Company Certification

Standards in
Welding
What is a code:

A systematic collection of regulations and rules of procedure
IPC Indian Penal Code - It is a comprehensive code, intended to
cover all substantive aspects of criminal law.

IBR Indian Boiler regulation - Regulations in respect of
materials, design and construction, inspection and testing of
boilers and boiler components for compliance by the
manufacturer's and users of boilers in the country.

ASME BPVC Section IX - Welding and Brazing Qualifications


What is a standard:

A Standard can be defined as a set of technical definitions
and guidelines that function as instructions for designers,
manufacturers, operators, or users of equipment.

Different standards adopted :
American Welding Society Standards (AWS)
American petroleum institute standards (API)
Australian / New zealand standards (AS/NZS)
British Standards (BS)
International Organisation for standardisation (ISO)
European Union Standards (EN)
German Standards (DIN)
Bureau of Indian Standards (BIS)


Difference between a code and a
standard

A code is a model, a set of rules that knowledgeable people
recommend for others to follow. It is not a law, but can be
adopted into law.
A standard tends be a more detailed elaboration, the nuts
and bolts of meeting a code.

A standard becomes a Code when it has been adopted by
one or more governmental bodies and is enforceable by law,
or when it has been incorporated into a business contract.

SOME OF THE MANAGEMENT
STANDARD.
ISO 900O -QMS
ISO 14000 -EMS
ISO 18000-Occupational Health and Safety
Management System (OH& S MS) And
International Standard
OHSAS 18001:1999
ISO 27000-ISO/IEC 27002 provides best
practice recommendations on IS security
management systems (ISMS).

EMERGING STANDARDS
ISO-3834 Quality
requirements for fusion
welding of metallic materials.
EN -15085- Welding of
railway vehicles and
components.
IRIS- International Railway
Industry Standard
Welding is a Special Process-Why

7 - Product realization
7.5 Production and service provision
7.5.2 Validation of processes for production and
service provision

The organization shall validate any processes for
production and service provision where the resulting
output cannot be verified by subsequent monitoring or
measurement and as a consequence, deficiencies
become apparent only after the product is in use or the
service has been delivered.
What is ISO-3834&EN 15085
It is an international standard created by the
welding professionals.
ISO 9001 defines requirements for quality
management system
ISO 3834 also defines the quality
requirements, only welded products.
EN 15085 for railway applications.

What is ISO-3834&EN 15085(contd)
The standard specifies the requirements
relating only to the welded structure.
The standard can also be used as a production
control system.
ISO 3834 is not a product standard, but it is
often cited as a requirement of various
products to ensure good practice in the
welding and to prevent premature failures.

What is ISO-3834&EN 15085(contd)
The standards provides details of how to
control the various welding and welding-
related operations to achieve the desired
quality consistently
The company that is certified according to this
standard gains an advantage when competing
with other companies in European and World
wide markets.

What is ISO-3834&EN 15085(contd)
Fusion welding processes are widely used in
many products. In some companies it is a key
manufacturing process. Products may be both
simple and complex, for example, Pressure
vessels, domestic and agricultural equipment,
cranes, bridges, railway transport and other
facilities.

What is ISO-3834&EN 15085(contd)
These processes have a significant impact on
production costs and product quality. It is
important to ensure that these processes are
carried out in the most efficient manner and
that all transactions are properly controlled.

What is ISO-3834&EN 15085(contd)
It is noted that ISO 3834 is not quality
management system standard, which replaces
ISO 9001:2000,
but it may be beneficial to producers in the
application of ISO 9001:2000.
Description of the quality requirements of
welding processes is important as the quality of
these processes is not easy to verify,
because they belong to the ISO 9000:2000 for
special processes.

ISO 3834 part-1 to 4
ISO 3834-1-General requirements

ISO 3834-2- Comprehensive quality
requirement
ISO 3834-3- Standard quality requirement
ISO 3834-4 -elementary quality requirement



ISO 3834-2- Comprehensive quality
requirement

Constructions in which the failure of welds may
lead to
total product failure
with significant financial consequences
Major injury.
The product may be subject to dynamic
loading
In addition to high static loading.

ISO 3834-3- Standard quality
requirement

Constructions in which failure of welds
impair the intended use of construction.
Normal safety risk
Financial losses not extreme.

ISO 3834-4 elementary quality
requirement


Constructions in which failure of welds
Not fundamentally impair the intended use.
No adverse effects on safety of people
Minor financial consequences.

EN 15085
Railway applications Welding of
railway vehicles and components
Part 1: General
Part 2: Quality requirements and certification
of welding manufacturer
Part 3: Design requirements
Part 4: Production requirements
Part 5: Inspection, testing and documentation

EN 15085 Part 1: General

EN 15085 Part 1 provides an overview and
scope of the 15085 series of standards and
how it applies to the welding of metallic
materials in the manufacture and
maintenance of railway vehicles and their
parts.


EN 15085 Part 2: Quality requirements and
certification of welding manufacturer

EN 15085 Part 2 of the standard defines the
certification and quality requirements for the
welding manufacturer to undertake for new
fabrication and repair work.
It then provides an essential link
between performance requirements defined
during design to achieve the appropriate
quality welds during production and the
demonstration of the required quality by
inspection

EN 15085 Part 3: Design requirements

EN 15085 Part 3 defines weld performance
class during design, which is based on safety
and stress factors relevant to railway
operation.
Quality levels of imperfections are assigned to
weld performance classes to ensure a certain
level of performance intended during design

EN 15085 Part 4: Production
requirements

Based on the weld performance classes,
certification levels for production, as well as
inspection and testing and qualifications for
welding personnel of the manufacturer are
specified.

EN 15085 Part 5: Inspection, testing and
documentation

This standard deals with inspections and
testing to be executed on the welds,
destructive as well as non-destructive tests to
be performed and necessary documentation
to issue to declare the conformity of the
products.
The EN 15085 series of standards does not
deal with product qualification

Some important terms used in
EN15085:

Certification level (CL): It is level to classify
the welded railway vehicle or the welded
component depending on the weld
performance class (CP)
The certification level is abbreviated by CL
CERTIFICATION LEVEL -1(CL-1)
This level applies to welding manufacturers
which manufacture welded railway vehicles or
their welded parts with welded joints
classified in weld performance classes CP A
to CP D.
Certification level CL 2 to CL 4 is included.
Examples Of CL -1 level manufacturers.
Bogie frames and bolsters;

Body shell components (e.g. under frames, structures);

Buffers and draw gear;

Wheel set components (e.g. wheel set mountings,
axle boxes, spring supports);

Brake equipment (e.g. magnetic track brake, brake
rods, brake triangles, brake cylinders, brake cross
beams);



Examples Of CL -1 level manufacturers
welded components for drag transmission from
bogie to vehicle;

Vibration dampers and their link between bogie
and vehicle or between vehicles;
supporting frames for heavy components (e.g.
traction units, pantographs);

finishing welding of castings within components
indicated above;

External fuel tanks
CERTIFICATION LEVEL -2(CL-2)
This level applies to welding manufacturers which
manufacture welded parts of railway vehicles with
welded joints classified in weld performance classes
CP C2 to CP D.

Welded joints classified in weld performance class CP
C1 are included if these welds are checked
according to weld inspection class CT 1 according to EN
15085-5:2007, Table 1. Certification level CL 4 is only
included according to welded
joints of certification level CL 2 or CL 3.
CERTIFICATION LEVEL -3(CL-3)
This level applies to welding manufacturers
which manufacture welded parts of railway
vehicles with welded joints classified in
weld performance class CP D.
This level applies to manufacturers which do
not weld but design railway vehicles and parts
of rail vehicles or buy and assemble or sell
them. Certification not required for welding
works of certification level CL 3.
Weld performance class(CP)
It is performance requirements of the welded
joint as defined by the stress category and the
safety category of the welded joint.
Note: The weld performance class is
abbreviated by CP (class of performance).

Weld performance classes

Stress categories
Safety
High Medium Low
High CP A (*) CP B CP C2
Medium CP B b CP C2 CP C3
Low CP C1 d CP C3 CP D
CP A (*) - Weld performance class CP A is a special class which applies only for
welds with full penetration and full accessibility for inspection in production and
maintenance
Weld inspection class(CT):
defines the inspections to be carried out for a
given weld with respect to the weld
performance class.
NOTE The weld inspection class is
abbreviated by CT (class of testing).


Correspondence between weld
performance classes and inspection
classes

Stress category:category determined by the
stress factor
Stress factor: It is ratio of the calculated
fatigue stress to the admissible fatigue stress
of the joint type, adjusted by the appropriate
safety factor

Safety categories
The safety category defines the consequences of failure of the single
welded joint in respect to the effects on persons, facilities and the
environment.
The safety categories are differentiated as follows:

Low: Failure of the welded joint does not lead to any direct
impairment of the overall function.Consequential events with personal
injuries are unlikely.

Medium: Failure of the welded joint leads to an impairment of the
overall function or can lead to consequential events with personal
injuries.

High: Failure of the welded joint leads to consequential events with
personal injuries and breakdown of the overall function

Relationship between

Stress category.
Safety category.
Weld performance class.
Quality levels for imperfections.
Inspection class and testing.

Given In Next Slide.
Stress
categor
y
Safety
categor
y
Weld
performa
nce
class
Quality
levels for
imperfect
ions EN
ISO 5817
Inspectio
n class
Volumet
ric tests
RT or
UT
Surface
tests
MT or PT
Visual
examination
VT
High High CP A see Table
5 or
Table 6
CT 1 100% 100 % 100 %
High Medium CP B B CT 2 10% 10 % 100 %
High Low CP C2 C CT 3 Not
required
Not
required
100 %
REQUIREMENTS TO IMPLEMENT
ISO 3834&EN 15085

MEN
MATERIAL
METHOD
MACHINE
MONEY
Welding personnel(Men)

Welders and welding operators
Welding co-ordination personnel
Inspection & testing personnel
Welding inspection personnel
Non-destructive testing personnel

Welder qualification standards
American
standards
ISO/EURO INDIAN
ASME/Sec IX
AWS D1.1

BS EN 287
ISO 9606

IS 817
IS 7318
IS7310
EN 287-Part-1 -2011
QUALIFICATION TEST OF WELDERS
FUSION WELDING
PART-1- STEEL
Validity Of Approval


Valid for 2years, providing
that the welders supervisor
can confirm that at every six
month period the welder has
been working within his
range of qualification.






Job knowledge for welders as per en 287
Job knowledge test shall comprise:
identification of the range of qualification based on the current
qualification test,
properties and identification of parent materials within the material
groups or sub-groups of the test pieces,
properties and identification of parent materials within the material
groups or
sub-groups covered by the range of the qualification certificate to be
issued,
characteristic features of the welding process being the subject of the
qualifica- tion test,
properties and identification of welding consumables used for the
particular welding process,
the principles of edge preparation for welding and pre-welding
assembly,
the principles of selecting proper welding parameters,
the principles of pre-heating and pre-heating control,
proper interpass temperatures and their control,
weld imperfections and their causes,
method of repair of the welds below the acceptance level.





Visual Testing


Each test piece shall be subjected to visual testing (VT):
after the root run of the butt weld has been performed in the test piece,
after completion of the test piece.
Visual testing and its recording shall comply with the guidelines contained in
EN ISO 17637.
The quality level of the test pieces, based on type and size of imperfections, shall be assessed in
accordance with EN ISO 5817 for steel test pieces and EN ISO
10042 for the test pieces of aluminium or its alloys.
Surface imperfections of the test piece shall be within quality level B.
Only the following types of imperfections in quality level C are permitted:
excess butt weld metal (502),
excess fillet weld metal (503),
excess throat of the fillet weld (5214),
excessive penetration (504),
incorrect weld toe (505),
undercuts (501).
The reference numbers given in brackets are in accordance with EN ISO 6520-1. In the assessment of the
root run of the butt weld test piece welded from both
sides, weld root removed, surface imperfections shall not exceed limits for imper fections within quality
level D.

Welder qualification designation
standard Welding
process
Prod
uct
type
Weld
type
Material
group
Weldi
ng
consu
mable
s
Material
thickness
Pipe out
side
diameter
Welding
position
Weld
details
EN 287
-1
111 P BW 1.1 B 10 mm D 60 PA ss nb
1-Steel SMAW PLATE Butt
Weld
Steel with
steel
classified
based on
yield
strength
Basic
coated
electro
de.
plate
thickness
out side
dia
down
hand
single
side
with no
backing
BS EN ISO 5817 -2007
Welding-fusion welded joints in steel
,nickel,titanium and their alloys( beam
welding excluded).

Quality levels for imperfections
Different quality levels.
Three quality levels are given
Quality level C -stringent
Quality level C- Intermediate
Quality level D- Moderate.




BS EN ISO 4063-2009
WELDING AND ALLIED PROCESSES
NOMENCLATURE OF PROCESSES AND
REFRENCE NUMBERS.
ISO 4063
Process number
1 arc welding 2- resistance
welding
3- gas welding 5 beam
welding
8- cutting
&gouging
52
Laser welding
81 oxy fuel
cutting
83
Plasma
cutting
833 air
plasma
cutting
84
Laser beam
welding
1 arc welding
111- SMAW/MMAW
12- Sub merged welding.(SAW)
121- sub merged arc welding with solid wire
electrode.
13- GMAW
131- MIG welding with solid wire
135-MAG welding with solid wire
136- MAG welding with flux core wire.
14- GTAW.
141- TIG welding with solid filler material.
142- Autogenous welding.
15-PLASMA ARC WELDING
Resistance Welding
2- Resistance welding
21- resistance spot welding.
211- indirect spot welding
212- DIrect Spot Welding.
22 Resistance seam welding
225- foil butt seam welding
Beam welding
5- beam welding
52- laser beam welding
521- solid state laser welding
522-gas laser welding
523- diode laser welding
Gas cutting and gouging
81- oxy fuel/flame /oxygen cutting.
83- plasma cutting.
831- plasma cutting with oxidising gas.
832- plasma cutting with out oxidising gas.
833- air plasma cutting.
84-laser beam cutting
86- flame gouging
Please stay on track
Thank you for you attention
56
THE QUALITY LADDER
Zero
Defect
Prevent
Act in such
a way that
the problem
does not occur

Think
3rd Ladder
Eliminate cause
of the problem
Improve
Take corrective
action, analyse
Establish causes
Temporary
elimination
Solve for
limited period
I am responsible
2nd Ladder

Rationalise
I dont
have time
Accuse
It is others
fault
It is not
true
Ignore
Dont
know
1st ladder
Quality ladder defined
Is a overall picture of steps an Organization goes
through while climbing a Quality Ladder for reaching
peak performances.
The peak performance is like the peak to be climbed.
This peak has 3 plateau. Each plateau has to be
climbed using the Quality ladder. At the top of each
plateau the Organization has some respite before
starting up the next ladder to climb up the next
plateau.
The first ladder is the rightmost ladder. Each step in the
ladder is like an obstacle the organization has to
overcome.
Quality ladder defined
The first obstacle is in the dont know
barrier.
People in the Organization use this term to
give a reason for not involving themselves in a
new concept.


Quality ladder defined(Contd)
If this barrier is overcome the Organization
enters the barrier ignore.
People may learn about a new concept but
then they tend to ignore it.


Quality ladder defined(Contd)
If this barrier is over come then the next
barrier is it is not true barrier.
In other words I know about the new
concept, I dont want to ignore it but I do not
believe it, it is not true, I am not prepared to
accept it.


Quality ladder defined(Contd)
If this barrier is overcome the next barrier is
the scapegoat culture.
Somebody else is to be blamed for all failures
in the Organization and accuse others.


Quality ladder defined(Contd)
If this barrier is overcome and people are planned to
accept that they are at fault, they take shelter under
the most popular excuse
I dont have time. I am too busy.
Rationalization of the situation is the next barrier to
overcome. If this barrier is overcome the Organization
reaches the first plateau and there is some respite
before you start climbing the second ladder.

The second and third ladders are self explanatory.

Any questions