ISO:3834 MANUAL PREPARATION GUIDE LINE
LOGO
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YOUR FIRM’S NAME
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M
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WELDING
MANAGEMENT SYSTEM MANUAL
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Issue
No. 1
ISO: 3834-2005
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YOUR FIRM’S NAME
ISO 3834 -Welding Manual For
Quality Requirements For Fusion Welding
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FIRM’S PICTURE
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Document No
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XXXXX/XX/01
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Issue No
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01
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Revision
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00
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Dated
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XXXXXXXXX
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Amendment
Record Sheet for Welding System Manual
The
Welding System Manual is amended or modified by Leadership performing Management
Representative function. It is effected after receiving sanction of the in -
charge
Section
3 ISO 3834-2:2005
Distribution List Clause
No
Abbreviations Clause No
BU Business Unit
Section
5 ISO 3834-2:2005
Company
Profile Clause No
Section 6 ISO 3834-2:2005
Introduction Clause No
Introduction (Contd) Clause No
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PUT A FRONT VIEW
PICTURE
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Registered
Office
Telephone Fax
Works/Head
Office
Telephone Fax
Other Offices
Telephone Fax |
Section
7 ISO 3834-2:2005
Organization Chart – Clause No
Section
7 ISO 3834-2:2005
Welding
Organization Chart (Contd) – Clause No
The
scope of this manual relates to the quality requirements for fusion welding of
metallic material while manufacturing of Different
types PRODUCT
XXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXX&
other structures as per ISO 3834-
Material Group – Weldable carbon steels & weldable
structural steels within groups 1.1, 1.2 & 1.3 as per EN ISO 15608
Material Thicknesses – Product thickness 2 mm to XX mm of
Steel. Welding thickness from 3 mm to XX mm
Welding processes – MMAW 111, GMAW 135, SAW 121, Robotic
GMAW as per ISO 4063 - 2009
Based on Customer requirements, YOUR FIRM uses equivalent
steel grades from other international standards
For further reference this manual is co-relate with the IMS (ISO
9001:2015, ISO 14001:2015 & OHSAS 18001:2007) Manual.
The management system (IMS) that has been in place covers the entire
operations of the organization and is designed to meet the needs of all
stakeholders of the Company.
Internal audit for EN 3834-2 shall be scheduled in conjunction with IMS
internal audit.
Management Review Meeting for IMS shall cover outcome of EN 3834-2
internal audit and performance
This Welding Manual as per ISO 3834-2 & 3 Manual addresses the
requirements of standard shall be practiced by FIRM Lighting Ltd- Pole
Division.
This document is the sole property of “YOUR FIRM” and shall not be copied fully or partly without the
consent of “YOUR FIRM” Head of
Management.
Section
8 ISO 3834-2:2005
Normative References Clause No 2
Rx.xx
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1.
Management System Documents
·
IMS Manual- XXXX-QM
·
FPC Manual- XXXXX-QM
2.
NDT Procedures (PT, VT, UT & LT)
- adopted from approved NDT source
3.
Technical Specifications &
Guidelines
4.
ISO 3834 series of standards
Quality requirements for fusion welding of metallic materials
a. Part 1: Criteria for the selection of the appropriate level of
quality requirements
b. Part 2: Comprehensive quality requirements
c. Part 3: Standard quality requirements
d. Part 4: Elementary quality requirements
e. Part 5: Documents with which it is necessary to conform to claim
conformity to the quality requirements of ISO 3834-2, ISO 3834-3 or ISO 3834-4
f.
Part 6:
5.
BS EN ISO 15607- Specification and
Qualification of welding procedures for materials-General Rules
6.
ISO 9001 – Quality Management System-
Requirements
7.
EN 1090 - series of standards
8.
ISO 14731- Welding coordination —
Tasks and responsibilities
9.
EN ISO 9712- Non-destructive testing
— Qualification and certification of NDT personnel
10. ISO 148-1, Metallic materials — Charpy pendulum impact test —
Part 1: Test method
11. ISO 3452-1, Non-destructive testing — Penetrant testing — Part
1: General principles
12. ISO 4063, Welding and allied processes — Nomenclature of
processes and reference numbers
13. ISO 4136, Destructive tests on welds in metallic materials —
Transverse tensile test
ISO 5173, Destructive tests on welds in metallic materials
— Bend tests
14. ISO 5173, Destructive tests on welds in metallic materials —
Bend tests
Section
8 ISO 3834-2:2005
Rx.xx
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15. ISO 5817, Welding — Fusion-welded joints in steel, nickel, titanium
and their alloys (beam welding excluded) — Quality levels for imperfections
16. ISO 6520-1, Welding and allied processes — Classification of
geometric imperfections in metallic materials — Part 1: Fusion welding
17. ISO 6947, Welding and allied processes — Welding positions
18. ISO 9015-1, Destructive tests on welds in metallic materials —
Hardness testing — Part 1: Hardness test on arc welded joints
19. ISO 9016, Destructive tests on welds in metallic materials —
Impact tests — Test specimen location, notch orientation and examination
20. ISO 14175, Welding consumables — Gases and gas mixtures for
fusion welding and allied processes
21. ISO 15609-1, Specification and qualification of welding
procedures for metallic materials — Welding procedure specification — Part 1:
Arc welding
22. ISO 15609-2, Specification and qualification of welding
procedures for metallic materials — Welding procedure specification — Part 2:
Gas welding
23. ISO 15613, Specification and qualification of welding procedures
for metallic materials — Qualification based on pre-production welding test
24. ISO 17636-1, Non-destructive testing of welds — Radiographic
testing — Part 1: X- and gamma-ray techniques with film
25. ISO 17636-2, Non-destructive testing of welds — Radiographic
testing — Part 2: X- and gamma-ray techniques with digital detectors
26. ISO 17637, Non-destructive testing of welds — Visual testing of
fusion-welded joints
27. ISO 17638, Non-destructive testing of welds — Magnetic particle
testing
28. ISO 17639, Destructive tests on welds in metallic materials —
Macroscopic and microscopic examination of welds
29. ISO 17640, Non-destructive testing of welds — Ultrasonic testing
— Techniques, testing levels, and assessment
30. ISO/TR 15608, Welding — Guidelines for a metallic materials
grouping system
31. ISO/TR 17671-1, Welding — Recommendations for welding of
metallic materials — Part 1: General guidance for arc welding
32. ISO/TR 18491, Welding and allied processes — Guidelines for
measurement of welding energies
33. ISO/TR 20172, Welding — Grouping systems for materials —
European materials
34. ISO/TR 20173, Welding — Grouping systems for materials —
American materials
35. ISO/TR 20174, Welding — Grouping systems for materials —
Japanese materials
36. ISO/TR 25901 (all parts), Welding and allied processes —
Vocabulary
37. ASME SECTION IX- Qualification standard for welding and Brazing
procedure, Welders, Braziers and Welding and Brazing Operators
Section
9 ISO 3834-2:2005
Terms and Definitions Clause No 3
Company : YOUR FIRM
Document : This is information and its supporting medium.
Design specification :
Requirements for products specified
by customers or by the organization in anticipation of customer requirements,
or by regulation
Qualified person :
Person whose competence and knowledge
have been obtained by education, training and/or relevant practical experience
Construction : Product, structure or any other welded item
Manufacturer : Person or organization responsible for the welding production
Sub-contractor :
Supplier of products, services and/or
activities to the manufacturer in a contractual situation
Welding operator : Person who performs fusion welding processes
Non-Conformity : Non-fulfilment of a requirement
Corrective Action : Action initiated to prevent
re-occurrence.
Preventive Action : Action initiated to prevent potential
non-conformance.
Procedure : Specified way to carry out an activity or a process.
Section
10 ISO 3834-2:2005
Review of Requirements and Technical Review - Clause No 5, 5.1, 5.2,5.3
5.1 General
5.2 Review of Requirements
FIRM review the following aspects;
a) The
product standard shall be used, together with any supplementary requirements
b) Statutory
& regulatory requirements
c) Any
additional requirements determined by the manufacturer
d) Own
capability to meet the prescribed requirements
Section
10 (Contd) ISO 3834-2:2005
Review of Requirements and Technical Review - Clause No 5, 5.1, 5.2,5.3
5.3 Technical
Review
Reference: -
1)
Procedure for Review of Requirements – No.
2)
Contract review Form- No
3)
Weld Map - Projectwise
Section 11 ISO 3834-2:2005
Sub-Contracting Clause No 6
Reference
Section
11 ISO 3834-2:2005
Sub-Contracting (Contd) Clause No 6
1. Calibration of the measuring
instruments
Scope –
2. Non Destructive testing
Section
11 ISO 3834-2:2005
Sub-Contracting (Contd) Clause No 6
Section
12 ISO 3834-2:2005
Welding Personnel Clause No 7, 7.1,7.2, 7.3
7.1 General
7.2
Welders and Welding Personnel
Reference:
7.3 Welding
Coordination Personnel
FIRM has outsourced welding coordinator’s function
as per requirement of EN ISO 14731 having clearly defined task, responsibility
and authority.
Welding coordinator is assisted by
suitable deputy welding coordinators & demonstrates adequate technical
knowledge to enable all tasks assigned to be performed satisfactorily.
Reference: Tasks & Responsibilities Matrix of Welding Co-ordinator (Refer
ANNEXURE-I)
Section
12 ISO 3834-2:2005
Welding Personnel ( Contd) Clause No 7, 7.1,7.2, 7.3
Reference
- 1)
Procedure for Qualification of
Welders and Welding Operators No.
- 2)
Procedure for Qualification of
Welding Coordination Personnel No.
- 3)
Master List of Qualified Welders
- 4)
Master List of Welding Coordinators
Section 13 ISO 3834-2:2005
Inspection
and Testing Personnel Clause No 8, 8.1, 8.2
8.1 General
Reference: Master list of Welding Inspector-IMS/WI/01
8.2 Non-destructive
Testing Personnel
NDT qualified personnel are responsible
for performing respective NDT test
FIRM has outsourced the NDT testing (VT/UT/MT/RT/PT) to personnel qualified as per ISO 9712 & PCN & Other
equivalent national & international certification (e.g. ASNT) when asked by
customer)
For Visual Testing (VT) &
Penetrant Testing (PT) inspection, FIRM has the competent qualified personnel.
FIRM also has NDT personnel as per ASNT (Level-II).
Reference: List of NDT Personal-IMS/NDT/01.
Reference
Section
14 ISO 3834-2:2005
Equipment Clause No 9.
9.1, 9.2, 9.3, 9.4
9.1
Production and Testing Equipment
FIRM has ensured
that all necessary equipment required for welding production work is available,
when necessary:
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power sources and other machines;
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equipment for joint and surface preparation and
for cutting, including thermal cutting;
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jigs and fixtures;
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cranes and handling equipment used for the
production;
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personal protective equipment and other safety
equipment directly associated with the applicable manufacturing process;
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ovens, quivers, etc. used for treatment of
welding consumables;
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facilities for surface cleaning;
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destructive and non-destructive testing
facilities.
9.2
Description of Equipment
FIRM
maintains a Master List of essential equipment, used for the production. This
list identifies items of major equipment, essential for an evaluation of
workshop capacity and capability. This includes, for example:
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Maximum
capacity of crane(s)
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Size
of components that the workshop is able to handle;
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Capacity
of mechanized and automatic welding equipment;
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Capacity
of rolling, bending and cutting equipment.
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Dimension
and maximum temperature of furnace / oven
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Other
equipment of general type mentioned as necessary.
9.3 Suitability of Equipment
The
Equipment is suitable and adequate for the necessary application
9.4 New Equipment
After
installation of new equipment, appropriate test of equipment will be performed.
The test will verify the correct function of the equipment. The test will be
carried out and documented in accordance with appropriate standard, whenever
relevant.
Section
14 ISO 3834-2:2005
Equipment (Contd) Clause No 9.5
9.5 Equipment Maintenance
Rx.xx
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Examples of
those items are as follows:
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Condition of ammeters, voltmeters
and flow meters etc. used for the welding equipment;
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Condition of cables, hoses,
connectors, etc.;
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Condition of temperature-measurement
instruments;
9.6 Defective
Equipment
Defective
equipment is not used by FIRM. Proper tagging or visual display on the
defective machines like “Machine under Breakdown” will be done.
Without
approval of Maintenance Engineer a machine or equipment cannot be used directly
on production line.
Reference
Section
15 ISO 3834-2:2005
Rx.xx
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10.1 Production Planning
10.2 Welding Procedure Specifications (WPS)
Section
15 ISO 3834-2:2005
Rx.xxis
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10.3 Qualification of the Welding Procedures
(WPS)
FIRM qualifies the
welding procedure prior to production according to ISO 15614-1.
Ø New welding procedures are qualified prior to
production as applicable.
Ø Use of a standard &/or qualified welding
procedure is ensured for all full penetration welds & all welding works
including, Butt welds, fillet welds, repair welds & tack welds.
A standard or specific weld plan is maintained
10.4 Work Instructions
FIRM
uses Component Process Sheets and WPS. These are displayed at the point of
work, if necessary in Vernacular language.
To
demonstrate the achieved quality of the welded product, all the welding related
documents (e.g. WPS, WPQR, Welder’s Qualification record, relevant inspection
reports etc) shall be maintained.
10.5 Procedures for preparation and control of documents
FIRM
establishes and maintains procedure for the preparation and control of relevant
quality
documents (e.g.
welding-procedure specification, welding-procedure qualification record,
welders and welding-operators qualification certificates).
Reference
1)
Component
Process Sheet Format no.
2)
Route / Job
Card Format No.
3)
Welding
Procedure Specifications Format no.
4)
Weld Map
5)
Order
acceptance / Contract review format no
6)
Master list of
WPS and record
7)
Procedure for Control
of Documents FIRM/IMS/P/02
8)
Welding
consumable control – PPP-11
Section
16 ISO 3834-2:2005
Rx.xxis
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1.1 General
Storage
of Parent Material Clause
No. 12
Section 18 ISO 3834-2:2005
Post
Weld Heat treatment Clause
No. 13
Section
19
Inspection
and Testing
Clause 14
Section
20
Non-Conformance
and Corrective Actions Clause 14
Section
21 ISO 3834-2:2005
Calibration and validation of measuring,
inspection and testing equipment Clause No 16
Section
22 ISO 3834-2:2005
Identification
and Traceability
Clause No 17
Section
23 ISO 3834-2:2005
Quality Records
Clause No 18
Section
24 ISO 3834-2:2005
Annexure-I RESPONSIBILITIES MATRIX FOR WELDING
COORDINATORS (Contd)
Note – In the absence of RWC, his
tasks will be delegated to the other welding coordinator as marked in above
responsibility Matrix.
Name
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Short
Name
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Qualification
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Total
year’s Experience
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Designation
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References
1 Master List of Quality Records (if required)
for detail write to us
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