a %, LY a ve cSWIP Welding Quality Centrol Co-ordinator (WIS20) TWI ee | Training & Examination Services Granta Park, Great Abingion ‘Cambridge CB21 GAL, UK Copyright © Tt LtdFev 0 August 2010 GSWIP Welding Quality Control Co-ordinator Contents Section Subject 1 Duties of the QC Co-ordinator 2 Inspection Test Plans 6 Planning 4 Contract Design Review and Subcontractor Control 5 Materials and Consumables: Inspection anc Control 6 Wolding Documontation:- WPSs, WPQRs and Woldor Qualification 7 Calibration of Welding and Inspection Equipment 8 Inspection and Tosting Personnel 9 Quality in Welding 10 Non-destructive Testing Ty Repair Welding 12 Control of Preheat, Intorpass Temperature and PWHT 13 Prossure Testing 14 Non-conformance, Concessions and Engineering Queries 15 Destructive TestingSection 1 Duties of the QC co-ordinator4.2 ey 0 August 2040 Duos of tie QU Co oidiater Copyright© TI LW 2010 Duties of the Quality Control Co-ordinator General QC Co-ordinators are employed to ensure that production follows the QC activities necessary to onsure that the product will meet specified requirements and be fit for application. For employers to have confidence in their work, QC Co-ordinators need to have the ability to understand/nterpret the various QC procedures and also have sound knowledge of fabrication and welding technology. The relevant standards, rules and specifications that a QC Co-ordinator should be familiar with at the start of a new contract are all the documents he will need to refer to during the fabrication sequence in order to make judgements about particutar detalls. The QC Co-ordinator has primarily a supervisoryimanagerial role, which could encompass the management and contrat of an inspection contract. The role would certainly include leading a team of inspectors (welding, non destructive testing, dimensional, painting/coating etc), who will look to the QC Co-ordinator for guidance, especially on technical subjects. The QG Co- ordinator will be expected to give advice, resolve probloms, taka dovisions and generally lead from the front, sometimes in difficult situations. The altributes required by the QC Co-ordinator are varied and the emphasis ‘on certain attributes and skills may differ from project to project. Essentially though tho QC Co-ordinator will require leadership skills, technical skills and experience. Leadership skills ‘Some aspects on the theory of leadership may be taught in the classroom, but leadership is an inherent part of the character and temperament of an individual, Practical application and experience play a major part in the development of leadership skills and the QC Co-ordinator should strive to improve and fino tune these skills at every opportunity. ‘The skills required for the development of leadership include © Willingness and ability to accept instructions or orders {rom senior staff and {o act in the manner prescribed. © Willingness and ability to give orders in a clear and concise manner, whether verbal or written, which will leave the recipient in no doubt as to what action or actions are required, ° Willingness to take responsibility, particularly when things go wrong, perhaps due to the QC Co-ordinator's direction, or lack of it * Capacity to listen (the basis for good communication skills) if and when explanations are necessary, and to provide constructive reasoning and advice.kn WI with St scope with respect t * QA and QC procedures. * Limitations and advantages of the four fnost commonly used NDT methods. » Assessment of NDT reports for compliance to procedure. + Where applicable, advanced NDT (phased array or TOFD could be required). > Basic understanding of metallurgy in welding and fracture surfaces. Wi IL Agf eieloa & Exaravaion Beiveas * Impossible to memorise normative documents for a project and each project may have many. All specifications, codes and workplace instruction must be available at the workplace at the current revision level. You must read and understand all requirements to be able to. direct your team.ypical examples of normativ » BS EN ISO 15614 Standard for welding : procedure approval. * BS EN 970 Requirements NDE of fusion welds and visual inspection * M-601 Norsok requirement for the welding and inspection of piping. + BS EN 14161 Pipeline transportation systems for petroleum and gas industries. Ww. FLAY ing & Bxanivatonsentees weattrtng-cont _* To fail to plan is to plan to fal * Later we will study effective tools to plan a project from the contract review stage through to signing the product off and shipping. * if the planning is not coordinated effectively between all departments production and quality will suffer, WI HL Woivea & trartnalton SarisOrganise your inspection team to ensure that the quality and inspection and test plans can be adhered to may take considerable time and there can be many permutations. To ensure you meet your budget and delivery schedules, assessment of manning levels and the skills and qualification of each operative need to be addressed before the start of a project, TW. Ey Ae Mev E ig Man 2 has an MPI ticket and is on day shift. All pre-welding NDE is MPI, ail post-welding NDE is LPI (clue to the welding consumables used being non-ferro magnetic, Inconel overlay 625) ‘There is a hold point on all finished component NDE by third party inspectors who do not gonorally work night shift. There would now be a requirement of a shift change with financial implications to bring man 1 in at short notice to comply with the hold point. Root causes: poor organisation and use of available resources. TWI FAT Volvo 8 Cramatonertcos tleangncom[ uiremont you are a lead auditor but it is an advantage to have in-depth knowledgo of the process you will often be involved in. It is often the case that we swap sides (contracting certainly) client to sub-contractor or vice versa for example, You may be part of the technical review of a sub-contractor as easily as you could be the sub-contractor being audited, Reviewed in QA,QC and inspection in more detail. ae a Gee Y ee verntitabicom coordinator’s technical ability or management _ style. Strengthening these areas Improves your personal attributes and shows a willingness to embrace the reality that we cannot know it all. With a problem or question act professionally and ompathise with the person asking the question and be interested in finding the solution. Delegation in this area can cause problems if your technique Is to tell your subordinates to find the answer. TW IEG Veivog 8 exeeivaina Baecees vate. som* Quality control (QC): Concerned with the inspection function and concentrates on the product quality. The QA management system provides the detail as to how to apply the QC function. Quality assurance (QA): Concerned with the management system that operates to provide the resource and procedures to produce the product, The QC function is operated under a defined system to ensure product quality Is controlled as part of the assurance process. & My “eaning & Examinatlon Servos their purpose and complimentary in their. implementation. The system cannot be ndeponidort of the product (QA cannot do without QC) and the product would not be produced without the system (QC cannot do without QA). The QC coordinator’s role with respect to QA and QC is to operate under the QA system, to facilitate the management of the QC function, within the management system. This requires awareness of the QC related QA activities (detailed later) and follow thom to bring about the QC activities. TWE YL Waving s exainavonsertcos vv teaiag somBe pro-active to issues, not reactive and confrontational, try to resist apportioning blame. Have strong personal and professional values that are not for sale and ensure you cannot be compromised, Don’t be afraid to object to issues you are not entirely happy about. (ignorance is not an excuse your honour | know but I did not like to ask ) Seek clarification on anything which you do net understand before proceeding. WI LLL Wag & cxaminston soeveee vevutltaag 990) of welding and fabrication to the highest standards. In-depth knowledge of the systems and system requirements. Application of this knowledge in different situations to give maximum confidence to the end user or purchaser. Itis not the coordinator’ role to carry out the QC activities, only to apply tho QMS requirements and ensure that the QC department operates as required within the company. a ‘Training & Examination ServicosAny Questions WI LU Valens SExovationBere08 rnutieainganSection 2 Inspection Test PlansRev August 20:0 Insteetiovand Test Plans Gopyrght © Twi Li 2010 Document definition: An instruction of sorts eg any information where an unauthorised change could cause a problem A mandatory records procedure is required to specify Which records aro kept, By whom. For how long, How they are disposed of.ur “SuERI AM re aa MT) TM. ae Sar TEEN PRAPIOTS| OF Vee 1 TOKE SSN SHOR ROPE Be aN SPN HOIST KISS |S ELPUOZL TH Sen or SuRES OD PORCH | a TE] | 7 TO TIO z Co aay Tune SaM = Tea T 7 TOR PEN SaESGH = | 3 Sai r = SORES = 1 URED Sa DAR ATTRA SRVODTS | = ERGOT PROV Taras, Te |RSS TERRE | SOTA PEO SOUNENC | SOTTRDL RMA SATS TIE OUR TRS TT PTS i SQN FUE WoHESUaE | a t za was | eeaaUT aR = SHES] TERRI CEPR RET TED z Sane mew seve | Seon @ | sows sue eco VO i PROT] O SETS SBE ESTED | NAT PROCS STOO TISAI ORTE TT | E STE RSS SCRE Tae BW eaReOHRTE wieIedSRINTUEA | SRST EMT apa SAB SP SI WOES, SRDS AE SABO | Sa FOROS Te BOuES SUPRN ed ARIE TOTS Due SSA IETS | E FEDER Ty] suas Da EW z saa eES ca THeBAS | SSSR | SE PETISSTTS PE SA SIT Soe + i BUDGEReE SUUAPRIUET ARATMTDIT |S SORE BORE EN SIS RITES RD BapTeMORRT aTeUTS | RCPS a FREE FOEE | BOB el Od WES -SURATR U5905 FUE HEALED ABE |b TaeG |v ‘suaances wor | Aared | Ruedas | —ineisaodsen or ieee BORED "OH Banna ps souasejet oreisrez Beep es jwonsed su) do | ‘Dox voreoy Lee TAL ORES Pus inedEINE sz IML woo-Bunenyay wR TPES ETERS 7 7 FISTS TREO] TRE OSS Ry SET ST SOO Ec 1 RSS BEBE | T ‘Bou a8eeitay W Euan RTO | PRR | EF Lt ST SaTTTEHRTAT | 8 a co) TORTS WO | Svea FUE VOERURE TeszEN A] UOTEIRINNGOD BreweIS | —T T SIE STSSSSA RESID | T gaa 7 TEST SRS SIRES | DEST ye SINGSUET HES Toa ue AIMEETON | —L T Toy OE TO z © aes TREC SE t T TORERDGSENS AG BETES |e Torr ¥ SET WOE TE . Ayesoisuouyp pur medsy Ayensy y95s0n veo! Bue MS TORE] L¥ TBST ETT Eoansvan iueusda, ue wssan ores | i t ‘SRE REST |S SIRES VRS W_ | sipaee eur EOE z I TORE 7 TSE aE T { ha '88uynesp Yooc 90.6 9. T ie USSR |S | TTT Lo TST OTT SET a f Sy | eaedsaoReM Seth o t Tae WF cea SE EGN B SY _| SERS TORT Sait 7 i TEE w TapaTsoT | OCP SON = I SY | SRO ROAR Bath a Tay a Tapa | PEK SON rRev 0 August 10 Inspaction aed Tast Pons Cepyighh © TW LE 2010 Links between the IP and other contract documents ‘The [TPs used on projects do not exist in isolation, they take their piace among all the other documents; some contractual and some net, Figure 1 shows this. The ITP highlights the contractual document requirements that are to be referenced and used throughout all fabrication activities. Figure 1 The {TPs and other contract documents. How do the ITPs link with these other documents? Figure 2 shows the linkages and this is basically the way that contracts work. Figure 2 The links which help to proviele an effective inspection regime.evo Aust 2040, Inepoctien and Fos! Plane Copy e THN Las 2910 Link 1: Responsibility The responsibilitias stated in the contract specification are used (© pass the requirements for compliance with stanclards down to subcontractors, Link 2: Decisions Tho document hicrarchy has operational links to the ITPs which help ensure that the acceptance criteria in the ITPs are closely controlled and compliant with the actual contract requirements not the manufacturer's opinion of what they may be or those that he usually uses, Link 3: Implementation Link 3 is about the implementation of the ITP. The level of inspection activities often depends on tho contract requiroments or any specific client! end user requiremenis and any designated specific testing requirements imposed ciue to service conditions.Inspection and Test Plans TWI Training & Examination Services PAL, Vetoes ® oxarninatna Sarees natu 208 ‘Key working documents for the QC and inspection team and normally have high — status in the QC hierarchy as are a direct instruction detailing the sequence of operations to be carried out in accordance with the specification requirements, A large contract can have several hundred ITPs, using different formats and containing varying degrees of detail. One of the best mechanisms for controlling and organising the various inspection activities. Wr PLGA Yesng * examination sarees voutntra ng com~ Mechanism for organising inspection activities, — also forum for discussion and agreement of technical matters between purchaser, contractor and manufacturer without enforced rigidity of the purchase contract, Excellent documentary record of the activities and commitments of the multiple parties involved, ITPs are an excellent document for production and inspection personnel as they define.all the inspection activities and level of involvement for each inspection discipline and show what to expect. WI ELA Yeivoa 8 Cram'ation Serveos wvutulealntg cont recommendations but any attempt at uniformity, gets very difficult when faced with the variety of ment, processes and practices ina large engineering plant contract. The tendency is for contractors and manufacturers to use differing types of content and format for their ITPs. Some contract specifications will often include a specimen pro-forma ITP to indicate the level of information required DLA Veieog 8 Ceaninatonsuecte00 wunutudsietagcortrove documents (procedures, flow charts, proc maps, otc) prior to use (signod-off papor versions or added to computer network via password protected system). + Updato and re-approve amended documents ~ computer-based systems much easier to maintain. + Identify changes (by date, issue number, different fonts or colours). + Ensure documents available where needed. + Control documents of external origin. + Provont Inadvortont uso of obsoloto documents ~ obsolete but still in use is the most commen non-compliance WH FLA, Weteg ain ston Santees What is it? Does it vary between purchasers/supplier? What does it look like’? TwL PLUG, watiog texonivanion Savieos rv sulateig coreTW TW La ‘raving & Gxarabation Senvtent anttesnbagcom Tataamae = el cee voc [_ Tema [inte aes \ ‘aleing & Examhieton rvoee atitaing.eon documents. The ITPs used do not exist in isolation, they take their place among all the other documents, some contractual and some not. The ITP highlights the contractual document requirements to be referenced and used throughout all the fabrication activities.All these be included (somewhere) JAG) ving § tinea en things should aan wonutaitatntacon documents? TW TIA, weiieg eracknation services How do the ITPs link with these other The following diagram shows the links and how in essence the contract will operate. ‘netting coneThe ITPs are. inked to other contract documents: Whai are these links? Tantanoeneeneteoabiatoend SWI TAU ewe 6 exsist Sorveos wonton cor The responsibilities stated in the contract specification pass the requirements for compliance with standards down to sub-contractors TW LAP Wate sexasenton su ve09 vvmtytratna.comThe document hierarchy has operational links to the ITPs, helping to ensure the acceptance criteria shown in the ITPs are closely controlled and compliant with the actual contract requirements, not the manufacturer's opinion of what they may be, or those that he usually uses. 1 TLE Weg & Beownation sericas wonattnina.con Link 3 is about implementation of the ITP. The level of inspection activities often depends on the contract or any specific client/end user requirements and any designated specific testing requirements imposed due to service conditions. TAG weer nesminst anders niteire will not proceed until all the ve te have witnessed the activily. a W = Witness pone All parties will be informed about the Inspection/test but if they do not attend, the work will continue, $ = Survel Ripotlse cen vl the works ay timo and cary out survelliance of any worldtests, efe In progress. Rs Review ‘The parties will review relevant documentation at a convenient time (either during a visit to the works or after ved the document package by po! WI Lif eslnieg & Examinston Soo Bea eerson fommene [nfo [a ne + |Woityerotnes —|ursear |e nsevan (Rey F | Witirornoas —[eseuar—[w ~ [eer [er 3 [ena eae wR > iecasatan [ee a [onan cao wR > cardarent |e | Wewalnspaten [Beam [Ww fw ecrdahant fore | beanie] ele fe Ta = H=Wae jot Rafer =Manolce (Cetcammer Pls thd py chet paca crgtia808 TWI FLAT tena 8 examination Seveos samurai 2070+ Most ITPs are job specific, there are rio stan designs » Most manufacturers will want to limit the number of inspections as they are disruptive, time consuming and costly! + Too many hold points will dolay the job and cause disruption to the manufacturing process, which helps no-one. TAG ‘exc nian seis sii + Some parts are more important than others. * Look for the documentation requirements. + Technical standards should be referenced, * Key acceptance criteria should be referenced. EEO ng nesses tins neIs the information that a QC Coordinator references when planning and coordinating inspections TW LAG tenog & exarninsion Suricon rvauneteieg com and will review an ITP against the documents presented along with it: + Weld procedure. + Weld history log. + Heat treatment procedure, report and chart. « NDT procedures and reports. * Pressure test procedure and reports. TWL LLU Weaving & exarvna¥on senteos nusatealning comPlanning Fail to plan Is to plan to Fail TWI Training & Examination Services TWL FLU, vento cemmeston Sanlese Dates agreed between client and manufacturer must be maintained. Reputation of the manufacturer in meeting those dates. Profit and loss controls. To plan future contracts. De esisTwL LIAB, Vebsing & txorinsion Saeicee wonianingcory “TWL Critical path analysis (CPA) Programme evaluation and review technique (PERT) ELAS Teng 8 Evarintion Services wreleclieg corn Gantt chartsBar charts, Gantt charts, CPA show us when to start activities and also planned end dates, = not cnough to ensure success of a project, supervision of activities within these timescales will he needed. orlees ymuauttateingeons late rarely changes but producti Factors affecting production plans: » Design office being late with designs and technical drawings Design changes Late delivery of materials and resources. Weather conditions. » Resources available we —— senateand paint Ifa department is late in delivery thon FT Load out production becomes compressed within au: the main production plan, —? Any slack in the production plan gots used. Lup putting cach of the remaining dopartmants under difficulty in trying to meet targets TWH a PLA, Yesing 8 exaeination tericos nesting. com Procurement: Steel delivery late 1 week Cut and prep: Assembly: No work 4 week No work 1 woek Foreed holidays Forced holidays Lay offs Lay offs. Lae RREIE Low morale starr leaving Staff leaving Tw ee ‘Trang & Grerinston Serviene ronatoastning oorProcurement: Stool delivery arrivos 1 week late WL Cut and prep: Increased overtime High levels of supervision Holiday leave cancelled Low morale Staff leaving LEM Wing & Examination €srteae wurututeabungecnn TW TLUG, vemos & examination Sertees Possible impacts of departments not meeting targets When the production programme starts to slip management/supervision needs to react. Managers and supervisors look backwards on the production programme to view work still to come and forward to look ahead and plan. sumuttraing.c0n)_ Possible impacts o imonts not Suporvision will use thoir own planning skills within the main production plan and use different strategios, + Holiday planning for staff Overtime and shift patterns Levels of supervision The workforce (strengths and weaknesses) Manning levels Resources Production meetings wong con Events that cannot be planned for: * Staff sickness Accidents + Power failure takes in assembly Mistalcos in welding + Weather conditions: + Major resource failure TWI HLA Teno 8 Examination Services wratidiinine.certject or different parts of a particular project at production level, adding complexity to the production at shoptloor level. + Differing materials + Differing client requirements + Differing skill levels + Product knowledge + Health and safety concerns LEGG ‘eviog t exarvuanay services vue com “Quality plan Document setting out the specific quality practices, resources and sequence of activities relevant to a particular product, project or contract. ‘rang & examiiatton sevens vevmuntaltig commTW ITF Vebsng 8 ceantasion Services a |pweemrasacan lassen lice een lea |) emmy es eg at 1, hacatasaraniy cleans — leat (ime (os ee eam wo emaectng com TW VLG Votsng & exzmtnation Sorces neering comSection 4 Contract Design Review and Subcontractor Control44 42 43 ov 0 Auguct 2010 (Contract Design Reviews anal Subcentator Conk} Copyright © TW Ld 2010 Contract Design Review and Subcontractor Control The client will specify prior to contract award ail the relevant codes and standards that must be adhered to during fabrication. Before contract placement it is essential that the following conditions have been met. Manufacturing specifications and standards © Does the contractor have a copy of the client's code or specifications and are the contractor's personnel familiar with those specifications? ¢ Does the contractor have the latest copy of tho code? ® Does the contractor have copies of all tho current relevant material specifications (eg BS EN ISO or ASTM ete)? * Does the contactor have personnel who are knowledgeable and experienced with the material standards, codes and specifications? e Is there a writlen procedure in place to oxplain the specification requirements and changes or special requiroments to appropriate personnel? Reading/interpreting shopftoor drawings © Does the contractor have personnel capable of supervising, evaluating and coordinating shoptloor drawings for proparation and raviow? © Do the shopfloor drawings for the current work clearly identify the NDT requirements for the various welded connections? * Do the materials and processes specified on the shopfloer drawings for the current scope of work agree with the relevant contract documents material requirements for work being Issued to the shoptloor? ® Do the shopfioor drawings for'the current work scope olearly identify the materials to be used in fabrication? Drawing control © Does the contractor have a written procedure for tracking the fabrication drawings and also how are modified! drawings controlled and issued to the shopfloor? ® Does the tracking procedure trace each phasa from drawing preparation, showing receipt, submittal for approval, approval, re-submittals and date sent to the shopfioor for fabrication? This is controlled by the issue of a drawing register * Do the shopfloor plans for ourrent work correspond to the latost revision?specified by EN standard - visual, MT or PT and RT or ‘The test weld may need to be destructively tested - for certain materials and/or welding processes specified by the EN Standard or the Glient Specification + Awelder’s qualitication certificate is prepared showing conditions used for the fest weld and the range of qualification allowed by the EN Standard for production welding. + ‘The qualification certificate is usually endorsed by a third party inspector as a fruo record of the tost. ae =m LLU eling 8 Enantaton Savina swrdnivehingcom rango of qualification allowed for production welding Is based on the limits that the EN Standard specifies for the welder qualification essential variables. Awelder's qualification certificate automatically expires if the welder has not used the walding process for 6 months or longer. A certificate may be withdrawn by the employer if there is reason to doubt the ability of the welder, for example: + High repair rate + Not working in accordance with a qualified WPS TWH PERF Vesloing 8 Cuesintion Srvces rn seaaing comQuestion: What is a welder qualification essential variable? What makes the variable essential? Answer: A variable that if changed beyond the limits specified by the EN standard may require more skill than has been demonstrated by the test weld. TW! YL Veiviog 2 exemineton Serviess emantabiageont « Welding process: « Material type « Electrode type * Material thickness « Pipe diameter * Welding position * Weld backing (an unbacked weld requires more skill). Tw TL, V2Wi0g 2 examination Services sworanottsbengeontqualification, eg BS EN 287. Once the procedure is approved the next stage is to approve the welders to the approved procedure using a test known as a welders qualification test (WQIT). Objectives of a wolding qualification test: * Give confidence that the welder meets the quality requirements of the approved procedure (WPS). + ‘The test weld should be carried out using the same matorial and conditions as for the production welds, TW LAAG Weting & examination Seriees wasretraning com 18 Welder’s name and identification number. Date of test and expiry date of certifleate + Standardicode eg BS EN 207 + Test plece details Welding process Welding parameters, amps, volts Consumablos, flux typo and filler classification details + Sketch of r + Welding posit Joint configuration details Material type qualified, pipo dlamoter, otc + Test results, romarks + Test location and witnessed by Extent (range) of approval TL eves & examinxion Serica won ttcryng.comUnder normal circumstances only one test weld per welder is permitted If the welder fails the test weld and the failure is not the fault of the welder eg faulty welding equipment then a re-tost would be permitted. ‘The fest weld Is tested in accordance with the applicable code. itis not normal to carry out tests to ascortain the mechanical properties of welds eg tensile, Charpy and hardness tests. WI TLRS trnoa texan seetoes xara com TWI — ~ cnet “Tlning & Examinnton Services seated corwiring comSection 7 Calibration of Welding and Inspection Equipmentsesha TA 12 Fey @ August 2010 Calbiavon ot vlog znd wspecion FqupIE Gopwighi 9 TW! Lid 2010 Calibration of Welding and Inspection Equipment Introduction BS 7570 - Code of practice for validation of arc welding equipment ~ a standard that gives guidance to: © Manufacturors about the accuracy required from ouput meters fitted to welding equipment to show welding current, voltage, etc, © End users who need fo ensure that the output meters provide accurate reaclings, ‘The standard refers to two grades of equipment - standard and precision grades, ¢ Standard grade equipment is suitable for manual and semiautomatic welding processes. © Precision grade equipment is intended for mechanised or automatic welding because there is usually a need for greater precision for all welding variables 2s well as the prospect of the equipment being used for higher duty cycle welding, Terminology BS 7570 defines the terms it uses, such as: Calibration Operations for the purpose of determining the magnitude of errors of a measuring instrument, etc, Validation Operations for the purpose of demonstrating that an item of welding equipment or a welding system conforms to tha operating specification for that equipment or system: Accuracy Closeness of an observed quantity to the defined, or true, value. Thus, when considering welding equipment, those with ouput meters for welding parameters (current, voltago, travel speed, etc.) can be calibrated by checking the meter reading with a more accurate measuring device and adjusting the readings appropriately. Equipment without output meters (some power sources for MMA, MIG/MAG) cannot be calibrated but can be validated, that is make checks to see that the controls are functioning properly.73 74 75 Fey 0 Aug nt 2010 (Catbaton a! Wolding and inepesien Equpire Gayl 9 TW Ld 2 Calibration frequency BS 7570 recommends ro-calibration/validation: (parametor monitoring an @ monthly basis would be preferred to ensure no great amount of welding could be carried out using out of calibration or invalidated equipment leading fo no confidence in the weids made) © Yearly intervals (following an initial consistency test at 3. monthly intervals) for standard grade equipment, © Six monthly intervals for precision grade equipment. However, the standard also recommends that re-calibrationWalidation may be necessary more froquantly. Factors that need fo be considered are; Equipment manufacturer's recommendations. User's requirements. If the equipment has been repaired re-calibration should always be cattied out. © If there is reason to believe the performance of the equipment has deteriorated, Instruments for calibration Instruments used for calibration should: * Bo calibrated by a recognised calibrator using standards traceable to a national standard, ® Be at least twice and preferably five times more accurate than the accuracy required for the grade of equipment. © For precision grade equipment instruments with much greater precision must bo used for checking output motors. Calibration methods The standard gives details about the characteristics of power source typos, how many readings should be taken for each parameter and guidance on precautions that may be necessary. For the main welding parameters, recommendations from the standard are: Current Details are given about instrumentation requirements and how to measure pulsed current. There ate no requirements specified or recommendations made about where in the circuit current measurements should be made. The implication is that current can be measured at any position in the circuit — the value should be the same.Fev 0 Aust 2010 Cabeton of Woiding anil Inspection Equpment apy! 91h Id 2010, Voltage: The standard emphasises that for processes where vollage is pre-sel (on constant vollage power sources) the connection points used for the voltmeter incorporated into the power source may differ from the arc Voltage, which is the important parameter. ‘To obtain an accurate measure of are voltage the voltmeter should be positioned as near as practical to the arc. The figure shows the power source voltage meter connected across paints 1 and 7. Power Soares C Figure 1 Example of a welding circui (for MIGMAG). However, because there will be some voltage drops in sections 1-2, 3-4 and 6-7 due fo connection points introducing extra resistance into the circuit, the voltage meter reading on the power source will tend to give a higher reading than the true arc voltage. Even if the power source voltmeter is connecled across points 3 and 7 (which it may be) the meter reading would not take account of any significant voltage drops in the return cable - sectlon 6-7.Rav o August 2010 Cotbeton of Welding and Irepeetion Eaupirent ‘Copyright ©.1Wi Ls 2010 The magnitude of any voltage drops in the welding circuit will depend on cablo diameter, longth and temporaturo and tho standard emphasises the following It is desirable to measure the tue arc voltage between points 4-5 but for some welding processes it Is not practical to measure are voltage 60 close to the are. ° For MMA it is possible to take a voltage reading relatively close to the arc by connecting one terminal of the voltmeter through the cable sheath as close as ~2m from the arc and connect the other terminal ta the workpioce (or to earth), * For MIGIMAG the nearest practical connection points have to be 3-5 but a change from an air- to a water-cooled torch or vice versa may have a significant effect on the measured voltage. ® Voltage drops between points 5-8 will be insignificant if there is a good connection of the return cable at point 6 The standard gives guidance about mi ensuring that the: ising any drop in line voltage by ° Current return cable is as short as practical and is heavy, low resistance, cable, © Current return connector is suitably rated and is firmly atlached so does not overheat due to high resistance. ‘Tho standard gives data for line voltage drops (DC voltage) according to current, cable cross-section and cable length (for both copper and aluminium cables) Wire fed spood For constant voltage (self-adjusting arc) processes such as MIG/MAG the standard recognises that calibration of the wire feeder is generally not needed because it is linked to current. If calibration is required, it is recommended that the time be measured (in seconds) for ~1m of wire to be delivered (using a stopwatch or an electronic timor). The length of wire should then be measured (with a steel rule) to an accuracy of imm and the foed speed calculated. Travel speed Welding manipulators, such as rotators and robotic manipulators, as well as the more conventional linear travel carriages, influence heat input and other properties of a weld and should be checked at intervals. Most of the standard devices can be checked using a stopwatch and measuring rule but mere sophisticated equipment, such as a tacho- generator, may be appropriate,Fev 0 Aut 7010 Cotbietono! Waiag end repeston EqUEEAL ws Soxgsign TH! Ld 7010 What is instrument calibration? ILis one of the main processes to maintain instrumenYequipment acouracy. ‘This process configures an instument to provide an accurate result for within an acceptable range, highlighting any factors that may cause inaccurate measurements. Procedures may vary from product to procluct; the calibration process involves the use of instrument with test samples with known values called calibrators. The results are used to establish a range of accuracy between tho measurement technique used by the instrument and the known vatues Calibrations are performed using a range of calibrators to establish the acouracy at specific points within the instrument's operating range, While it may be an advantage lo use a large number of calibrators to establish the calibration relationship or curve, the cost associated with preparing and testing a large number of calibrators may be prohibitive and time consuming. How often should an instrument be calibrated? ‘When it needs it, Calibration interval Base the calibration interval on the instrument's stability, purpose, usage, environment, past history of equivalent instruments and manufacturer’s recommendations, Use the table below as a guideline: Table 1 Suggested calibration frequenoios How offen used | Calibration inferval, months Dail 3 = Every second day | 6 Once perweek [12 Once permonth [24 ‘One per year 36 Calibration may be required when any of the following occur: Observations appear questionable. Spocified time has elapsed. Specified time or usage (based on operating hours) has elapsed. Anew instrument is introduced. Results seem inconsistent. An instrument has been damaged or used beyond its working range which potentially may have put it out of calibration.n theory any MMA operati monitoring of: + Welding curront « Are voltage * ROL + Preheat/interpass temperature + Electrode treatment and storage In practice (depending on the application) only the welding current could require monitoring with a tongue test ammeter, DY vasa seonhatosuscn iain theory this might require monitoi activities previously mentioned. Equipment required: Ammeter Voltmeter Stop watch or » aPAMS Tape measure Thermometer Calculator All the above plus any meters fitted to the power source or electrode ovens would require calibration. 1 Saran ZU Waineg & Cromlnation Services vattlnin.corn+ Amperage * Voltage * Travel speed * Gas flow rate + Repeatability of the controls In practice a data logger would be preferred to monitor all the parameters; also a PAMS would be required to check the repeatability of the contro! knobs. WI ‘aling& Exertanion Saveos if meters are fitted. * The inspector should check for calibration stickers, dates, etc. * Awelding power source without meters can only be validated that the control knobs provide repeatability. * The main role is to carry out in process monitoring to ensure that the welding requirements are met during produ n TWI PLA ‘tne 8 rseveaton sees vemetateinngcamAlways check the certification matches the sticker and that serial numbers are correct for the equipment attached. | PO NOT USE TW PLA Ving & excavation Serlees swoatwitaiiageon WL TEA W009 & exarvaton seers evitlallna somSection 8 Inspection and Testing Personnel8.2 8.3 Fey 0 Auguet 2010 Irspaion art Testy Pease (Copyilght © THVT Ltd 2010 Inspection and Testing Personnel Responsibilities Inspection and testing personnel should be approved for the level of responsibility they have been authorised to work to: Specifications, contracts and standards will define the minimum level of the required qualification, It is sometimes permissible for a level one person to work under the supervision of a level two, (only if the laval two is the required level, some contracts would require a level three), however the level two must accept all responsibilily for the level one's work and sign it off to say that as the responsible level two (or level three dependent on contract requirements) he is completely satisfied with the techniques used and the interpretation of the results and will demonstrate this by signing off the report. Qualifications and registers ‘An up to date register with all the operators names and qualifications should be maintained and approved and may include the main contractor and any ‘subcontractors The initial approval should be carried out by reviewing the register and the original copies (or verified copies") of the applicable operator's ceilificaltes, verified copies are usually used and become part of the final documentation’ certification. ‘Verified copies are established by the client or third parly inspectorate reviewing the original and stamping the photocopy as a true and verified copy of the original Reporting methods An established system for reporting shall be agreed prior to any production activities. There are several systems available as standalone packages which can be bought off the shelf. Electronic databases are becoming more popular, such systems when input with all the required data, ie Welder's register site and subcontractor. Inspector's quialification register site and subcontractor. Welding procedure register site and subcontractor. NDT operators-registor site and subcontractor. Drawings. Materials/associated test certificates. PWHT. Whatever is required as per the project traceability requirements.Rev O Agus 2040 Inspecton and Tasing Porconret Copyright © TW Lid 2010 ‘The use of databases is very useful in highlighting problem areas, eg if welder A was recorded as welding pipe spool weld number 1 using WPS number abet and this did not match the system data welder A may not have been qualified to that procedure or WPS abct was not suitable for that material etc, Systems are only as good as the data input operator and associated information rubbish in rubbish outInspection and Test Personnel ‘TWI Training & Examination Services TW TLE, vain & bxamiaton Sesioas ttaing.com ispecti ve houl re ~ for the level of responsibility they have been authorise to work to. Specifications, contracts and standards will define the minimum level of the required qualification. It is sometimes permissible for a level one person to work under the supervision of a level two, (only if the level two is the required level, some contracts would require a level three), but the level two must accent all responsibility for the level one’s work and sign it off to say that as the responsible level two (or three depencient on contract requirements) he is completely satisfied with the techniques used and the interpretation of the results, he will demonstrate this by signing off the report. HEAP “aviv 8 exanivaton secon titeinta.conthis may Include the main contractor and any sub- contractors he uses. Initial approval should be carried out by reviewing the register and the original copies (or verified copies) of the applicable operators certificates, verified copies are usually used and become part of the final documentation/certification. *Verified copies are established by the elient or third party inspectorate reviewing the original and stamping the photocopy as a true and verified copy of the original So eaciveammau Established system for repor agreed prior to any production activities - taking place. Are several systems available as standalone packages which can be bought off the shelf. Use of electronic databases is becoming more popular.highlighting problem areas eg if welder A ‘was recorded as welding pipe spool weld number 1 using WPS number abe and this did not match the system data as for example welder A may not have been qualified to that procedure or WPS abe1 was not suitable for that material, etc. However it is worth noting that the systems are only as good as the data input operator and associated information. Rubbish in, rubbish out. ce nities if 7 Ae runatwivanng com1 eve August 20:0 ‘ay in Wen Copyright© 1WI Lid 2010, Quality in Welding QC ina fabrication and welding situation is achieved by working to company procedures and codes of construction or standards. The latter may be international, national, company's own or specific to the particular client or contract. Company procedures are usually covered in quality manuals the scope of which may vary widely depending on the size of company, range of work, working practices and many other factors, Quality system standards Quality system standards specify the minimum requirements of quality systems for application to specific products or services, Standards are normally used for the following purposes: © Guidance to an organisation introducing QA, * The basis for evaluating an organisation's quality system {an assessment). * To specify the QA requirements when invoked in a contract. The standard common in the UK is [SO 9000.Rev 0 August 2010, ‘Gully in Welding Copyright 2 1Wi Ld 2010 9.2 What areas of a business need to be covered by ISO 20007 The standard requires the following elements to have set procedures: ¢ Management responsibility ‘Who is responsible for what? * Quality system How does the system operate? * Contract review: Allows personnel to see what the requirement is and who has been asked to do what. © Design review and control Ensure smooth passage from drawing board to end product, ° Documentation controls Make sure the correct documents are available. © Purchasing Make sure we have the right products and services. ® Purchaser supplied product i Make sure those items are OK. * Product identification and traceability What and where is it? ° Process control Lets everyone know clearly how to make the product. ° Inspection and test Lets everyone know how to inspect and test it © Inspection, measuring and test equipmont Makes suire the equipment used is correct © Inspection and test status Where Is the product in the inspection cycle? © Control of non-conforming product Ensures incorrect product is not used, ° Corrective action Find the root cause of the problem and solve it » Handling, storage, packing and delivery ‘ Don't damage it now it's made. © Quality records Documented evidence that the company meets specific requirements. ® Intornal quality audits Ave quality activities performing as planned? ® Training It cannot be manufactured effectively if people are not adequately trained and qualified. © Servicing If carried out by the company, effective procedures are required. ° Statistical techniques Use them to build-in product quality93 9.34 Fey 0 Auauct 2010 ‘aly in Weasng Company manuals QA manual QA is defined in ISO 9000 as; ‘part of qualily managoment focused on providing conficionce that quality requirements will be fulfilled’. Essentially what the QA manual sets out is how the company is organised, lays down the responsibilities anc authority of the various departments, how those departments interlink and usually covers all aspects of the company quality structure, not just those aspects of manufacture. QC manuat QC is defined in ISO 9000 as; ‘part of quality management focused on {ulfling quality requiements’ The QC manual will be the manual most often referred to by the senior wolding inspector (SWI) as it details how different departments and operations are organised and controlled. Typical examples would be: Production and control of drawings, how materials and consumables are purchased, how welding procedures are produced, ete. Essentially all operations to be carried out within the organisation will have control procedures laid down. In particular it will lay down how inspection arabe whether visual, dimensional or NDT will be performed. Inspection being defined as ‘the activity of measuring, examining and testing characteristics of a product or service and comparing these to a specified requirement’, such requirements are laid down in codes of practice and standards. QA refers to a programme for the systematic monitoring and evaluation of the vatious aspects of a project, service or facility to ensure that standards of quality are being met. It Is important to realise that quality is detormined by the programme sponsor. QA cannot absolutely guarantee the production of quality products, unfortunately, but makes this more likely. Two key principles characterise QA: fit for purpose (the product should be suilable for the intended purpose) and right first time (mistakes should be eliminated), QA includes regulation of the quality of raw materials, assomblics, products and components; services related to production and management, production and inspection processes.Rev 0 August 2010 Cali in woe Gopyighto TH Lt 2010 It is important to realise that quality is determined by the intended usors, clients or customers, even goods with low prices can be considered quality items if they meet a market need. QA is more than just testing the quality of aspects of a product, service or facility, it analyses the quality to make sure it conforms to specific requiromants and complies with established plans. QA versus QC QC emphasises testing products to uncover defects and reporting to management who make tho dacision to allow or deny the release, whereas QA allempts to improve and stabilise production and associated processes, to avoid ar at least minimise issues that led to the defects in the first place. QA does not eliminate the need for QC, some product parameters are so critical that testing is still essential. QC activities are treated as one of the overall QA processes. QC reviews quality factors involved in production and this approach places emphasis the following aspects: * Elements such as controls, job management, defined and well managed procasses, performance and integrity criteria and identification of records. * Competence, such as knowledge, skills, experience, and qualifications. * oft elements, such as personnel integrity, confidence, organisational culture, motivation, team spirit and quality relationships. QG co-ordinator References the company’s quality manuel, quality system and relevant internationally recognised standards thereby ensuring that the company’s QC procedures/inspection and test plans reflect these requirements during subsequent inspection and testing of fabricated components. The QC co-ordinator is responsible for the issue and control of all QC procedures (QCPs) and inspection test plans (|TPs) and their implementation during fabrication. He controls via the QCP and ITP the timely inspection activities of all QC inspectors who report direcily to him on all quality matters,Quality programme documentation Fey 0 Auguet 2010 ‘Guaityin Weitag Copyiiaht © TH Ltd 2050 7” [eaneany Jonsectives, loncnausntion, & “SOUTLINE OF UALITYE SYSTEMS. FERFORuiNS Wore] rAILED INSTRUCTIONS FOR Acrivirtes9.3.2 Rey 0 Avast 2010 Guojay im Weisng Codes and standards itis nol necessary for the inspector to cary a wide range of codes and standards in the performance of his/her duties. Normally the specification or more precisely the contact specification is the only document required but this may reference supporling codes and sandards and the inspector should know where fo access these normative documents, The following is a list of definitions relating to codes and standards which the inspector may come across whilst carrying oul inspection duties, Defi Normative document Document that provides rules and guidelines or characteristics for activities or their results. jons The term normative document is a generic term covering documents such as standards, technical specifications, codes of practice and regulations.” Standard Document established by consensus and approved by a recognised body. ‘A standard provides for common and repeated use guidelines, rules and characteristics for activities or their results, aimed at the achievement of the optimum degree of order in a given context.* Harmonised standards Standards on the same subject approved by different standardising bodies, that establish interchangeabiliy of products, processes and services or mutual understanding of test results or information provided according to these standards* Code of practice Document that recommends practices or procedures for the design, manufacture, installation, maintenance, utilisation of equipment, structures or products, A code of practice may be a standard, part of a standard or independent of a standard* Regulation Document providing binding legislative rules that is adopted by an authority.* Authority Body responsible for standards and regulations, legal or administrative entity that has specific tasks and composition) that has ‘egal powors and rights.* Regulatory authority Authority responsible for preparing or adopting regulations*Rey 0 August 2010 Galan Wrong oq © TaN 14 2010 Enforcement authority Authorily responsible for enforcing regulations* Specification Document stating requirements. Meaning full data and its supporting medium stating needs or expectations that is stated, generally implied or obligatory. Procedure Document that describes how an activity is to be performed and by whom. Usually a written description of all essential parameters and precautions to be ohserved when applying a techniquie to a specific application following an established standard, code or specification: © BS 4778; Part 1: ISO 8402: Qualily vocabulary international terms. BS 4778; Part 2: Glossary of terms used in QA, Note A procedure is not a detailed work instruction such as a welding procedure but a statement of who does what and how, it describes the corporate plan for achieving quality. There may be times an organisation needs to operate in a different way from the corporate system, for example, for a unique project or to satisfy a specific customer's requirements. In these circumstances an appropriate quality system can be documented in the form of a project or contract specific quality plan. Project procedures may well include: » Existing procedures appropriate to the contract. © Existing procedures amended for the contract. ° New procedures to meet specific requirements or the contract. Some contracts may call for a combination of all three. Instruction Writton description of the precise steps to be followed based on an established procedure, standard, code or specification. ie Dooument specifying which procedures and associated resources shall be applied by whom and when to a specific project, product, process or contract* 4180 IEC Guide 2 — Standardisation and related activities ~ general vocabulary. “EN ISO 9000 — 2000 — Quality management systems — fundamentals and vocabulary, The quality plan is the corporate quality system suitably modified to reflect specific requirements. It may comprise a project quality manual incorporatingRev 0 August 2010 ‘Guay in wwetang _Seppight © TW Lid 2010 appropriate sections from the corporate quality manual as they apply and is generally a detailed document Project procedures may include: Existing procedures appropriate to the contract. » Existing procedures amended for the contract. © New procedures to meet specific requirements for the contract. Some contracts may well call for a combination of all three. Quality records Any document that indicates the inspection performed, quantities inspected, results obtained, positive Identification of the material inspected to drawing or part number, the signature or stamp of the person carrying out the inspection and date of inspection, Quality records might also indicate the qualification of personnel, calibration of equipment or other records not directly related to the product. Summary Application of the requirements of the quality manuals, standards and codes of practice ensure that a structure or component will have an acceptable level of qualily and be fit for the intended purpose. Applying the requirements of @ standard, code of practice or specification can be a problem for the inexperienced inspector. Confidence in applying the requirements of one or all of these documents to @ specific application only comes with use. if in doubt the inspector must always refer to @ higher authority to avoid confusion and potential problems.ovo August 2010 uel Weidiig copyightio Tan bud 2an0 QA is therefore the documented plans and systems by which confidence in a product is provided and comprises all the paperwork systems used to plan, control and record activities - the documentation. QC Is those activities which monitor the quality of the product, the operational {echniques of checking matorials and dimensions, inspection before, during and after welding, NDT, hydraulic or leak testing. Activities which take place after the event and which check that a specified activity has been carried out correctly. QA was inttoduced to ensure that the activity is right first time since prevention is better than cure, achieved by planning and anticipating problems, To satisfy this requirement a documented quality system is needed which sets out in a formal framework the basis of control for the critical activities This framework in goneral comprisos four tits of documentation: The highest being the company qualily manual, cascading down through quality systems, quality plans and detailed manufacturing and_ inspection instructions, Quality requirement for welding Within the international community welding has been confirmed as a special process and requires control by specialist management and uses specialist personnel The welding co-ordination standard (ISO 14734) and the welding quallly systems (ISO 3834) have been prepared in support of this ruling. It Is porcelved that those standards will be referenced in other application standards and used as set criteria for the qualification of fabricators. ‘The role of a welding QC co-ordinator BS EN ISO 14731 defines tasks and responsibilities for the responsible welding QC co-ordinator: Must be involved at all stages of BS EN [SO 3834 requirements. Needs to be a named individual, although tasks can be delegated in the quality plan, ‘Suggested ways of demonstrating knowledge requirements (clause 6.2): Comprehensive: International Welding Engineer (IWE) Specific: (WT) Basic: (IWS) eeee Ne ‘The welding co-ordinator is required to demonsirate a level of knowledge appropriate for the work being carried out.Rev 0 Augist 2019 sity in Weis OTWiLd2010 Working to the requirements of BS EN ISO 3834 (Quality requirements for fusion wolding of metallic matertals) BS EN SO 3834, covers 3 levels of quality requirements, Part 2 Comprehensive. Part 3 Standard. Part 4 Elementary. The standard is compatible with [SO 8001 (QA standard) but concentrates on walding as a special process, Level 2, 3 or 4 dependent on: Safoty criticality, Complexity of manufacture. Range of products and materials used. Likelihood of metallurgical problems. Extent of likely manufacturing problems. oRens BS EN 3834 Part 2 Gomprehensive needs a procedure for review of requirements and technical review. Technical requirements 1 Parent materials, specifications and welded joint properties. 2 Quality and acceptance requirements for welds. 3 Location, accessibility and sequence of welds, including accessibility for inspection and NOT. Specification of walding procedures. NOT procedures. Qualification of welding procedures. Qualification of personnel, Selection, identification and/or traceability eg materials and welds, Inspection and testing. 410 PWHT 14 Other welding requirements eg batch testing of consumables, ferrite content of weld metal, ageing. 12 Hydrogen content, permanent backing, use of peening, surface finish, and weld profile. 13 Dimensions and details of joint preparation and competed weld. 14 Handling of consumables, 15 Sub-contracting: requires all sub-contracting activities relating to welding to be controlled. 16 Welding personnel - welders, inspectors and welding co-ordinator must all be appropriately qualified, 17 Responsible welding co-ordinator must be named and the responsibilities shown in a written procedure. 18 Equipment must be listed, suitable for the work, weil maintained and calibrated, 19 Production planning: Specification of sequence of assembly, order and timing of processes and Inspection and testing. eoxoan9.4 9.4.4 Row @ August 2010 Guay im Websng Copyright © TWILid 2010, 20 Qualification: Procedures, welders inspection. (Are writlen and specific WPS available? Do welders have a written work instruction?) 21 Handling of materials and consumables: Bonded stores, written procedure for handling. 22 PWHT: Inspection and testing, before welding aro welding certificates signed off? Is fit up specified? During welding are parameters checked? After welding, final inspection, PWHT. Procedures also roquired for © Non-conformance and corrective actions. » Identification and traceability. © Quality records. Auditing Ensuring success by audit How do you ensure that the system is working? The well adopted and recommended method is auditing, Auditing originates from accountancy practice and involves an independent accountant checking the accounts of a company to see if the accounts are fair and accurate. A similar checking process is widely practised in manufacturing and construction industries and inspection personnel will be involved in carrying out this operation. Quality manuals, procedures, work instructions, etc provide the objective evidence that the systems of contral have been adequately planned, The records and documentation generated by carrying out work in accordance with these systems provide evidence that the systems are being followed but all systoms of control, no matter how offoctive, tond to deteriorate because of human error or changes in the nature of the business. To ensure the systems are being followed, are effective and if changes are needed it Is necessaty to monitor the systems, achieved by auditing the system and reviewing the resulls and implementing any changes. What is an audit? Quality audits examine a quality system for adequacy and correct implementation and are defined in BS 4778. Pt1 as: Systematic and independent examinations to determine whether quality activiies and related results comply with planned arrangements and whether these arrangements are implemented effectively, and aro sullablo to achieve objectives. Auditing provides objective evidence that the system is working in accordance with the procedures, When an audit is complete, the results are9.5 Rey 0 Augist 2010 ‘Cuan ekg Copyright © TALL 2010 analysed by management who must ensure that the quality policy is salisfied and modify tho quality system if necessary. There are two depths of audit: ¢ Systems audit: Simply examines the system to confirm that it follows the quality manual and that procedures are in place. — Full audit of a company usually carried out by a third party such as a certifying authority, checking the company for the award of a QA accreditation system such as {SO 9000 or ASME stamp, © Compliance audit: in-depth examining compliance with procedures. Major audit by a potential customer prior to placement of a large contract usually carried out to demonstrate the company has all the necessary facilities, piant, machinery, personnel and quality systems. iin place to enable them to successfully complete the contract. There is also an ongoing audit © Parl audits carried’ out as an ongoing demonstration that the quality system is working properly. An example of the latter would be a senior inspector responsible for sighing- off the data book or release certificate for a product. After checking that all the necessary documents are in the package and have been correctly completed and approved where necessary, the SWI would look at a part of the job - a beam, a piece of pipework, etc and cross-check against the drawings, mill certificates, inspection reports, ete that all comply with the job requirements. Auditing of documentation Regarded as being a compliance audit, it Is where documentation is ‘examined in depth. Items to check include © Isall the documentation available? @ Is the documentation schedule in accordance with contract or specification requirements? * Does the documentation comply with contract or specification requirements, eg are weld procedure and welders correctly qualified? Is it the correct material composition? Is the documentation legible? Have all interested parties, eg inspection department, independent third party inspectors, client inspectors, signed off where required? * Has provision been made for storage, including the ability to retrieve documents and the storage concitions to prevent deterioration? Documentation audits should be carried out by the manufaclurer/supplier as a matter of course.9.6 Fey 0 Ausust 2010 ‘Guay a Ween Customers froquontly require access to carry out thelr own audits, remember no job is finished until the paperwork is complete. Failure of a documentation audit carried out by a cliont often results in a dolay in payment even though the component may have been delivered to the client ang often carries a consequential financial penalty. Questions that need to be addressed includo: © Which quality records are to be maintained; eg recoiving inspection reports, NOT results, test certificates, final inspection reports, non- conformance reports (including any feedback or corrective action generated)? «Where are the records filed and by whom? «How long are the quality records retained? * Ate the quality records available to the customer for analysis and review? * Ate records easily retrievable? ® Is a suitable environment available to minimise deterioration or damage to stored records? Typical quality record contents ‘The quality record package for a welded product will be defined specifically for a contract and may include: Records of stage inspections in the form of check sheets or quality plans. Non-conformity reports and caneassion records. Where appropriate as-built drawings. Welding procedures. Welder approvals. Welding consumable records. Wald history records. NDT reports. NDT operator qualifications, Heat treatment records. Hydraulic and/or other testing records, Where appropriate material test ceriificates. Final acceptance certificates. Gapyilght © TL Ltd 2010Fev 0 Aunt 2010 ‘Quoity in oi Copyright © TW LAs 2010, Class exercise You are required to visit a site where your inspection team has been working. The fabrication is completed in accordance with a nominated specification and is awaiting your final inspectionapproval and sign off. Your role is to select a random number of welded joints and investigate the complete start to finish of these welds including material certification, welder ID, etc through to final NDT. Prior to signing the certificate of conformance: 1 What questions do you ask? 2. What measurements would you take’? 3° What documents would you review? Prior to the site visit it is vital to spend time planning the visit so that a logical approach be made and important details are not overlooked. Knowledge of the standard used and an idea of the service conditions would be useful in assessing the fitness-for-purpose of the product, A list of all personnel in the inspection team(s) and contact details of team leader(a) will ensure that relevant personnel are available to answer questions as required. Questions may include any difficulties encountered with the job, particular attention being given to those concerning the contractor. Further information regarding repair rates, safely standards on-site and the general motale and standard of work amongst the inspection team(s) throughout production. Any unusual incidents may need investigating. The availability of qualily plans will help greally in planning the sign off. The review/aucit of all relevant documentation is a major requirement prior to signing any Certificate of Conformance or compliance. In some major slandards/codes the list of documents to be included within the fabrication file are listed. In the absence of such the following is @ basic quide to the documents for review/audit: * Reviow of the quality plan and inspection check list to ensure all stages are completed and signed off. © Material certificates, mill test reports, and material traceability records are documented and accepted. This may include welding consumables. 2 Process control procedures should be reviewed for adequacy, accuracy and approval. These should include approved procedures for cutting, welding, repair, NDT, heat treatment, coating, etc. * Review of qualifications should include welder approvals, NOT operator or technician approvals, All inspection approvals should be in date at time of fabrication and as identified and deseribed within the contract documents.Royo August 2070 vali Wing Copyight © TW Ue 2070 9.6.2 Inspection feports should be reviewed and include visual inspection, NDT, dimensional control, painting/coating, etc. If the product is pressure containment ie pressure vessel or high pressure pipeline, otc. than hydrostatic testing procedures and a test feportiacceptance reports should be reviewed along with test gauge calibration certificates and any associated documentation, As-built drawings showing materials anc weld mapsfhistory should be reviewed for completeness. Transit and tie down procedures should have been approved by the rolovant engineer prior to the final acceptance of the product and Issue of any signed certificate of conformance. Check list Reference: to the specification, As-built weld maps, weld traceability log. Weld numbers. Welder Identification Material classification and certification, Welding procedure numbers (WPSs, PQRs) and documentation Material traceability and material certificates. Consumable control procedures and certificates. Welders’ register and all approval certificates. Weld visual inspection procedures and reports. List of NDT operators and approval certificates, NDT procedures. NDT reports. RT report numbers. UT report numbers. MPI report numbers, Dyefpen report numbers, Dimensional control procedures and reports. PWHT procedures and reports and calibration certificates. Hydrotest procedures and reports and calibration cerlificates. Painting procedures and conformance reports, Non-conformance reports, Load out procedure, Engineering queries. As-built drawings.Quality in Welding tw FL, ‘200 keaieaton senicas ‘wwrattrabingesn What is quality? Quality is the ability of a product/service to satisfy explicit and implicit requirements WL YLAT V0I0m &ecennaten Sericos ‘warattesning.conreferred to by the coordinator as it spells out in detail how different departments and operations are organised and controlled. Typical examples would he production and control of drawings, how materials and consumables are purchased, how welding procedures are produced, etc. Essentially all operations to be carried out within the organisation will have control procedures laid down. Organisations involved in welding must document their activities to show who is involved in welding decisions. These activities include but are not limited to: Design Material selection Procedure development and approval Storage and issue of consumables Weld inspection PWHT and other special process survey Planning for welding WI VLA wexneg m examination services sn ttecting comQuality system BS EN 180 3834 - Quelty requirements for a = sens BS EN ISO 14731 EN 2874 1S EN ISO 15614 . Approval testing Specification Welding coordination ] | of wokdors -stocl ‘end qualification of — |_wolaling procedures, EN 2507 EN 479 iso cs20 (80 5612) ualifization Classification of aucttytovets_| |_of nor persomel_| | _mnportectons PLU ‘esiong & cuarinston Sarvleee esata 200 His duties are stated in EN ISO 14731 Welding coordination; Tasks and responsibilities Welding coordinator: Must be designated by employer Appointed by the company to issue/approve the necessary welding documents demonstrated competence and knowledge Must have special technical knowledge Extent of knowledge is defined by employer +_Job sper only if required by ctBS ENISO 9634-2 Comprehensive quality foquiramonts ‘Main requiremonts: ey, pe BS EN ISO 28343 | [ BS EN SO 3034-8 Standard quality | | Elementary quality {uiromonts + Welder and NDT personal approval (EN 287-1 & 473) + Welding is done according fo a WPS with supparling WPAR (EN ISO 15607) + Consumables storage and handling + Traceability of parent material + PWHT under control TW LAY Teving 8 xamtnaton Services sworntntcningcom Quality system Quality requirements for welding ‘ASME |, land Vill eal ‘ASME |, Vil Quality fevels “rw EN1SO 14734 Welding | [ ASME DX Approval | [ASNIE Dx Specification coordination testing of welders and approval of welding procedures ‘ASNT TC-14, [AWS A3.0 Qualification Classificatton of of NDT personnel Imperfections LAP Veouing & xasiation Sortent wontteingcem‘Visual NDT dimensional, ensure they cover all appropriate. joints. Calibration reports: For those items of equipment deemed necessary gauges, otc PWHT charts: Ensure all necessary information is on the chart - speed, data, etc Hydro tests: Reports aro complete and signed off, ete. As-bullt drawings: Are completed and marked as built. TWE JAG Vel A CvoairatonSeroes sunning Specifications Material test certificates (mill sheets, chemicai analysis and mechanical properties) Transfer of cast numbers markings, etc Welding procedures Welder approvals Production welds (weld history) Any problems with interruptions of welding cycle Documentation (welding consumables) TW eoraiewoune LLB Weioig 8 Exerintin Baeicns musntaining contWhen applicable Concessions: Permits: Coatings: TW LLG Teobing § Exantaaiion Services 1c tthe ‘Assi ala naps, Weld numbors numeers classifeation and cetication ing procedure numbers (WPS PGR) and doeumontaton Motil raceabtly and matereh cortiates ‘Consumable conto! procedures and ‘consumablo eerfifeales Welaers register ana all approval coriteates ‘Wild visual inspection prosodure visual inspection reports List of HOT operators and aporoval corleztos NOT procodur NDT roports wh TAA Wg 8 neste Ses Engineering queries, deviations, etc Degas certificates, hot work, etc Final painting or coating certificates signed off roltehing com, RT report surmbors UrT report numbers, IML report numbers Dyofoon report numbers Dimensional control proseduros and Liimansional contol raports PYNIT procedutes and PWHT reports and ‘caltbration carineates. Hydrotest procedures and hydrotest roports and ealbration cortiicctos Painting procociures and patnitng ‘conformance reports Non-contormanes raperts Lond out procedure Englasering quariee ‘Asche drasvings ieitealeg.cor