WPS & ISO

4.1 Welding quality management system

[Q4.1-1]
Technical review is specified in ISO 14731 Welding coordination Tasks and responsibilities.
What activities are required for Technical review.

[Q4.1-2]
Welding is treated as Special process in ISO 3834. What is Special process? Explain it briefly
according to ISO 9000/ISO 3834.

[Q4.1-3]
In ISO 9000, it is prescribed that the following five requirements shall be established by the
organization for special process. To what requirement does each item given in the [Group A]
correspond? Put each alphabetical symbol of items in the parenthesis of the requirements.

[Requirements]
(1) Defined criteria for review and approval of the process. ( )
(2) Approval of equipment and qualification of personnel. ( )
(3) Use of specific methods and procedures. ( )
(4) Requirement for records ( )
(5) Revalidation of the process. ( )
[Group A]
(a) Performing welding procedure test according to e.g. ISO 15614 (JIS Z 3422).
(b) Issuance of work instruction.
(c) Custody of the records of NDT.
(d) Establishment of the procedure for traceability.
(e) Maintenance of welding equipment, including calibration of ammeter.
(f) Certification/qualification of welding personnel by the third party organization.
(g) Application of ISO 15607 and related standards (h) Issuance of WPS.
(i) Performing production welds test
(j) Review of WPS

[Q4.1-4]
The following sentences are describing the definition of the terms given in the [Word group] which are
used in ISO 9000 or ISO 15607 Specification and qualification of welding procedure specification Put
alphabet of each corresponding term in the parenthesis.
(1) Record comprising all necessary data needed for qualification of a preliminary welding procedure
specification. ( )
(2) Simplified specification of the welding procedure, suitable for direct application in the workshop.
( )
(3) Document providing in detail the required variables of the welding procedure to ensure repeatability.
 ( )
(4) Something sought, or aimed for, related to quality. These are generally based on the organizations
quality policy. ( )
(5) Document stating results achieved or providing evidence of activities performed concerning quality.
( )
[Word group]
(a) Quality objectives.
(b) Quality records
(c) Welding procedure specification
(d) Welding procedure qualification records (WPQR)
(e) Work instruction

[Q4.1-5]
Inspection and testing before, during and after welding are specified in ISO 3834-Part 2.
Pick out three items of inspection and testing for each before, during and after welding.

[Q4.1-6]
According to ISO 15609-1 Specification and approval of welding procedures for metallic materials
Welding procedure specification Part 1: Arc welding, pick out at least five of the variables which
should be described in WPS.

[Q4.1-7]
The following sentences are describing the terms used in quality management or production
management. Choose the relevant one and circle its alphabet.
(1) Process capability means the ability of the achievement of activities in;
(a) Inspection
(b) manufacturing
(c) top management
(d) cutting] process
(2) Process capability also represents the characteristics of;
(a) quantity
(b) publicity
(c) quality
(d) intelligence, because it is usually evaluated by the accuracy or level of defectiveness of the
products.

(3) On the other hand;

(a) Process capacity
(b) Process equipment
(c) Quality capacity

2
 (d) Analysis capability means the maximum output and maximum labor man-hours or maximum
capacity of the equipment when the labors or the equipment are fully worked or operated.
So, it represents the characteristic of;
(a) quantity
(b) publicity
(c) quality
(d) intelligence
(4) Welding coordinators (Welding Engineers) should recognize the requirement of the quality and
perform the activities of;
(a) manufacturing management
(b) principal design
(c) functional design
(d) procurement control quality control and improvement.

4.2 Welding fabrication planning

[Q4.2-1]
According to ISO 15609-1 Specification and approval of welding procedures for metallic materials
-Welding procedure specification--, what items of welding variable should be described in a format of
WPS? Pick out at least ten (10) welding variables in case of arc welding of butt joint of thick steel
plates.

[Q4.2-2]
Describe briefly the objects of welding procedure qualification test , and name five major conditions
for repeating the qualification test, explaining the contents therein.

[Q4.2-3]
Welding procedure test is specified in ISO 15614 (JIS Z 3422) in order to qualify and approve pWPS
(preliminary WPS). What kind of test and specimens are prescribed in the standard for butt welding
test piece? Give two NDT methods and three kinds of test specimens for destructive tests.
(1)Non-destructive test methods: ( ), ( )
(2)Specimens for destructive testing: ( ), ( ), ( )

[Q4.2-4]
The test and inspection of weld are made before welding, during welding and after welding.
Give two examples of test or inspection made in each of these three stages, explaining the contents in
brief. [Q4.2-5]
What items should be instructed to the welders as a Welding Coordinator (Welding Engineer)
regarding to the welding work at higher stage like on scaffolding.
Pick out four (4) items to be checked, confirmed and taken into consideration before working and
explain them in brief.

[Q4.2-6]
3
 A steel pipe whose wall thickness is 6 mm and diameter approximate 400 mm must be butt- welded
from one side in fixed pipe position. In order to ensure a sound backside bead, what kinds of welding
processes are considered suitable?
Give at least two welding processes, showing each proper groove shape and/or welding
consumables.

[Q4.2-7]
According to ISO 3834 (JIS Z 3400), testing and inspection should be performed before, during or
after welding. When testing, checking or inspection item given in the [Words group] should be
performed? Choose the relevant one and put their alphabets in each parenthesis.
(1) Before welding ( )
(2) During welding ( )
(3) After welding ( )
[Words group]
(a) Qualification (or Approval) of WPS.
(b) Checking mill inspection certificates.
(c) UT or RT for welds
(d) Checking pre-heating and inter-pass temperature.
(e) Measurement of welding current
(f) Checking removal of slag on weld surface.
(g) Inspection of back gouging.
(h) Measurement of dimensions of welding products including welding deformation.
(i) Confirmation of status of qualification/certification of welders.
(j) Checking flow rate of shielding gas.

[Q4.2-8]
The following sentences and equation are related to planning of welding performance control. Choose
the relevant one and put its alphabet in each parenthesis.
(1)Deposition rate = [Weight of consumed wire] [Efficiency of deposition] ( )
(2)Low hydrogen electrode shall be baked at ( ) C for 30 ~ 60 minutes before use.
(3)In order to increase fatigue strength of butt weld, it is recommended that ( ) should be carefully
ground off by a grinder.
(4)When an austenitic stainless steel plate is placed in contact with a low carbon steel plate in the
stockyard, stainless steel easily get ( ).
(5)In ISO 3834, welding is treated as ( ).

4
[Words group]
(a)Arc time ratio (b) 300 ~ 400 (c) rouging (d) production process
(e) Arc time, (f) weld reinforcement (g) 150 ~ 200
(h) special process (i) cracking
495