject to the requirements presented in ISO 3834-2,
3, and 4. The aim is to avoid unnecessary documentation and procedures and ensure that the
quality management is appropriate for the welded products to be manufactured. This
publication gives examples of the key procedures and the related work instructions and forms.
The key issues to be taken into account in the quality management of welding:
Technical review verifies the companys capabilities for manufacturing the product that has
been ordered and identifies particular welding requirements related to the contract. Only a
correctly conducted technical review ensures well-managed, risk-free and cost-effective
production.
Competence requirements specified for the welding personnel will, in the case of some
workshops, be clearly different from present practice. Product liability gives additional
emphasis on the responsibilities and role of the welding coordination personnel. The
requirements relating to qualification of welders and welding operators strengthens the quality
management of welding and can also reduce costs caused by errors. The standard may not
bring any significant changes to the current practice regarding inspection personnel.
Production plan and qualified welding procedures assure that production is carried out
systematically and the characteristics of the welded joints meet the specified requirements.
There are several alternatives for the method of qualifying welding procedures and the
company shall apply the one that is technically and economically the most appropriate for the
product concerned.
Description of production and testing equipment used in connection with welding allows
the company to check the suitability of its equipment pool for the manufacturing and
inspection of the product it sells. Acceptance tests of equipment, regular maintenance and
possible calibration or validation, in order to ensure that it will be possible to follow the
welding procedures sufficiently and that the inspection and testing results are reliable.
Systematic dealing of non conformances ensures that a defective product is not put into
service by mistake. The reasons for non conformances are analysed and corrective actions
carried out in order to prevent similar non conformances in the future.
Adopting ISO 3834-2, 3, or 4 requires considerable time and effort by the company, with all the
personnel being committing to the work and the additional activities required: developing work
practices, performing new duties, ensuring the flow of information, etc. When the
implementation starts it might be advantageous to engage external expertise in order to obtain
an objective picture of the starting point. The company may decide to focus on reaching a point
where the conditions are fit for certification by documentation and procedures for tasks and
activities, but the real economic and technical benefit from the adoption of ISO 3834 will be
achieved only when the activities and content concerning the welding work are developed. For
this reason, ISO 3834-2, 3, and 4 should be understood primarily as a tool for developing the
welding activities in the company.
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Contents
Page
1. General
2. Reasons for using ISO 3834
3. Choice of quality requirement level
4. Procedures and forms
4.1 General
4.2 Purpose and content
4.3 Relevant procedures and forms/check lists
4.4 Review of requirements
4.5 Technical review
4.6 Sub-contracting
4.7 Welding and associated personnel
4.8 Inspection and testing personnel
4.9 Equipment
4.10 Welding and related activities
4.11 Storage and handling of welding consumables
4.12 Storage of parent material
4.13 Post- weld heat treatment
4.14 Inspection and testing
4.15 Non-conformance and corrective actions
4.16 Calibration and validation of measuring, inspection and testing
equipment
4.17 Identification and traceability
4.18 Quality records
6
7
7
10
11
14
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20
20
21
23
24
25
25
27
28
30
30
5. Need for certification
32
6. Adopting standard 3834 in a company
33
Annexes
A Example of check list for technical review
36
B Example of procedural guidelines for welders qualification test
52
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1 General
Welding is a general production method for manufacturing of metal products. Welding has a
considerable impact on both the products costs and quality. Consequently, it is important that
the welding is carried out as efficiently as possible, meeting all specified quality requirements.
Weld quality is achieved by sound welding, not by inspection. Inspection, however, provides a
check of the reliability of the product, but cannot improve poor quality. Welding requires
continuous control and/or to follow documented procedures. On this basis, the ISO 3834 series
of welding standards has been prepared.
The purpose of the ISO 9000 series is that the company designates as a special process any
work where the final quality of the product cannot be verified only by inspection. If quality
requirements are specified for the welds in the product, it is appropriate to define welding as a
special process.
It shall be observed that ISO 3834 is not a quality control standard that replaces ISO 9001, but
more an auxiliary tool for applying ISO 9001 in companies which carry out welding as a special
process. In such a case, the additional compliance with ISO 3834 will be included by a
reference in the ISO 9001 quality system. It is also possible to obtain certification under ISO
3834 without any linkage to the ISO 9001 quality system.
The standards are general and not fixed to any certain product. The series of standards refers
to three different levels of quality requirements:
- ISO 3834-2 Comprehensive quality requirements
- ISO 3834-3 Standard quality requirements
- ISO 3834-4 Basic quality requirements.
Guidance for the choice of level of quality requirements is given in ISO 3834-1. ISO 3834-5
specifies documents and standards necessary to consider in order to claim conformity to ISO
3834-2, 3, or 4.
2 Reasons for using ISO 3834
Regulations
Regulations, eg, EU directives, define safety requirements on products and structures. Product
standards present the technical solutions that serve to fulfil the safety requirements specified in
the directives.
Product standards
Many European and some International product standards refer to the different parts of ISO
3834 regarding welding. For example, the standard concerning pressure vessels (EN 13445)
states that the manufacturer of the pressure vessel is obliged to fulfil as a minimum the welding
quality requirements given in ISO 3834-3.
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The European standard EN 1090-2, dealing with execution of steel structures, requires the use
of quality requirements according to ISO 3834. The level of quality requirements depends on
the execution class.
Customers
Once ISO 3834 is in use, companies could utilize it for marketing purposes and customers
might require certification to ISO 3834.
The welding company (manufacturer)
The welding company wishes to improve its welding quality management system, increase
productivity and, by applying quality control in welding, demonstrate to its customers to be a
reliable supplier.
Main contractors
A subcontractor working to ISO 3834 can expect to have a significant advantage over its
competitors, when a main contractor is outsourcing its welding or welding related activities.
ISO 9001
ISO 9001 states that, where necessary, special processes shall be identified. Welding is
typically considered as a special process. This requires that specific requirements, which are
specified in advance, are fulfilled. ISO 3834-2 is an excellent tool for doing this.
3 Choice of quality requirement level
ISO 3834-1 gives guidance on the choice of level of quality requirements.
When a welding company uses a quality control system conforming to ISO 9001, the
comprehensive quality requirements according to ISO 3834-2, 3, or 4 may all be selected.
There are only small technical differences between ISO 3834-2 and ISO 3834-3. The main
difference is the level of documentation. ISO 3834-4, presenting basic quality requirements is
the level of choice when the welded components have a low safety risk. Product standards and
national codes may also give references to the different parts of ISO 3834. Table 1 gives a
short summary of requirements for ISO 3834 in European product standards.
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Table 1 Selection of quality requirement level

Product or structure
Requirements
Steel structures (EN 1090-2)
Execution classes 3 and 4 ISO 3834-2

Execution class 2 ISO 3834-3
Execution class 1 ISO 3834-4
Pressure vessels (EN 13445)
At least ISO 3834-3
Railway vehicles (EN 15085)
Certification level 1 ISO 3834-2

Certification level 2 and 4 ISO 3834-3
Certification level 3 ISO 3834-4
Off shore (NORSOK)
ISO 3834-2
Water tube boilers (EN 12952-5)
Recommends parts of ISO 3834-2
When applying ISO 3834, it should be noted that all of the items presented in the standards do
not need to be implemented, if they are not relevant. In such cases clear reasons shall be given
for such a decision.
As a basis, it might be appropriate for a company to start applying the ISO 3834 by adopting
the requirements of ISO 3834-2 and identifying those items that are relevant from the
company's point of view. Care shall , however, be taken to ensure that the quality requirements
specified are not lower than those presented in ISO 3834-4.
The company may also apply different levels of quality requirements for different products.
Although the company may have adopted the standard ISO 3834-2, it may decide to apply
lower quality requirements according to ISO 3834-3 or ISO 3834-4 in respect of certain
products or certain production lines.
4 Procedures and forms
4.1
General
Quality control may be described at three different levels:

At the general level, a description of the companys organisation, areas of responsibility,
operation, equipment, personnel, etc. is given.
At the procedure level, the way in which the activity has to be performed is described as well as
responsible persons.
At the level relating to forms, the necessary forms, lists, reports, records, certificates and
detailed working instructions are prepared.
Often the company is not familiar with preparing procedures. The procedures should be as
simple as possible. A good procedure fits onto a single A4 sheet and is clear and concise
enough to be read without sitting down.
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Not every item needs a procedure. Sometimes it is enough just to know how things have to be
done. It is often difficult to decide whether only knowing how to do things is enough or whether
written procedures are needed. Written procedures are needed, when people ask a lot of
questions, different people do the same task or when lots of mistakes are made.
4.2
Purpose and content
The purpose of procedure is to:

ensure harmonised and effective working
establish responsibilities in respect of tasks and work activities
act as the practical starting point for preparatory work
provide information
act as a channel for exchanges of experience.
Procedures include e.g:
purpose and scope of the work activity
what is to be done and who does it (content of the procedure and the person responsible for
it)
when, where and how the work activity is carried out (content of activity, person responsible
for it)
materials, equipment and documents that are in use
how the work activity is managed and documented.
4.3
Relevant procedures and forms/check lists
Table 2 gives procedures and forms that are appropriate according to different clauses of ISO
3834-2. Where necessary, they can also be used when applying ISO 3834-3 and ISO 3834-4.
It may not be necessary to apply everything that is presented in Table 2; the company has fairly
free hands to make the appropriate choices. Under no circumstances must the table be used
as audit requirements.
The procedures provide examples of who could be the person responsible for certain work
activity. The examples are completely arbitrary. It is important to nominate the person and
ensure that the person is aware of his or her responsibilities and is also given the appropriate
power to act.
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Table 2 Useful procedures and forms/check lists

Clause
3834-2
in
ISO Procedure
Form/check list
5 Review of
requirement
review and
technical review
5.2 Procedure for requirement

review
5.2 Check list for

assessment
5.3 Procedure for technical

review 1)
5.2 Check list for

assessment
6 Subcontracting
6.1 Procedure for subcontracting of welding works
6.1 Form for

ordering/checking
6.2 Procedure for

subcontracting of heat
treatment
6.2 Form for

ordering/checking
6.3 Procedure for subcontracting of testing and

inspection
6.3 Form for

ordering/checking
6.4 Procedure for

subcontracting of maintenance
6.4 Form for

ordering/checking
6.5 Procedure for

subcontracting of calibration
6.5 Form for

ordering/checking
6.6 Procedure for acceptance

testing
6.6 Form
7.2 Procedure for welders and

welding operators 2)
7.2 File with certificates
7 Welding
personnel
7.3 Procedure for welding

coordinators
7.4 Procedure for other
personnel
7.3 File with CV, copies

of diplomas etc.
7.4 File
8 Inspection and
testing personnel
8.2 Procedures for testing and

inspection personnel
8.2 File with copies of

qualifications
9 Equipment
9.2. Procedure for capacity

and capability of equipment
9.2 Capacity list

of equipment
9.3 Acceptance reports
9.4 Procedure for starting to

use equipment and recording
9.4 List of equipment
9.5 Procedure for maintenance

of equipment
9.5 Maintenance and

dimensional reports
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10 Welding and
related activities
10.1.1 Procedure for

subassemblies
10.1.1 Welding plan
10.1.2 Procedure for flow chart
10.1.2 Flow chart
10.2 Procedure for preparation

of welding procedure
specifications
10.2 Welding procedure

specifications
10.3 Procedure for qualification 10.3 Welding procedure

of welding procedures
qualification record
of work instructions
10.4 Work instructions
10.5 Procedure for welding

related maintenance and
support
11 Welding
consumables
11.3 Procedure for storage and 11.3 Stock list

handling of welding
consumables
12 Storage of
parent materials
12 Procedure for storage of

parent materials
12 Stock list
13 Post-weld
heat treatment
13 Procedure for preparation

of heat treatment procedure
specifications
13.1 Het treatment

procedure specifications
14.2 Procedure for activities

prior to welding
14.2 Check form
14.3 Procedure for control

during welding
14.3 Check form
14.4 Procedure for final

inspection
14.4 Check form

of an inspection plan
14.5 Inspection plan
14 Inspection
and testing
15 Non15.1 Procedure when the WPS

conformance and has not been used
corrective actions 15.2 Procedure for nonconformances by inspection
16 Calibration
and validation of
13.2 Heat treatment

records
15.1 Non-conformance
report
report
15.3 Procedure for nonconformances found after

delivery
report
16.1 Procedures for calibration

and validation of thermometers
16.1 Calibration and

validation report
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measuring,
inspection and
testing
equipment
17 Identification
and traceability
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and validation of electrical
measuring devices

validation report

and validation of measuring
devices
16.3Calibration and
validation report

and validation of flow meters

validation report
17.1 Procedure for markings
17.1 Material card
17.2 Procedure for transfer of

markings
17.2 Routing cards
17.3 Procedure for

identification of welders
tests
18 Quality
records
18 Procedure for preparing

and filing of quality records
1)
Example, see annex A
2)
Example see annex B
18 Record forms
4.4 Review of requirements

The procedure for conducting the review of requirements concerns the part of the contract that
deals with welding. The purpose of the review is to ensure:
that the company is technically and otherwise capable (e.g. delivery schedule) to fulfil
all the requirements and wishes presented by the customer and
to check that all the fundamental requirements relating to the welding of the product are
recorded.
The review of requirements shall be conducted before any offer is submitted.

The review of requirements is the responsibility of the person, e.g. sales manager or project
manager, who goes through the orders and the proposed contract. It is important for the
welding coordinator to be present when matters concerning welding in the contract are dealt
with.
If there are ambiguities in the order or in the proposed contract, the person in charge solves
them together with the other parties and with the customer.
In the review of requirements the relevant items presented in clause 5.2 in ISO 3834-2 are
reviewed. It is useful to draft a form for dealing with the matters below. If the company has
previously supplied an identical or similar product, it is not essential to complete the form in
respect of each individual contract.
a) Product standard to be used, together with any supplementary requirements:
does the product relate to any directive?
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does a product standard exist (e.g. ISO-, EN- or national standard)?

does the customer have an existing product standard?
quality level and acceptance criteria?
the mechanical, thermal and/or chemical characteristics set for the welded joints
any additional requirements?
b) Statutory and regulatory requirements

does the product relate to any regulation?
c) Any additional requirement determined by the manufacturer
any additional requirements?
d) The capability of the manufacturer to meet the prescribed requirements
new project?
review of resources?
4.5 Technical review
The purpose of the procedure for the technical review is to look at the matters that shall be
taken into account when reviewing the contract. The procedure deals with matters concerning
welding.
Each company has to nominate the person who will take responsibility for these matters. That
person may be, for instance, the main project designer. The welding coordinator shall be
present whenever any welding matters are discussed.
The following issues should be resolved before the procedure is prepared:
has a technical review been conducted previously (have earlier experiences been taken into
account)?
what are the differences in relation to previous requirements? (any fundamental changes?)
The technical review should cover at least the matters presented in clause 5.3 of ISO 3834-2,
as described in the list below. If the product in question has been manufactured in the past, it is
not always necessary to review these matters again.
a) Specification of parent material(s) and welded joint properties:
weldability
chemical composition
strength
ductility (impact, tensile)
thickness of material
corrosion resistance
wear resistance
high temperature characteristics
quality of parent material surface
other characteristics
b) Quality and acceptance requirements for welds:
quality level
acceptance level
acceptance criteria for welding tests
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c) Location, accessibility and sequence of welds, including accessibility for inspection and for
NDT:
appropriate welding positions
welding equipment being used, including feasibility of automated welding
significance of the welding sequence due to distortion of the work piece
at which stage of manufacturing shall inspection be performed?
d1) Welding procedures:
do all necessary welding procedure specifications exist?
are welding procedure specifications required for all the joints?
d2) Written procedures for non-destructive testing (NDT):
will non-destructive testing (NDT) be conducted?
will the company perform the necessary non-destructive testing itself?
do the necessary written procedures exist, e.g. NDT standards, for the NDT methods to be
performed?
d3) Heat-treatment procedures:
are procedures needed for pre-heating and/or post-welding heat treatment?
will the company perform the necessary pre-heating/heat treatment itself?
are there appropriate procedures for pre-heating/heat treatment?
e) The approach to be used for the qualification of welding procedures:
how should the welding procedures be qualified (e.g. ISO 15607)?
additional requirements (e.g. product standards)?
acceptance criteria for the welding procedure test
are there any appropriate qualification records available?
f) Qualification of personnel:
is there a responsible welding coordinator?
do the welders have valid certificates for the job in hand according to ISO 9606/EN 287 or
other applicable standards? Are additional requirements necessary (e.g. product standards)?
are the welding operators qualified according to ISO 14732/EN 1418 or other applicable
standards?
are the NDT inspectors certified according to ISO 9712 or EN 473
are there any requirements for qualification of persons carrying out heat treatment?
g1) Selection of material, identification and/or traceability:
what is the parent material?, availability?, weldability/special characteristics?
supplier, approved?, known?
how is the parent material identified (transfer of marking)?
should the parent material used in the product be traceable?
are material certificates required? (what level?)
approved parent material/filler material
filler material? (test reports?)
g2) Selection of welders:
does the work require a welder who has a valid certificate for that particular welding job?
g3) Identification of welds:
do the welds have to be identifiable? (to the welder?)
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h) Quality control arrangements, including any involvement of an independent inspection body:

is external quality control required during manufacture?
- customer?
- third party?
- when?
i) Inspection and testing:
which parts will be inspected or tested?
- scope of inspection
- inspection methods
- inspection stages
- reporting level (everything, deviations, errors)
j) Sub-contracting:
welding work (required competences and licences)
NDT testing
post-weld heat treatment
does the customer approve the sub-contractor?
how should sub-contractors be audited?
previous experience of sub-contracting, approved suppliers
k) Post-weld heat treatment:
has the company taken into account the quality requirements presented in ISO 17633
concerning heat treatment in connection with welding?
l) Other welding requirements:
production weld tests
batch testing of welding consumables
determination of ferrite content of weld metal
ageing
hydrogen content
sufficient information on permanent backing
peening
surface finish
weld profile (undercuts, smooth transition, shape of root, convex weld (grinding)
welding plan
m) Using special methods:
root opening
root gas
buttering
n) dimensions and details of joint preparation on completed weld:
type of joint
type of joint preparation
groove preparation
tolerances
o) Welds which are to be made in workshop, or elsewhere:
where final installation takes place (on site)?
are the components produced in different workshops?
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p) Environmental conditions relevant to the application of processes:

low temperature
wind
moisture
lightening
q) Handling of non-conformances:
how to act in case of a non conformance?
- additional inspections (can the number of inspections be reduced?)
- alternative inspection methods
how to proceed if modifications are required after the contract stage?
- who is authorised to approve the changes?
- documentation of changes?
4.6 Sub-contracting
If the company intends to use sub-contracting services (e.g. in welding, inspection, NDT, heat
treatment, calibration, maintenance), he shall provide the subcontractor with all the relevant
specifications and requirements. The sub-contractor shall provide the documents and records
specified by the manufacturer concerning the sub-contracted work.
4.6.1 Sub-contracting of welding
The procedures on sub-contracting shall ensure that the sub-contractor has the technical and
qualitative capabilities (capacity and know-how) to manufacture the product such that the
product meets the requirements specified by the actual customer, comply with the appropriate
items of ISO 3834 and that the timetable requirements will be met.
The person responsible for the sub-contracting matters of the company has the responsibility to
ensure that the sub-contractor meets the technical preconditions required of manufacturing.
This person should use experts in the company, e.g. the responsible welding coordinator.
Scope of sub-contractor assessment
Only the part of the subcontractor's technical know-how has to be assessed as required for the
sub-contracting work. The scope of the assessment depends on what kind of quality system
the sub-contractor has in use. If the subcontractor works according to a certified quality system
including ISO 3834-2, it will be enough just to conform the technical competence (capacity) and
to check the equipment. A sub-contractor without any documented quality system should be
subjected to a separate quality audit conducted by the company.
Items to be addressed with the sub-contractor
Review of requirements
A review of requirements with the sub-contractor may be performed together with the technical
review. A review of requirements may include the following.
a) Product standard and possible additional requirements to be applied:
the sub-contractor needs to know what standard and requirements the product has to fulfil.
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Technical review
A technical review shall be performed with the sub-contractor wherein all the essential aspects
related to the sub-contractor's work will be addressed. Consideration should also be given to
any earlier technical reviews or similar reviews. If there is significance differences or changes in
resources of the sub-contractor an assessment is necessary. A technical review may include
the following.
1) Welding procedure specifications:
The sub-contractor's welding procedure specifications need to be checked. If they are not
suitable for the product to be welded, the sub-contractor shall qualify new welding procedures
to comply with the product and based on these qualifications new welding procedure
specifications shall be prepared.
Assessment to be made whether it is possible to use the main company's welding
procedure specifications (standard procedures)
2) Non destructive testing procedures:
Will NDT be performed and if so, what is the extent?
Will this be done:
- by the sub-contractor
- by the company itself
- by a testing company chosen by the sub-contractor
- by the testing company used by the main company, which will also inspect the main
company's own manufacturing
- for which authority shall the results be presented, and who will present them?
3) Heat-treatment procedures:
Is heat treatment needed?
Who will be the expert for heat treatment: The main company or the sub-contractor?
4) Qualification of welding procedures:
The sub-contractor's welding procedures shall be qualified by the method required by the
quality requirements of the product to be manufactured
5) Qualification of personnel:
Are the qualifications of personnel adequate or does the sub-contractors personnel need
new qualifications for the product to be manufactured, eg, welders and welding operators?
Has a responsible welding co-ordinator been nominated and what is his task?
Is the responsible welding co-ordinator employed by the sub-contractor?
6) Material
Does the main company deliver materials to the sub-contractor and how are these
identified and separated from the subcontractor's own materials?
If the subcontractor buys the material, the following need to be specified:
- Type of material (e.g. standard, composition, dimensional tolerances, etc.).
- Quality requirements for materials
- Approvals, material certificates required
- Requirements for identification and traceability of the material
7) Selection and identification of welders:
Where necessary, the same level as applied by the main company
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8) Inspection and testing:

The sub-contractor needs to be informed about what kinds of destructive and non
destructive testing is required and what the quality requirements are for the product
manufactured by the sub-contractor
Customers inspections
Inspections performed by others (is there a quality plan?)
9) Post-weld heat treatment:
If the product requires post-weld heat treatment, it is necessary to agree how the subcontractor deals with post-weld heat treatment and on the quality requirements
10) Other requirements related to welding:
The sub-contractor must be provided with all the necessary information in order to be able
to do the required work
11) Handling of non-conformances:
What to do and who makes the decisions concerning non-conformances?
Who conducts possible necessary negotiations with the main customer and as necessary
with the authorities (or equivalent)?
12) Other information
Design data
The sub-contractor shall be provided with clear workshop drawings and instructions, such as
the following:
material backing
details and dimensions of joint preparations
permitted welding processes and consumables
where necessary, welding sequence
specification of parent material and characteristics of welded joints
quality of the welds and acceptance requirements
possible special instructions
Quality records
When required by the main company, the subcontractor shall provide or present documents
such as the following:
Welding procedure specifications
Welding procedure qualification records
Welders' qualification test certificates
Measurement records
Test reports from NDT and possible destructive testing
Records of repairs and other non-conformance reports
Documents related to the delivery
The quality documents to be filed either by the sub-contractor or by the main company as
agreed.
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4.6.2 Sub-contracting of heat treatment

An assessment of the sub-contractor will be performed during which the items listed in clause
4.13 will be checked.
4.6.3 Sub-contracting of inspection and testing
An assessment of the sub-contractors will be performed during which the items listed below will
be checked.
a) Sub-contractors competence
Are there any requirements for accreditation?
b) Inspection plan
See clause 4.14.5
c) Qualification of NDT personnel (ISO 9712 or EN 473)
4.6.4 Sub-contracting of maintenance works
An assessment of the sub-contractor will be performed during which the items listed in clause
4.9.5 will be checked.
4.6.5 Sub-contracting of calibration
An assessment of the subcontractor will be performed during which the items listed in clause
4.16 will be checked.
4.7 Welding and the associated personnel
4.7.1 General
The purpose of the procedure is to ensure that the company has the required competent
personnel capable to fulfil the tasks required by the contract, by the regulatory requirements,
and by codes and orders of other bodies concerned.
The procedures apply to qualification of personnel and their various tasks.
The responsibility for the skill of the personnel can, for example, be allocated to the companys
HR manager or production manager. In the welding matters, the responsible welding coordinator will be contacted.
At technical reviews, personnel required for various projects are discussed along with their
qualifications.
4.7.2 Welders and welding operators
Those doing welding work are required to be qualified according to the relevant part of ISO
9606-1 or EN 287, ISO 14732 or EN 1418 unless otherwise required by the product standard
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or in the contract. The procedures show how qualifications and possible renewal including
possible special requirements are to be dealt with. In some cases, a production test on site is
required before the welder can start to work.
The welder's job description could also include the following activities:
joint preparation (according to instructions)
fitting (according to instructions)
maintenance (according to instructions).
4.7.3 Welding coordinator
The company shall nominate at least one welding coordinator (responsible), who has the
overall welding responsibility and the necessary authorisations (e.g. to stop production). It is
possible for one responsible welding coordinator to be responsible for several sub-contractors.
If the field of activities of the company is broad, the tasks can be shared, e.g. between the lead
welding coordinator and other welding coordinators or welding foremen. Where necessary, the
welding coordinators and welding foremen report to the lead coordinator. The qualifications of
the welding coordinators need to be demonstrated through sufficient experience or training
(e.g. IIW).
ISO 14731 shall be taken into consideration for the choice of welding coordinators' tasks.
Responsible welding coordinator (often the only welding coordinator in a company)
When defining tasks for the responsible welding coordinator, the following list can be used as
guidance (see also ISO 14731):
Organising of welding quality management according to ISO 3834
Coordination of qualification of welding procedures
Updating and distribution of files with welding procedure qualification records
Preparation and signing of welding procedure specifications
Publication of a table with qualified welding procedure specifications
General instructions for welders' qualification
Updating and publication of a centralised welder register
Expert tasks connected to purchasing of welding equipment and materials
Coordination of welder's training
Training of examiners for welder's qualification tests
Technical welding expert services for different departments and units in the company
(including the Design Department and Requirements Review).
Where necessary, a competence requirement may be specified for the responsible welding coordinator (e.g. IWE/IWT/IWS).
Welding coordinator (can also be responsible)
When preparing procedures for assisting welding coordinators, the following list can be used as
guidance (see also ISO 14731):
Department-specific organising and preparation of procedures and forms concerning
quality management in welding
Acting as the responsible welding coordinator of various projects
Having welding tests done according to the needs of the department
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Preparing and releasing of welding and heat-treatment procedure specifications to be

used
Ensuring functioning of welders' qualification systems
Welders training
nominating of personnel for transfer marking on materials
Controlling validity of welders' qualifications
Controlling to ensure that transfer of markings takes place according to instructions
Reserving of welding equipment
Reserving of welding consumables
Where necessary, a competence requirement may be specified for the welding coordinator
(e.g. IWT).
Welding foreman
A welding foremans tasks include:
Work planning
Organising and control of welding work
Ensuring welding is carried out in accordance with WPS
Organising and control of heat treatment
Organising and control of inspections.
Where necessary, a competence requirement may be specified for the welding coordinator
(e.g. IWS).
4.7.4 Other personnel
(not in ISO 3834)
Designer
Designers tasks include, e.g.:
Preparation of manufacturing and welding drawings
Design of welded joints
Preparation of prefabrication drawings
Determination of manufacturing tolerances and appropriate choice of reference points and
reference levels for dimensioning.
Heat-treatment personnel
The heat-treatment operators tasks include, e.g.:
Heat treatment according to specifications
Calibration of temperature measuring and recording equipment
Validation of the furnace controlled temperature zone
Control of temperatures
Documentation of heat treatments
Loading, supporting, protection, installation of measurement sensors, insulators, and
heating elements.
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4.8 Inspection and testing personnel

The purpose of the procedure is to ensure that the qualifications of the NDT personnel are of a
required level and in accordance with the ISO 9712 or EN 473 or as specified in the product
standard or contract.
4.9 Equipment
4.9.1 General
The purpose of the procedures is to ensure that the welding equipment can be used as
required by the welding procedure specifications. Defective equipment shall not be used.
The procedures apply to description, acceptance, use and maintenance of equipment. Machine
cards shall be kept of each equipment item showing the following:
Type and capacity
Manufacturer and machine number
Machine number used by the company or some other unique mark
Acceptance tests
Regular maintenance.
The responsibility for the maintenance of the equipment could be given to the maintenance
manager or service manager. The responsibility may also be delegated to users.
4.9.2 Procedure for capacity and capability of equipment
The procedure dealing with the description of the equipment shall specify what the capacity list
includes, e.g. number and capacity of welding equipment, such as maximum welding current.
4.9.3 Procedure for acceptance of equipment
Before equipments are accepted, it may be necessary to perform an acceptance test. If no
acceptance standard is available, the necessary procedures may be prepared together with the
equipment supplier.
4.9.4 Procedure for starting to use equipment and recording
Before the use of new or refurbished equipment, the following checks are necessary:
External integrity
Condition of cables
Operating functions.
Furthermore, a welding test should be performed to ensure that the equipment functions
normally.
4.9.5 Procedure for maintenance of equipment
a) Maintenance interval, responsible person and the person performing the maintenance.
The maintenance report of a welding machine may show the following, for example:
Inspections related to electrical safety
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Condition of welding cables

Condition of wire feeding devices
Condition of welding gun or welding torch
Output capacity
Condition of measuring devices.
b) In daily maintenance of welding machines the following shall be observed:

Condition of wire feed roller and correct compressive force
Condition of current and gas nozzles
Condition of insulator sleeve of gas nozzle
Condition of protection hose of welding gun
Condition of earthing
Gas flow of shielding gas
Condition of valves.
4.10 Welding and related activities

The purpose of the procedures is to ensure that welding and the related activities take place as
planned.
The responsibility for welding activities may be given to the responsible welding coordinator,
production manager, manufacturing manager or the welding foreman.
The procedures may apply to the production plan, preparation and qualification of welding
procedures, preparation of work instructions, maintenance work and auxiliary work, daily
planning and performance of welding, maintenance or supporting activities.
4.10.1 Procedures for preparing the production plan
ISO 3834-2 can be applied as such for procedures concerning the production plan. Separate
procedures could be prepared for individual work stages, e.g. cleaning, nestling, joint
preparation, post-weld treatment and inspection of welds. A routing card can also be used to
assist the preparation of the production plan.
4.10.2 Procedures for preparation of welding procedure specifications
The procedure for preparing of welding procedure specifications may include the following:
Which items shall be included and to what degree of accuracy?
Tolerances (for joint preparations; for welding parameters)
For which products may the procedures be used?
Method of qualification
Choice of welding consumables (based on performed tests, experience or customer's
requirements taking into account additional recommendations given by the consumable
manufacturer and possible authority requirements)
Who has the right to sign welding procedure specifications?
Special procedures
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- Cleaning
- tacking
- buttering
- root opening
- pre-heating (measurement according to ISO 13916)?
- repair welding.
4.10.3 Procedures for qualification of welding procedures
The preparation of welding procedure qualification records (WPQR) shall be included in the
procedure for qualification of welding procedures.
a)
The WPQR for qualification by tested welding consumables (ISO 15610) may be based
on the following:
inspection body's (e.g. TTK, TV, DNV, Lloyds, etc.) lists of parent materials and filler
materials
welding consumable manufacturers list (e.g. Esab, Elga, Bhler, etc.), which may include
filler material specific approvals.
b) The WPQR for qualification by previous experience (ISO 15611) may consist of the
following:
Test reports and
Customer's statement that the product has been in use the last five years without any need
for weld repair. This statement may be done e.g. in connection with maintenance at the
customer.
c) Standard welding procedure (ISO 15612):
WPQR prepared by the organisation which performed the welding procedure test (if
available).
d) Welding procedure tests (ISO 15614) and pre-production tests (ISO 15613):
Procedures for examination of tests (what to do before, during test, and after the tests)
Inspection and test reports.
The signatory of the qualification will be nominated in all cases.
4.10.4 Work instructions
The procedure for preparing of work instructions may include the following:
Which items of the welding procedure specification and to what extent?
Who has the right to sign the work instructions?
Who may use work instructions?
4.10.5 Procedure for welding maintenance and supporting activities
The welder shall be able to understand the maintenance procedures (daily maintenance and
periodic maintenance) for the equipment and its parts. See clause 4.9.5.
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4.11 Storage and handling of welding consumables

The purpose of the procedure is to ensure that the handling and storage of welding
consumables has been sufficiently addressed in order to prevent them from becoming moist,
oxidised and damaged or mixed with one another. The procedure for storage, drying, baking
and handling needs to comply with the recommendations of the manufacturer of welding
consumables.
Responsibility
The person responsible for the storage and handling of the welding consumables is the person
in charge of welding in the company, e.g. responsible welding coordinator or a person
authorised by the coordinator, e.g. the stock keeper.
Contents
The procedure for storage of welding consumables may include the following:
a)
Sufficiently detailed information for ordering welding consumables:
Is it enough to use the classification and then choosing other welding consumables with
the same classification?
Is it mandatory to purchase only welding consumables with specific trade names?
Is, in special cases, a material certificate necessary?
b) Acceptance of welding consumables:
Conforming that the purchased welding consumable is what was ordered
Check that sufficient markings are in place.
c) Storage of welding consumables:
Temperature range in the storehouse shall be defined
Existing maximum relative humidity in the storehouse shall be defined
Where necessary, other conditions in the storehouse shall be reported
Consumables to be stored in unopened original packages, and opened packages always
to be used first
Sequence of giving out of consumables from the storehouse: oldest consumables to be
used first (first in, first out)
The number of consumables that can be given out from the storehouse for use at the work
place shall be specified.
d) Handling of welding consumables:
The consumables shall not become mixed up during use
Where necessary, they shall be marked, e.g. with stickers or coloured markings
Where necessary, the welding consumables shall be dried
Where necessary, holding ovens or quivers shall be used
Where necessary, the maximum storage time at the work place shall be specified after
which the consumables need to be re-dried or scrapped
A minimum number of opened packages shall be permitted at the work place
Proper discipline required on the work place: e.g. covered electrodes shall not be left
around.
e) Drying and storage of welding consumables:
Devices used for drying need to be available
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Consumable specific instructions for drying based on the consumable manufacturer's

instructions (temperature and drying time) shall be given
The maximum holding time in holding oven shall be taken into account
Mixing of welding consumables shall not be possible.
4.12 Storage of parent materials
The purpose of the procedure is to ensure that the parent materials used for welded products
meet the requirements specified for the product.
The procedure applies to the storage and handling of the parent materials.
The person responsible for manufacturing in the company is responsible for the storage of
parent materials. The person responsible organises and ensures that the storage of parent
materials does not cause damage or that they become mixed during storage.
It is important to prevent wrong materials from being used.
Contents
The requirements specified for a product, or by a contract or a standard or the authorities shall
be observed in the identification of materials.
a) If the material supplier provides or is required to provide an order confirmation, this shall be
checked with care and expertise also in regard to its technical part.
b) Care shall be taken during acceptance inspections to ensure that all of the requirements in
the order have been fulfilled and that all of the markings are as required.
c) Care shall be taken in the storage that the materials will not be damaged or mixed up.
d) In nestling, care shall be taken in marking to ensure that the materials will not become mixed
up. The marking system shall correspond to the product standards. Marks made using crayons,
paint or stamps or batch-specific identifier cards may be used as necessary. For example, the
transfer of the markings of the pressure vessel materials shall be made before nestling. A
person appropriately trained will transfer the following markings:
Material quality
Cast and test numbers
Stamp of the person transferring the markings.
Small parts may be marked using code markings.
e) During manufacturing care shall be taken to ensure that the identification of the materials is
retained.
f) Where necessary, and according to the product standard, the customer shall be provided
with information about the materials used, and as necessary also with material certificates.
4.13 Post-weld heat treatment
The purpose of the procedure is to ensure that the welds are heat-treated in a specified
manner in order to fulfil the requirements of the welded product.
The procedure applies to the heat treatment after welding.
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The responsibility for the heat treatment can be allocated to the person responsible for
manufacturing or to the welding co-ordinator.
Contents
ISO 17663 describes heat treatment as a special process. It includes the following:
Review of requirements and technical review
Subcontracting
Personnel
Inspection and testing
Equipment for heat-treatment
Heat treatment activities
Heat treatment records
Non-conformance and corrective actions
Quality records
4.14 Inspection and testing
4.14.1 Contents
The purpose of the procedure (Inspection and Testing Plan) is mainly to ensure that quality
control is in place before welding, during welding, and after welding.
Procedures are prepared for visual inspection and for both destructive and non-destructive
testing.
The overall responsibility for inspections lies with a person who is independent of production,
e.g. the quality manager. The person or organisation performing the inspection is responsible
for the actual inspection work and its results. The inspectors' visual acuity should be checked at
regular intervals. The majority of inspections do not require an outside inspector, e.g. a welder
trained for inspection tasks can do the visual inspection of the welds he has made. The general
principle is that the person doing the work is responsible for that work.
4.14.2 Inspection and testing before welding
The procedure may include:
a) Inspection of the welders qualifications:
Validity
Suitability (range of qualification)
b) Welding procedure specifications/work instructions:
Necessity
Suitability
Correct welding procedure specification
Parent material and material thickness
Identity of parent material
Welding consumable(s) (marking, storage, and condition)
Dimensions of joint preparations (method of preparation, bevel angle, gap, depth of root
face)
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Fit-up, jigging and tacking

Setting of welding parameters (welding current, voltage, wire feed rate)
Measurement of preheating temperature
Environmental conditions (e.g. temperature and draught)
c) Production tests:
Extension parts to be welded for destructive testing
d) Non-conformances
4.14.3 Inspection during welding
a) Control of welding parameters (that they are in use):
Welding current
Arc voltage
Travel speed
Gas flow rate
Contact tube distance
b) Temperature measurements:
ISO 13916 may be used when measuring the pre-heating temperature, the interpass
temperature, and preheat maintenance temperature.
c) Use and handling of welding consumables
d) Cleaning, shape and number of runs
e) Welding sequence
f) Back gouging
g) Control of distortion
h) Required intermediate examinations
i) Non-conformances
4.14.4 Inspection after welding
a)
Implementation of the testing plan (destructive and non-destructive testing)
b) Checking of test reports:

Written instructions (e.g. a specific standard)
Acceptance levels
Qualifications of inspection personnel
c) Checking the shape, profile and dimensions of the structure
d) Results of post-treatment:
Grinding
Post-heating-treatment record
Ageing
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e) Non-conformances
Sometimes there could be a need to prepare testing plan (ITP). It might include:
Test object
Extent of testing
Testing time
Test methods/equipment
Subcontracting
Test instructions
Testing conditions (e.g. lighting, viewing angle, viewing distance)
Acceptance levels (e.g. corresponding to quality levels)
Recording instructions or report forms.
4.14.5 Inspection and testing status

The inspection or test status of the welded structure is given in an appropriate manner, e.g. by
means of a marking on the object itself or a traceability card.
4.15 Non-conformances and corrective actions
The purpose of procedures is to ensure that
a nonconforming product does not go forward into production, for use or to be delivered to
the customer
correction is taken to correct the nonconformance
corrective actions are taken to avoid repetition of the fault.
The procedures concern welding, inspection and non-conformances found after delivery. It is
important to define what a non-conformance is.
All parties are obliged to report of any non-conformance they have noted. Depending on the
nature of the non-conformance, the welder shall have the right, if necessary, to interrupt his/her
work.
A designated person shall be given the responsibility for ensuring that the corrections/repairs
are made according to instructions and completed, and that the required quality has been
reached.
4.15.1 Procedures when the welding procedure specification has not been followed or is
impossible to follow
If the welding procedure specifications/work instruction was not followed, the welder shall
inform e.g. the foreman/responsible welding coordinator about it. A non-conformance report
shall be made of this type of non-conformance.
The contents of the report should include e.g. of the following items:
Description of the non-conformance
Proposed action (correction of welding procedure specifications or work instructions?)
Decision
Control of implementation
Corrective action.
The procedure should describe how to proceed, e.g.
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a) No action
b) Correction without permission
c) Correction with permission from a certain person
d) Classification for alternative use
e) Scrapping.
Any repair welding shall be done according to the qualified welding procedures.
4.15.2 Procedures for non-conformances found during inspection
The following may be mentioned in procedures for how to handle weld imperfections found
during inspection:
The way in which the imperfection has to be marked
Acceptance of the non-conformance
Increasing the extent of testing and additional test methods (see, technical review)
corrective actions (see, technical review)
reporting (see 4.15.1).
4.15.3 Procedures for non-conformances found after delivery
Procedures for dealing with non-conformances found after delivery may include the following:
Classification of the non-conformance
NDT
Heat treatment
Does the welding procedure specification really meet the requirements for the work to be
done?
Has the welding procedure specification been wrongly prepared?
Has the welding procedure specification been qualified by previous welding experience
according EN ISO 15611 (the qualification of WPS to be withdrawn?)
What method has to be followed in corrective and preventive actions?
Reporting
Others
4.16 Calibration and validation of measuring, inspection and testing equipment
The purpose of the procedures is to ensure that the measurement instruments and equipment
in use meet the required technical and other criteria for fulfilling the requirements specified by
the customer. Requirements for calibration and validation of equipment used for welding,
including ancillary activities are given in ISO 17662.
The procedures refer to the measurement instruments and equipment used in manufacture and
inspection.
The company shall nominate a person responsible for calibration and validation. The company
is responsible for the appropriate calibration or validation of inspection, measurement and
testing equipment for welded products. The extent and level of accuracy of the calibration or
validation and the interval between these activities shall be defined by the company according
to required product standards. It shall be observed that tight production tolerances cause a
greater need for accuracy of calibrated or validated equipment. Generally, calibration concerns
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instruments and equipment (master instruments) used for validation of instruments used in
testing the final properties of a product. For products requiring great accuracy, the degree of
measurement uncertainty (accuracy) shall be known and it is necessary to ensure the
companys own measurement equipment is traceable to international measurement standards.
The company shall prepare the necessary calibration or validation procedures for instruments
and equipment. The most common objects of calibration or validation in the welding industry
include:
a) The equipment required for inspection by measuring of finished products or, if necessary,
parts, e.g.:
measuring tapes for final inspections
caliper gauges and micrometers
gauge blocks
dial indicators
angle gauges
measuring instruments for throat thicknesses
rulers
matrices
thickness gauges
theodolites and measuring machines
b)
Gauges and meters used in welding and flame cutting, e.g.:

ammeters and voltmeters
tachometers
gas flow meters (rotameter)
wire feed regulator
c)
measurement equipment required in heat treatment and pre-heating, e.g.:

plotters
regulators
thermoelements
thermometers
pyrometers
d) Equipment used in non-destructive testing, e.g.:

magnetization equipment
magnetic field gauge
light intensity meters
X-ray equipment
viewing devices
densitometers
ultrasonic equipment and calibration blocks
e) Destructive testing:
The equipment should be subject to official calibration inspection, e.g. hardness, tensile
testing machines and impact hammers.
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4.17 Identification and traceability

The purpose of the procedures is to ensure that the identification and traceability of the welded
product or its parts are maintained throughout the whole manufacturing process.
The procedures concern organizing and documenting the identification and traceability of
welding and related activities.
The company is responsible for planning, managing and documenting identification and
traceability at the product level.
Identification and traceability relating to welding should include, if necessary, depending on the
structure and its application:
identification of production plans (see also clause 4.10.1)
identification of routing cards or a list
identification of weld locations, e.g. by a drawing of the actual situation
identification of non-destructive testing procedures and personnel (for which object?)
identification of welding consumables, e.g. designation, trade name,, manufacturer of
welding consumables and batch or cast number, if required
identification and/or traceability of parent material, e.g. type, cast number, if required
identification of location of weld repairs
identification of location of temporary attachments
traceability for fully mechanized or automatic welding units to specific welds
traceability of welders and welding operators to specific welds
. traceability of welding procedure specifications to specific welds.
4.18 Quality records
4.18.1 General
The quality records are an essential part of the companys quality assurance system. They
provide the basis for its quality policy, quality objectives and working methods and they ensure
the repeatability of procedures. With the help of the quality records and systematic working
methods, it is possible to get customers and possible third parties, already interested at the first
contact. At the same time they may also be convinced of the companys ability to manufacture
and deliver the required product.
The records should be used by all those whose work is affected by the document in question.
The quality records can be divided into two groups:
1) The documents relating to the companys own activities e.g. operational and work
instructions for the organization, distribution of responsibilities and operations of the company.
2) Quality files derived from the documents, reports and check lists (forms) on actions relating
to the product and documents delivered to the customer together with the product.
4.18.2 Records relating to the companys own operations
In a welding company records are, for example, the organizational description/chart,
responsibilities and authorizations within the organization, the equipment list and documents
specified in ISO 3834-2.
These include instructions relating to document management and procedures for:
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how perform certain operations

references to standards, if possible
the person performing the operation
the timing of the operation
signing the completion of operation.
In addition to table 2 the following records may be useful:

correspondence with the customer, inquiries, offers/tenders, orders, confirmations of
orders
documents and confirmations of orders relating to purchasing
drawings
approved subcontractors
non-destructive and destructive testing procedures and reports
procedures for acceptance of parent materials and transfer of marks
material certificates
4.18.3 Quality files regarding a specific product
A contract, product standard or law may require that certain quality records have to be
delivered together with the product to the purchaser and in some cases also to the relevant
authorities.
Quality files should also be retained in order to demonstrate the achievement of the required
quality and the efficient functioning of the quality procedures.
The documents should be prepared at the stage of manufacture or inspection concerned and
collected so that they can be collected immediately when the product has been completed. The
welding coordinator or the person responsible for quality should check and approve the
documents before sending them to the customer.
The documents should be sufficiently clear, accurate and easily identifiable as belonging to a
specific product, so that it can be proved afterwards that the requirements of manufacture and
inspections have been fulfilled.
The manufacturer files the documents in accordance with its own archiving procedures.
Another way of ensuring that the necessary documents are created on schedule is to have a
production or quality plan covering the stages and operations involved in the products
manufacture and inspection, signed by the responsible person when the required actions have
been completed.
The documents specified in the contract shall be submitted together with the product. The
documents to be delivered may include the following:
records of requirement/technical reviews
production/quality plan
material certificates
information on welding consumables
reports of material testing
routing cards relating to inspection
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measurement and other test reports

list of welding procedure specifications used
list of qualified welders used
heat treatment procedure specifications and reports
records of repairs and non-conformance reports.
The periods for retention of individual records shall be defined and documented and the
record holders identified.
4.18.4 Document management
The manufacturer should create an easily usable list-based or other equivalent procedure for
document control, in order to verify their validity and to prevent the use of invalid and/or
outdated documents.
The documents shall be provided with an identification number, a revision number, signature
and date of approval. The persons to whom the documents have been delivered to shall be
listed, and at the same time it is ensured that all have the latest revised version at their
disposal. The documents may be filed as a hard copy or in an electronic format, for example for
10 years. The person who has approved the original document should also approve any
changes made. The points changed are to be marked in a suitable manner.
5 Need for certification
Fulfillment of the requirements of ISO 3834 can be demonstrated in different ways. Often the requirement may be
a certification of the system. The company should be able to choose itself whether it wants certification to promote
marketing, to improve overall quality and efficiency and to increase the credibility of its operations from the
customers or stakeholders perspective.
There are several ways of showing the customer or a potential customer that the companys
welding quality requirements have been met. These are:
a method bilaterally agreed on between the customer and the company
auditing by the customer
auditing by a third party chosen by the customer.
Quality is always a question of agreement between the customer and the supplier, which does
not necessarily require certification.
6 Adoption of ISO 3834 in a company

The adoption of ISO 3834 in a company may, for example, be carried out in as a project in
three stages.
AT the first stage the company has to carry out a survey of the current situation. This stage
should be performed with great care and sufficient time should be spent on it, as it forms the
basis for the success of the whole project. The current situation should be examined as
thoroughly and as truthfully as possible. It is human at this stage to embellish the actual
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situation in the company. Such embellishment, however, makes the actual advantage gained
from the project smaller than expected. Very often only the requirements of the standard will be
met, but the possibilities for improving the quality and efficiency of the production will be lost
already at the beginning of the project.
In many cases the examination of the initial situation is useful, if consultation with an outside
expert is used, because the expert has no need to describe the situation as better than it
actually is. Neither is an outside expert subject to workplace blindness, which is only human
for people who have worked for a long time at the same workplace.
When real quality improvement is defined as the goal, it is important to gain the commitment of
personnel at all levels in the companys hierarchy to the project. The executive management of
the company shall give and demonstrate its full support for the project from the beginning to the
end. This is supported by informing and training the personnel at the earliest possible stage.
It has been found useful to arrange training of the stuff in connection with the survey of the
current situation. The number of companys staff, products and company culture are important
factors making the organizing of a training event beneficial. Separate training events can be
organized for clerical staff and welding personnel, or all personnel groups can be gathered
together in one event. The advantage of the first alternative is that the content of the training
can be tailored accurately to meet the needs of target group. For example, for welders, the
items of the standard on Equipment, Welding activities and Welding consumables can be
highlighted. For the clerical staff it would be useful to concentrate, for example, the item
Requirement and technical reviews.
The advantage of a common training event organized for the whole personnel would be that it
would be possible to examine matters from different perspectives. The various personnel
groups would gain an overall picture of all the operations affecting quality management in
welding as required by the standard. The personnel groups would get knowledge of items dealt
with in other groups areas of responsibility and understand the actions required by themselves
and others and the linkages and dependencies between them.
The number of participants in the training events should be restricted to enable an open and
controlled discussion of matters. In large enterprises it is better to arrange several events than
to bring together the whole personnel or personnel group in one training event. There is no
reason to underestimate the importance of training or information events, because the basic
requirement for a successful project is that the whole personnel is involved in developing the
activities.
The main objective of the first stage is to identify and record items needing improvement. After
this stage it is often useful to update the project plan, in order to ensure a realistic schedule for
implementation.
At the second stage, on the basis of the initial survey, an action plan shall be prepared for
addressing the items needing development and the planned actions shall be performed. These
actions may be split into separate tasks, for example, according to the list of contents in the
standard or to the companies own quality manual. Chronologically the separate tasks may be
carried out either simultaneously or successively. The method of implementation depends on
the resources available for the project and how responsibilities are assigned in the company. At
latest at this stage of the project, it is recommended to nominate a responsible person(s) for
each item to be developed.
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Training of the companys personnel continues at this stage. While the first stage mainly gives
information on the content of ISO 3834 and the actions regarding needed procedures and
documentation to meet the requirements, at this stage the objective is focused on the technical
content of actions and procedures. Activities and training given at this stage are to a large
extent decisive as regards the technical and economic benefits that adopting ISO 3834 will
bring the company.
When the items according to ISO 3834 are used as a tool for measuring the quality producing
capacity of the company, and the weaknesses and disadvantages found as a result of using
the standard are addressed properly, the productivity of welding can be improved and quality
costs cut, so that the expenditure and effort put into the ISO 3834 project will be found as an
excellent investment.
The duration of the second stage depends very much on the size and initial situation of the
company. If the company has a certified ISO 9001 quality system in place and it has, for
example, successfully manufactured standardized products, it has in practice already had to
operate according to many of the items of ISO 3834-2. Readiness for certification can in this
case be achieved quite quickly and with a very reasonable amount of work. The additional work
may be limited to revising of a few operational procedures to bring them into the form required
by ISO 3834.
The work is considerably more demanding if the company does not have a certified quality
system, or a well documented quality management system has not been required for the
products it manufactures, especially as regards welding. The work of preparing procedures is in
any case quite extensive even though an effort is made to minimize the number of procedures
to what is appropriate. Time and resources shall also be reserved for understanding the
purpose of the procedures and for learning the tasks involved in practice and establishing them
on all levels of production.
Typically, 618 months shall be reserved for the second stage. In order to achieve a timetable
of 6 months, the ISO 3834 work shall be done by teams of several (> 3) people simultaneously
in the different areas of operations. If the implementation of the standard will be done in a
team, as small as possible, (e.g. in addition to normal workload), the project will easily take
more than a year.
The estimates above mainly concern companies with a wide production program. If the
company manufactures a clearly limited range of products, where the welding work is similar,
and the requirements are clearly established, the timetable for adopting ISO 3834 may be
much shorter.
The third stage involves checking the functional effectiveness of the quality management
system for welding and its compliance with standards, so that any remaining disadvantages are
found before the real audit by an external party. This pre-audit could be carried out by an
expert in the project, who has not participated in developing the procedures of the company
concerned. The pre-audit could also be done by an outside expert familiar with ISO 3834. The
idea here is to avoid a situation where a person could assess the results of his or her own
work. Any disadvantages found will, of course, be corrected, after which the company can ask
for an audit by an accredited certificating body. The end goal is an effectively functioning
quality management system for welding, and at this stage all the procedures will comply with
the appropriate requirements according to ISO 3834.
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Problems
The most common problems occurring with the implementation of ISO 3834 are:
purchasing or ordering
status of the responsible welding coordinator in the company
handling of welding consumables
following the welding procedure specifications
validation of ammeters and voltmeters
range of qualifications.
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Email : iiwceo@wanadoo.fr
WEB Site : http://www.iiw-iis.org
Annex A: Checklist according to EN ISO 3834:

Note:
The reduced requirements according to EN ISO 3834-3 and -4 shall be taken into consideration accordingly. In case of a certification
according to EN ISO 3834-4 the addressed documents in this checklist do not need to be submitted with the application.
Number of registration:
_____________________________________
Name of company:
_____________________________________
Type of audit:
Address:
_____________________________________
Audit
_____________________________________
Preliminary audit
Audit team leader:
_____________________________________
Follow-up audit
Auditor:
_____________________________________
Surveillance audit
Reference documents (Status):
_____________________________________
Re-Audit
Date of audit:
_____________________________________
_________________________
Signature (Audit team leader)
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Questions to the quality

requirements according
to ISO 3834-2
REVIEW OF REQUIREMENTS AND

TECHNICAL REVIEW
5.2
Are the following technical

aspects considered?
Product standards
Statutory and regulatory
requirements
Any additional requirement
determined by the
manufacturer
Any additional requirement
determined by the customer
The capability of the
manufacturer to meet the
prescribed requirements
Is the check of the requirements
indicated and appropriately
documented, if necessary?
Confirmation
Remarks, if required
To be completed by the
auditor
R2)
Result of the audit
Yes
No
Remarks:
e.g..
Checklist
Description
Records
2
5.3
Are the following technical

requirements checked?
Yes
No
Parent material(s)
Remarks:
specification, welded joint
properties
Quality and acceptance
requirements for welds
Location, accessibility, weld
sequence (Welding, NDT)
Welding procedures, nondestructive testing procedures,
heat treatment
Qualification of welding
procedures
Qualification of personnel
Selection, identification,
traceability
1)
2)
Graduation: part 2, 3 and 4 see table A of ISO 3834-1

R = Result, 0 = not applicable , 1 = met, 2 = partly met, but still acceptable, 3 = partly met, but not acceptable, 4 = not acceptable
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Confirmation

to ISO 3834-2
ISO
ISO
3834 38341)
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auditor
R2)
Result of the audit
Quality-control
Inspection, testing
Sub-contracting
Post-weld heat treatment
Specific welding requirements
Specific welding procedures
Specifications regarding joint
preparation and completed
weld
Environmental conditions
Handling of non-conformances
1,
2,
22
18

e.g..
Yes
No
Remarks:
Checklist
Description
Records
SUB-CONTRACTING
Are sub-contractings performed?
1)
2)
Sub-contracting of welding
works
Yes / No
Sub-contracting of
inspection
Yes / No
Sub-contracting of NDT
Yes / No
Sub-contracting of heat
treatment
Yes / No
Others:
Are the followings items considered by sub-contracting?
Yes
No

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ISO
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Confirmation
auditor
R2)
Result of the audit
Definition of preconditions and Remarks:

criterias of selection of subcontractors
Ensuring of the necessary
documents to the subcontractor
Observance of the relevant
requirements according to ISO
3834 by the sub-contractor
Fulfilling of the quality
requirements by the subcontractor

e.g..
Sub-contractor list
Subcontractor audit plan
Audit report undertaken by the
manufacturer
4
WELDING PERSONNEL
7.2
Welder and operators
4,
22
7.2
18
Is a sufficient number of welders/operators available and

qualified by suitable qualification
tests?
7.3
Welding coordination personnel
7.3
Is the welding coordination

personnel competent and
authorized to enable any
necessary action to be?
Yes
No
Submit certificates or present
them during the audit.
Remarks:
Is the number of qualified

welders/operators
sufficient?
Are the qualifications
suitable?
Yes
No
Remarks:
e.g.
Organisation chart
Appointment
1)
2)

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Are the tasks and responsibilities Yes

No
defined?
e.g.
7.3
7.3
Confirmation
Matrix of responsibilities
Description of position
Are the competences for the
review of requirements defined
and is the welding coordinator
integrated in the sense of EN
ISO 14731?
Organisation chart
Description of position
Matrix of competence
Other proof (Nomination, bulletin)
Is a sufficient number of
competent welding coordination
personnel according to the
designated production range
available?
auditor
R2)
Result of the audit
Are the determinations

suitable?
Remarks
Yes
No
Remarks:
DVS-SFI/IWE/EWE,
number:
DVS-ST/IWT/EWT,
number:
DVS-SFM/IWS/EWS,
number:
Other qualifications,
number:
Is the number sufficient?

Yes
No
Are the qualification
suitable?
Yes
No
In case of other
qualifications (DVSSFI/EWE/IWE, DVSST/EWT/IWT, DVSSFM/EWS/IWS): a
separate professional
interview is necessary
covering the following
items:
Welding Processes
Welding Consumables
Materials
Construction
Calculation
Manufacturing
Examination
Classification to DIN EN
1)
2)

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to ISO 3834-2
Confirmation
auditor
R2)
Result of the audit
ISO 14731:
C: S: B:
INSPECTION AND TESTING
PERSONNEL
6,
22
8.2
18
7,
8,
9
EQUIPMENT
7,
8,
9
9.2
Is an actual list of essential

equipment used for production
and testing available?
Power sources and other
machines
Equipment for joint and surface
preparation as well as for
cutting, including thermal
cutting.
1)
2)
Yes
Is a sufficient number of
No
competent personnel for
planning, performing, supervising
and testing of the welding
Remarks:
production available?
Are (additional to the direct visual Yes, which?
testing) testing methods used?
Visual testing using
devices (VT)
Penetrant testing (PT)
Magnetic particle testing
(MT)
Radiographic testing (RT)
Ultrasonic testing (UT)
Others
No
Yes
Is the personnel sufficient
No
qualified to perform nondestructive testing?
(see EN ISO 3834-5: 2005,
tables 3 and 10)
Yes
No
Submit the list or present it
during the audit with details to:
Maximum capacity of
crane(s)
Size of components that
the workshop is able to

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7,
8,
9
9.3
7,
8,
9
9.4
7,
8,
9,
22
9.5,
18
7,
8,
9,
22
9.5,
18
1)
2)
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to ISO 3834-2
Confirmation
auditor
R2)
Result of the audit
handle
Equipment for preheating and
post-heat treatment including
Capability of mechanised
temperature indicator
or automatic welding
Jigs and fixtures
equipment
Cranes and handling
Dimensions and
equipment used for the
maximum temperature of
production
furnaces
for heat
Personal protective equipment
treatment
and other safety equipment,
directly associated with the
Capacities of rolling,
applicable manufacturing
bending and cutting
process
equipment
Ovens, quivers etc. used for
treatment of welding
Facilities for surface cleaning
Destructive and nondestructive facilities
Is the equipment adequate to the Yes
welding application concerned?
No
(Proof of suitability only if
specified)
Yes
Is the correct function of new or
No
refurbished equipment verified
before the initial operation?
Remarks:
Yes
Are documented plans for the
No
maintenance of equipment
available, including control of
maintenance of the facilities used Remarks:
for checking the relevant
parameters of the welding
specifications?
Yes
Do the plans cover all
equipment, which are essential No
for the quality of the
components?
Remarks:
Condition of guides in
equipment for thermal cutting,

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8,
9
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9.6

to ISO 3834-2
mechanised fixtures etc.
Condition of ammeters,
voltmeters, flow meters etc,
used for the operation of the
welding
equipment
Condition of cables, hoses,
connectors, etc.
Condition of control system in
mechanised and/or automatic
welding unit
Condition of temperaturemeasurement instruments
Condition of wire feeders and
conduits
Is guaranteed that defective
equipment is not used?
Confirmation
auditor
R2)
Result of the audit
Yes
No
Remarks:
10,
11,
12
10
10,
11,
12
10.1
1)
2)
WELDING AND RELATED

ACTIVITIES
Is a production planning carried

out, including the equipment
foresight for use of
manufacturing and testing
Specification of the sequence
by which the
component/construction shall
be manufactured
Identification of the individual
processes required to
manufacture the
component/construction
Reference to the appropriate
procedure specifications for
welding and allied processes
Sequence in which the welds
are to be made
Yes
No
Remarks:

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to ISO 3834-2
auditor
Confirmation
R2)
Result of the audit
Order and timing in which the

individual processes are to be
performed
Specification for inspection and
testing, including the
involvement of any
independent inspection body
Environmental conditions (e.g.
protection from wind and rain)
Identification by batches,
components or parts
Allocation of qualifies
personnel
Arrangement for any
production test
10,
11,
12,
22
10.1,
18
10,
11,
12,
22
10.2,
18
10,
11,
12,
22
10.3,
18
1)
2)
Are the production plans suitable Yes

No
for the relevant application and
do they contain all necessary
information?
Remarks:
Are welding procedure

specifications (WPS) for the
welding procedures in use
available?
Arc welding (EN ISO 15609-1)
Gas welding (EN ISO 15609-2)
Electron beam welding (EN
ISO 15609-3)
Laser beam welding (EN ISO
15609-4)
Arc stud welding (EN ISO
14555)
Others:
By which method are these
welding procedures qualified?
Qualification by a welding
procedure test (EN ISO 15614)
Yes
No
Present examples during the
audit
Yes
No
Remarks:

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to ISO 3834-2
Confirmation
auditor
R2)
Result of the audit
Qualification based on tested

consumables (EN ISO 15610)
Qualification based on
previous experience (EN ISO
15611)
Qualification by adoption of a
standard welding procedure
(EN ISO 15612)
Qualification based on preproduction welding test (EN
ISO 15613)
Others:
10,
11,
12
10,
11,
12
10.4
10.5
13,
14
11
14,
22
11.1,
18
13
11.2
Are additional to the welding

procedures specifications also
work instructions used?
Is a procedure for establishing
and control of relevant quality
documents available?
Procedure for establishing and
controlling of e.g.:
- WPS
- WPQR
- Inspection documents
Yes
No
Remarks:
Yes
No
Remarks:
WELDING CONSUMABLES
Yes
Are responsibilities and
procedures for control of welding No
consumables specified?
Remarks:
e.g:
Conformity certificate
Inspection document
Yes
Is batch testing of welding
No
consumables required?
Remarks:
1)
2)

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11.3
15
12
15
12
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to ISO 3834-2
Are procedures for storage,
handling and use of welding
consumables produced and
implemented?
Moisture pick-up
Oxidation
Damage
Recommendations of supplier
STORAGE OF PARENT MATERIALS
Yes
No
Is the storage of the parent

material (including material
supplied by the customer)
performed in such a way, that
they are not be adversely
affected?
Yes
No
Are measures and plans

available for environmental
influences?
Are tasks and responsibilities for
control of the storage of parent
material specified and
implemented in production
(identification, storage and
handling)?
15,
22
12
18
Is the marking/identification
during the time of storing guaranteed?
Type of marking
Inspection documents
16
13
POST-WELD HEAT TREATMENT
16
13
Is post-weld heat treatment

performed? (also subcontracting)?
16
13
Are the responsibilities for the

performance of post-weld heat
treatment specified?
1)
2)
Confirmation
auditor
R2)
Result of the audit
Remarks:
Remarks:
Yes
No
Remarks:
Yes
No
Remarks:
Yes
No
Remarks:
Yes
No (Further questions are
not applicable)
Yes
No

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to ISO 3834-2
Confirmation
auditor
R2)
Result of the audit
Remarks:
16,
22
16,
22
13,
18
13,
18
17
14
17,
22
14.2,
18
1)
2)
Is post-weld heat treatment

performed according to written
instructions?
Related to e.g.:
Parent material
Welded joint
Component
Product
standards/specifications
Can, on the basis of the record,
the traceability of the
performance of the post-weld
heat treatment to the particular
component be demonstrated?
Recording of the process
parameter (e.g. heat treatment
record)
Size of the furnace
Conditions of supporting in the
furnace
INSPECTION AND TESTING
Yes
No
Remarks:
Yes
No
Remarks:
Are inspection and testing before Yes

welding performed in accordance No
with the contact/rules?
Remarks:
Suitability and validity of
welders and operators
qualification certificates
Suitability of the welding
procedure specification
Identity of parent material
Identity of welding
consumables
Joint preparation
Fit-up, jigging and tacking
Any special requirements in

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3834 38341)
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17,
22
17,
22
17,
22
18
1)
2)
14.3,
18
14.4,
18
14.5,
18
15
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to ISO 3834-2
the welding procedure
specification
Suitability of working
conditions, including
environment
Are inspection and testing during
welding performed in accordance
with the contract/rules?
Essential welding parameters
Preheating/interpass
temperature
Cleaning and shape of runs
and layers of weld metal
Back gouging
Weld sequence
Correct use and handling of
welding consumables
Control of distortion
And intermediate examination
(e.g. checking of dimensions)
Are inspection and testing after
welding performed in accordance
with the contact/rules?
By visual testing
By non-destructive testing
By destructive testing
Form, shape and dimension of
the component/construction
Results and records of postweld operations
Is the status of inspection and
testing given, as appropriate? e.g..
At the component
In the routing cards
Confirmation
auditor
R2)
Result of the audit
Yes
No
Remarks:
Yes
No
Remarks:
Yes
No
Remarks:
NON-CONFORMANCE AND
CORRECTIVE ACTIONS

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18,
22
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15,
18

to ISO 3834-2
Are measures implemented to
handle items, which are not
conform to specified
requirements?
Identification
Responsibilities
Repair specification/repair
Re-inspection
Measures for avoiding
recurrence
Are non-conformance records

maintained?
19
16
CALIBRATION AND VALIDATION OF

MEASURING, INSPECTION AND
TESTING EQUIPMENT
19
16
20,
21
17
Are measuring, inspection and

testing equipment calibrated and
validated?
Equipment
Procedure
Responsibilities
Check list
(see EN ISO 3834-5: 2005,
Tables 9 and 10)
IDENTIFICATION AND
20,
21
17
1)
2)
Confirmation
auditor
R2)
Result of the audit
Yes
No
Remarks:
Yes
No
Submit a list or present it
during the audit
TRACEABILITYI
Are rules for identification and

traceability during the
manufacturing process
available?
e.g. it can be required:
Identification of production
plans
Identification by routing cards
Identification of weld locations
in the component/construction
Yes
No
Remarks:

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3834 38341)
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22
18
22
18
1)
2)
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to ISO 3834-2
Confirmation
auditor
R2)
Result of the audit
Identification of non-destructive
testing procedures and
personnel
Identification of welding
consumables
Identification and/or traceability
of the parent material
Identification of location of
repairs
Identification of location of
temporary attachments
Traceability of fully
mechanised and automatic
welding units to specific welds
Traceability of welder and
operators to specific welds
Traceability of welding
procedure specifications to
specific welds
QUALITY RECORDS
Are quality records available and Yes
No
for which time period are they
retained?
Remarks:
Time period 5 years
Record of
requirement/technical review
Material inspection documents
Welding consumables
inspection documents
Welding procedure
specifications (WPS)
Equipment maintenance
records
Welding procedure
qualification records (WPQR)
Welder or welder operator
qualification
Production plan
Non-destructive testing

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3834 38341)
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---
---
---
---
---
---
---
---
1)
2)
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to ISO 3834-2
Confirmation
auditor
R2)
Result of the audit
personnel certificates
Heat treatment specifications
and records
Non-destructive and
destructive testing procedures
reports
Dimensional reports
Records of repairs and nonconformance reports
Other documents, if required
USE OF STANDARDS NOT
COVERED IN ISO 3834-5
Does the manufacturer specify
the use of standards different
than those referred in ISO 38345?
Yes
No
Remarks:
USE OF THE CERTIFICATE

Does the use of the certificate by Yes
the manufacturer give a true and No
accurate image of the
Remarks:
manufacturers capability
covered by the certification?

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Annex B: Example of a simple procedure for qualification of welders

Scope
This procedure ensures that the welders have the required qualification
Field of application
This procedure concerns qualification of welders according to ISO 9606/EN 287-1.
Qualification testing of welders and examination
All welders perform qualification tests according to ISO 9606/EN 287-1. Annex A includes a list of the qualification
tests to be performed. For examination check list C 6.2 will be used.
Testing
The welding co-ordinator performs the visual testing according to ISO 17637. After acceptance the test pieces will be
sent to testing laboratory (Inspection Ltd) for radiographic testing. (see procedure B 5.3j).
Quality records
The responsible welding co-ordinator files a data base including all welders' certificates. The data base includes a list
of welders, their qualification and validity.
Validity
The welding co-ordinator signs the certificates every six months. For signing the welding foreman provides the welding
co-ordinator with all necessary information concerning welding work. Every two years new qualification tests are
carried out.
3)
4)

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Implementing ISO 3834 for Welding Quality

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Implementing ISO 3834 for Welding Quality

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International Institute of Welding

A world of joining experience

WEB Site : http://www.iiwelding.org

To act as the world-wide network for knowledge exchange of joining technologies

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International Institute of Welding

WEB Site : http://www.iiwelding.org

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International Institute of Welding

WEB Site : http://www.iiwelding.org

2. Reasons for using ISO 3834

3. Choice of quality requirement level

4. Procedures and forms

5. Need for certification

6. Adopting standard 3834 in a company

B Example of procedural guidelines for welders qualification test

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International Institute of Welding

WEB Site : http://www.iiwelding.org

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International Institute of Welding

WEB Site : http://www.iiwelding.org

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International Institute of Welding

WEB Site : http://www.iiwelding.org

Table 1 Selection of quality requirement level

Steel structures (EN 1090-2)

Execution classes 3 and 4 ISO 3834-2

Pressure vessels (EN 13445)

At least ISO 3834-3

Railway vehicles (EN 15085)

Certification level 1 ISO 3834-2

Off shore (NORSOK)

Water tube boilers (EN 12952-5)

Recommends parts of ISO 3834-2

Quality control may be described at three different levels:

International Institute of Welding

WEB Site : http://www.iiwelding.org

Purpose and content

The purpose of procedure is to:

Relevant procedures and forms/check lists

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International Institute of Welding

WEB Site : http://www.iiwelding.org

Table 2 Useful procedures and forms/check lists

5.2 Procedure for requirement

5.2 Check list for

5.3 Procedure for technical

5.2 Check list for

6.1 Procedure for subcontracting of welding works

6.1 Form for

6.2 Procedure for

6.2 Form for

6.3 Procedure for subcontracting of testing and

6.3 Form for

6.4 Procedure for

6.4 Form for

6.5 Procedure for

6.5 Form for

6.6 Procedure for acceptance

7.2 Procedure for welders and

7.2 File with certificates