Implement ISO 3834 welding standards

EUROPEAN TRAINING PROGRAMME FOR COMPLETING
THE REQUIREMENTS FOR QUALITY WELDING

UNDER STANDARD SERIES EN ISO 3834

Best practices for
implementation of ISO 3834

GOOD PRACTICES GUIDE
REV. 1
30/11/11

BEST PRACTICES GUIDE
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EUROPEAN TRAINING PROGRAMME FOR COMPLETING THE REQUIREMENTS FOR
QUALITY WELDING UNDER STANDARD SERIES EN-ISO 3834

INDEX

A. OBJ ECTIVE ........................................................................................................................................................ 3
B. CONTENT ........................................................................................................................................................... 3
1 GENERAL ..................................................................................................................................................... 4
2 REASONS FOR USING ISO 3834 .................................................................................................................... 4
3 CHOICE OF QUALITY REQUIREMENT LEVEL ................................................................................................... 5
4 PROCEDURES AND FORMS ............................................................................................................................. 6
4.1 General ............................................................................................................................................... 6
4.2 Purpose and content ........................................................................................................................... 6
4.3 Relevant procedures and forms/check lists ......................................................................................... 7
4.4 Review of requirements....................................................................................................................... 9
4.5 Technical review ............................................................................................................................... 10
4.6 Sub-contracting ................................................................................................................................ 13
4.7 Welding and the associated personnel ............................................................................................. 16
4.8 Inspection and testing personnel ...................................................................................................... 19
4.9 Equipment ......................................................................................................................................... 19
4.10 Welding and related activities .......................................................................................................... 20
4.11 Storage and handling of welding consumables ................................................................................ 22
4.12 Storage of parent materials .............................................................................................................. 23
4.13 Post-weld heat treatment .................................................................................................................. 24
4.14 Inspection and testing ....................................................................................................................... 24
4.15 Non-conformances and corrective actions ....................................................................................... 26
4.16 Calibration and validation of measuring, inspection and testing equipment ................................... 28
4.17 Identification and traceability .......................................................................................................... 29
4.18 Quality records ................................................................................................................................. 30

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Best practice for implementation of ISO 3834

a. Objective

To provide companies intending to apply the standard ISO 3834 dealing with the quality
management of welding, advice on the kind of procedures and forms that might be beneficial
to them and on the content of such procedures.

b. Content

1 General
2 Reasons for using ISO 3834
3 Choice of quality requirement level
4 Procedures and forms
4.1 General
4.2 Purpose and content
4.3 Relevant procedures and forms/check lists
4.4 Review of requirements
4.5 Technical review
4.6 Sub-contracting
4.7 Welding and associated personnel
4.8 Inspection and testing personnel
4.9 Equipment
4.10 Welding and related activities
4.11 Storage and handling of welding consumables
4.12 Storage of parent material
4.13 Post- weld heat treatment
4.14 Inspection and testing
4.15 Non-conformance and corrective actions
4.16 Calibration and validation of measuring, inspection and testing equipment
4.17 Identification and traceability
4.18 Quality records

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1 General

Welding is a general production method for manufacturing of metal products. Welding
has a considerable impact on both the products costs and quality. Consequently, it is
important that the welding is carried out as efficiently as possible, meeting all specified
quality requirements.

Weld quality is achieved by sound welding, not by inspection. Inspection, however,
provides a check of the reliability of the product, but cannot improve poor quality. Welding
requires continuous control and/or to follow documented procedures. On this basis, the
ISO 3834 series of welding standards has been prepared.

The purpose of the ISO 9000 series is that the company designates as a special process
any work where the final quality of the product cannot be verified only by inspection. If
quality requirements are specified for the welds in the product, it is appropriate to define
welding as a special process.

It shall be observed that ISO 3834 is not a quality control standard that replaces ISO
9001, but more an auxiliary tool for applying ISO 9001 in companies which carry out
welding as a special process. In such a case, the additional compliance with ISO 3834
will be included by a reference in the ISO 9001 quality system. It is also possible to
obtain certification under ISO 3834 without any linkage to the ISO 9001 quality system.

The standards are general and not fixed to any certain product. The series of standards
refers to three different levels of quality requirements:
ISO 3834-2 Comprehensive quality requirements
ISO 3834-3 Standard quality requirements
ISO 3834-4 Basic quality requirements.

Guidance for the choice of level of quality requirements is given in ISO 3834-1. ISO
3834-5 specifies documents and standards necessary to consider in order to claim
conformity to ISO 3834-2, 3, or 4.

2 Reasons for using ISO 3834

Regulations
Regulations, eg, EU directives, define safety requirements on products and structures.
Product standards present the technical solutions that serve to fulfill the safety
requirements specified in the directives.

Product standards
Many European and some International product standards refer to the different parts of
ISO 3834 regarding welding. For example, the standard concerning pressure vessels
(EN 13445) states that the manufacturer of the pressure vessel is obliged to fulfill as a
minimum the welding quality requirements given in ISO 3834-3.

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The European standard EN 1090-2, dealing with execution of steel structures, requires
the use of quality requirements according to ISO 3834. The level of quality requirements
depends on the execution class.

Customers
Once ISO 3834 is in use, companies could utilize it for marketing purposes and
customers might require certification to ISO 3834.

The welding company (manufacturer)
The welding company wishes to improve its welding quality management system,
increase productivity and, by applying quality control in welding, demonstrate to its
customers to be a reliable supplier.

Main contractors
A subcontractor working to ISO 3834 can expect to have a significant advantage over its
competitors, when a main contractor is outsourcing its welding or welding related
activities.

ISO 9001
ISO 9001 states that, where necessary, special processes shall be identified. Welding is
typically considered as a special process. This requires that specific requirements, which
are specified in advance, are fulfilled. ISO 3834-2 is an excellent tool for doing this.

3 Choice of quality requirement level

ISO 3834-1 gives guidance on the choice of level of quality requirements.

When a welding company uses a quality control system conforming to ISO 9001, the
comprehensive quality requirements according to ISO 3834-2, 3, or 4 may all be
selected. There are only small technical differences between ISO 3834-2 and ISO 3834-
3. The main difference is the level of documentation. ISO 3834-4, presenting basic
quality requirements is the level of choice when the welded components have a low
safety risk. Product standards and national codes may also give references to the
different parts of ISO 3834. Table 1 gives a short summary of requirements for ISO 3834
in European product standards.

Table 1 Sel ecti on of qual i ty requirement l evel
Product or structure Requirements
Steel structures (EN 1090-2)
Execution classes 3 and 4 ISO 3834-2
Execution class 2 ISO 3834-3
Execution class 1 ISO 3834-4
Pressure vessels (EN 13445) At least ISO 3834-3
Railway vehicles (EN 15085)
Certification level 1 ISO 3834-2
Certification level 2 and 4 ISO 3834-3
Certification level 3 ISO 3834-4
Off shore (NORSOK) ISO 3834-2

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Water tube boilers (EN 12952-5) Recommends parts of ISO 3834-2
When applying ISO 3834, it should be noted that all of the items presented in the
standards do not need to be implemented, if they are not relevant. In such cases clear
reasons shall be given for such a decision.

As a basis, it might be appropriate for a company to start applying the ISO 3834 by
adopting the requirements of ISO 3834-2 and identifying those items that are relevant
from the company's point of view. Care shall, however, be taken to ensure that the quality
requirements specified are not lower than those presented in ISO 3834-4.

The company may also apply different levels of quality requirements for different
products. Although the company may have adopted the standard ISO 3834-2, it may
decide to apply lower quality requirements according to ISO 3834-3 or ISO 3834-4 in
respect of certain products or certain production lines.

4 Procedures and forms

4.1 General
Quality control may be described at three different levels:
at the general level, a description of the companys organisation, areas of
responsibility, operation, equipment, personnel, etc. is given
at the procedure level, the way in which the activity has to be performed is described
as well as responsible persons
at the level relating to forms, the necessary forms, lists, reports, records, certificates
and detailed working instructions are prepared.

Often the company is not familiar with preparing procedures. The procedures should be
as simple as possible. A good procedure fits onto a single A4 sheet and is clear and
concise enough to be read without sitting down.

Not every item needs a procedure. Sometimes it is enough just to know how things have
to be done. It is often difficult to decide whether only knowing how to do things is enough
or whether written procedures are needed. Written procedures are needed, when people
ask a lot of questions, different people do the same task or when lots of mistakes are
made.

4.2 Purpose and content
The purpose of procedure is to:
ensure harmonised and effective working
establish responsibilities in respect of tasks and work activities
act as the practical starting point for preparatory work
provide information
act as a channel for exchanges of experience.

Procedures include e.g:
purpose and scope of the work activity
what is to be done and who does it (content of the procedure and the person

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responsible for it)
when, where and how the work activity is carried out (content of activity, person
responsible for it)
materials, equipment and documents that are in use
how the work activity is managed and documented.

4.3 Relevant procedures and forms/check lists
Table 2 gives procedures and forms that are appropriate according to different clauses of
ISO 3834-2. Where necessary, they can also be used when applying ISO 3834-3 and
ISO 3834-4.

It may not be necessary to apply everything that is presented in Table 2; the company
has fairly free hands to make the appropriate choices. Under no circumstances must the
table be used as audit requirements.

The procedures provide examples of who could be the person responsible for certain
work activity. The examples are completely arbitrary. It is important to nominate the
person and ensure that the person is aware of his or her responsibilities and is also given
the appropriate power to act.

Table 2 Useful procedures and forms/check lists

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

5.2 Check list for assessment
6 Sub-contracting 6.1 Procedure for sub-contracting of
welding works
6.2 Procedure for subcontracting of
heat treatment
6.3 Procedure for sub- contracting of
testing and inspection
maintenance
calibration
6.6 Procedure for acceptance testing
6.1 Form for ordering/checking





6.6 Form
7 Welding personnel 7.2 Procedure for welders and
welding operators 2)
7.3 Procedure for welding
coordinators
7.4 Procedure for other personnel
7.2 File with certificates
7.3 File with CV, copies of
diplomas etc.
7.4 File
8 Inspection and testing
personnel
8.2 Procedures for testing and
inspection personnel
8.2 File with copies of
qualifications

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9 Equipment 9.2 Procedure for capacity and
capability of equipment
9.3 Procedure for acceptance of
equipment
9.4 Procedure for starting to use
equipment and recording
9.5 Procedure for maintenance of
equipment
9.2 Capacity list

9.3 Acceptance reports

9.4 List of equipment

9.5 Maintenance and
dimensional reports
10 Welding and related
activities
10.1.1 Procedure for subassemblies
10.1.2 Procedure for flow chart
10.2 Procedure for preparation of
welding procedure specifications
10.3 Procedure for qualification of
welding procedures
10.4 Procedure for preparation of
work instructions
10.5 Procedure for welding related
maintenance and support
10.1.1 Welding plan
10.1.2
Flow chart
10.2 Welding procedure
specifications
10.3 Welding procedure
qualification record

10.4 Work instructions
11 Welding consumables 11.3 Procedure for storage and
handling of welding consumables
11.3 Stock list
12 Storage of parent
materials
12 Procedure for storage of parent
materials
12 Stock list
13 Post-weld heat
treatment
13 Procedure for preparation of heat
treatment procedure
specifications
13.1 Heat treatment procedure
specifications
13.2 Heat treatment records
14 Inspection and testing 14.2 Procedure for activities prior to
welding
14.3 Procedure for control during
welding
14.4 Procedure for final inspection
14.5 Procedure for preparation of an
inspection plan
14.2 Check form

14.3 Check form

14.4 Check form
14.5 Inspection plan
15 Non-conformance and
corrective actions
15.1Procedure when the WPS has not
been used
15.2 Procedure for non-
conformances by inspection
15.3 Procedure for non-
conformances found after
delivery
15.1 Non-conformance report



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16 Calibration and
validation of
measuring, inspection
and testing equipment
16.1 Procedures for calibration and
validation of thermometers
validation of electrical measuring
devices
validation of measuring devices
validation of flow meters
16.1 Calibration and validation
report
report
report
report
17 Identification and
traceability
17.1 Procedure for markings
17.2 Procedure for transfer of
markings
17.3 Procedure for identification of
welders
17.4 Procedure for acceptance tests
17.1 Material card
17.2 Routing cards
18 Quality records 18 Procedure for preparing and
filing of quality records
18 Record forms

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

The review of requirements shall be conducted before any offer is submitted.

The review of requirements is the responsibility of the person, e.g. sales manager or
project manager, who goes through the orders and the proposed contract. It is important
for the welding coordinator to be present when matters concerning welding in the
contract are dealt with.

If there are ambiguities in the order or in the proposed contract, the person in charge
solves them together with the other parties and with the customer.

In the review of requirements the relevant items presented in clause 5.2 in ISO 3834-2
are reviewed. It is useful to draft a form for dealing with the matters below. If the
company has previously supplied an identical or similar product, it is not essential to
complete the form in respect of each individual contract.

a) Product standard to be used, together with any supplementary requirements:
does the product relate to any directive?
does a product standard exist (e.g. ISO-, EN- or national standard)?
does the customer have an existing product standard?
quality level and acceptance criteria?
the mechanical, thermal and/or chemical characteristics set for the welded joints

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any additional requirements?

b) Statutory and regulatory requirements
does the product relate to any regulation?

c) Any additional requirement determined by the manufacturer
any additional requirements?

d) The capability of the manufacturer to meet the prescribed requirements
new project?
review of resources?

4.5 Technical review
The purpose of the procedure for the technical review is to look at the matters that shall
be taken into account when reviewing the contract. The procedure deals with matters
concerning welding.

Each company has to nominate the person who will take responsibility for these matters.
That person may be, for instance, the main project designer. The welding coordinator
shall be present whenever any welding matters are discussed.

The following issues should be resolved before the procedure is prepared:
has a technical review been conducted previously (have earlier experiences been
taken into account)?
what are the differences in relation to previous requirements? (any fundamental
changes?)

The technical review should cover at least the matters presented in clause 5.3 of ISO
3834-2, as described in the list below. If the product in question has been manufactured
in the past, it is not always necessary to review these matters again.

a) Specification of parent material(s) and welded joint properties:
weldability
chemical composition
strength
ductility (impact, tensile)
thickness of material
corrosion resistance
wear resistance
high temperature characteristics
quality of parent material surface
other characteristics

b) Quality and acceptance requirements for welds:
quality level
acceptance level
acceptance criteria for welding tests

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c) Location, accessibility and sequence of welds, including accessibility for inspection
and for NDT:
appropriate welding positions
welding equipment being used, including feasibility of automated welding
significance of the welding sequence due to distortion of the work piece
at which stage of manufacturing shall inspection be performed?

d1) Welding procedures:
do all necessary welding procedure specifications exist?
are welding procedure specifications required for all the joints?

d2) Written procedures for non-destructive testing (NDT):
will non-destructive testing (NDT) be conducted?
will the company perform the necessary non-destructive testing itself?
do the necessary written procedures exist, e.g. NDT standards, for the NDT methods
to be performed?

d3) Heat-treatment procedures:
are procedures needed for pre-heating and/or post-welding heat treatment?
will the company perform the necessary pre-heating/heat treatment itself?
are there appropriate procedures for pre-heating/heat treatment?

e) The approach to be used for the qualification of welding procedures:
how should the welding procedures be qualified (e.g. ISO 15607)?
additional requirements (e.g. product standards)?
acceptance criteria for the welding procedure test
are there any appropriate qualification records available?

f) Qualification of personnel:
is there a responsible welding coordinator?
do the welders have valid certificates for the job in hand according to ISO 9606/EN
287 or other applicable standards? Are additional requirements necessary (e.g.
product standards)?
are the welding operators qualified according to ISO 14732/EN 1418 or other
applicable standards?
are the NDT inspectors certified according to ISO 9712 or EN 473
are there any requirements for qualification of persons carrying out heat treatment?

g1) Selection of material, identification and/or traceability:
what is the parent material?, availability?, weldability/special characteristics?
supplier, approved?, known?
how is the parent material identified (transfer of marking)?
should the parent material used in the product be traceable?
are material certificates required? (what level?)
approved parent material/filler material
filler material? (test reports?)

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g2) Selection of welders:
does the work require a welder who has a valid certificate for that particular welding
job?

g3) Identification of welds:
do the welds have to be identifiable? (to the welder?)

h) Quality control arrangements, including any involvement of an independent inspection
body:
is external quality control required during manufacture?
- customer?
- third party?
- when?

i) Inspection and testing:
which parts will be inspected or tested?
- scope of inspection
- inspection methods
- inspection stages
- reporting level (everything, deviations, errors)

j) Sub-contracting:
welding work (required competences and licences)
NDT testing
post-weld heat treatment
does the customer approve the sub-contractor?
how should sub-contractors be audited?
previous experience of sub-contracting, approved suppliers

k) Post-weld heat treatment:
has the company taken into account the quality requirements presented in ISO 17633
concerning heat treatment in connection with welding?

l) Other welding requirements:
production weld tests
batch testing of welding consumables
determination of ferrite content of weld metal
ageing
hydrogen content
sufficient information on permanent backing
peening
surface finish
weld profile (undercuts, smooth transition, shape of root, convex weld (grinding)
welding plan

m) Using special methods:
root opening
root gas

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buttering

n) Dimensions and details of joint preparation on completed weld:
type of joint
type of joint preparation
groove preparation
tolerances

o) Welds which are to be made in workshop, or elsewhere:
where final installation takes place (on site)?
are the components produced in different workshops?

p) Environmental conditions relevant to the application of processes:
low temperature
wind
moisture
lightening

q) Handling of non-conformances:
how to act in case of a non conformance?
- additional inspections (can the number of inspections be reduced?)
- alternative inspection methods
- how to proceed if modifications are required after the contract stage?
- who is authorised to approve the changes?
- documentation of changes?

4.6 Sub-contracting
If the company intends to use sub-contracting services (e.g. in welding, inspection, NDT,
heat treatment, calibration, maintenance), he shall provide the subcontractor with all the
relevant specifications and requirements. The sub-contractor shall provide the
documents and records specified by the manufacturer concerning the sub-contracted
work.

4.6.1 Sub-contracting of welding
The procedures on sub-contracting shall ensure that the sub-contractor has the technical
and qualitative capabilities (capacity and know-how) to manufacture the product such
that the product meets the requirements specified by the actual customer, comply with
the appropriate items of ISO 3834 and that the timetable requirements will be met.

The person responsible for the sub-contracting matters of the company has the
responsibility to ensure that the sub-contractor meets the technical preconditions
required of manufacturing. This person should use experts in the company, e.g. the
responsible welding coordinator.

Scope of sub-contractor assessment
Only the part of the subcontractor's technical know-how has to be assessed as required
for the sub-contracting work. The scope of the assessment depends on what kind of
quality system the sub-contractor has in use. If the subcontractor works according to a

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certified quality system including ISO 3834-2, it will be enough just to conform the
technical competence (capacity) and to check the equipment. A sub-contractor without
any documented quality system should be subjected to a separate quality audit
conducted by the company.

Items to be addressed with the sub-contractor

Review of requirements
A review of requirements with the sub-contractor may be performed together with the
technical review. A review of requirements may include the following.

a) Product standard and possible additional requirements to be applied:
the sub-contractor needs to know what standard and requirements the product has to
fulfil.

Technical review
A technical review shall be performed with the sub-contractor wherein all the essential
aspects related to the sub-contractor's work will be addressed. Consideration should also
be given to any earlier technical reviews or similar reviews. If there is significance
differences or changes in resources of the sub-contractor an assessment is necessary. A
technical review may include the following.

1) Welding procedure specifications:
the sub-contractor's welding procedure specifications need to be checked. If they are
not suitable for the product to be welded, the sub-contractor shall qualify new welding
procedures to comply with the product and based on these qualifications new
welding procedure specifications shall be prepared
assessment to be made whether it is possible to use the main company's welding
procedure specifications (standard procedures)

2) Non destructive testing procedures:
will NDT be performed and if so, what is the extent?
will this be done:
- by the sub-contractor
- by the company itself
- by a testing company chosen by the sub-contractor
- by the testing company used by the main company, which will also inspect the main
company's own manufacturing
- for which authority shall the results be presented, and who will present them?

3) Heat-treatment procedures:
is heat treatment needed?
who will be the expert for heat treatment: The main company or the sub-contractor?

4) Qualification of welding procedures:
the sub-contractor's welding procedures shall be qualified by the method required by
the quality requirements of the product to be manufactured

5) Qualification of personnel:

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are the qualifications of personnel adequate or does the sub-contractors personnel
need new qualifications for the product to be manufactured, eg, welders and welding
operators?
has a responsible welding co-ordinator been nominated and what is his task?
is the responsible welding co-ordinator employed by the sub-contractor?

6) Material:
does the main company deliver materials to the sub-contractor and how are these
identified and separated from the subcontractor's own materials?
If the subcontractor buys the material, the following need to be specified:
- type of material (e.g. standard, composition, dimensional tolerances, etc.).
- quality requirements for materials
- approvals, material certificates required
- requirements for identification and traceability of the material

7) Selection and identification of welders:
where necessary, the same level as applied by the main company

8) Inspection and testing:
the sub-contractor needs to be informed about what kinds of destructive and non
destructive testing is required and what the quality requirements are for the product
manufactured by the sub-contractor
customers inspections
inspections performed by others (is there a quality plan?)

9) Post-weld heat treatment:
if the product requires post-weld heat treatment, it is necessary to agree how the sub-
contractor deals with post-weld heat treatment and on the quality requirements

10) Other requirements related to welding:
the sub-contractor must be provided with all the necessary information in order to be
able to do the required work

11) Handling of non-conformances:
what to do and who makes the decisions concerning non-conformances?
who conducts possible necessary negotiations with the main customer and as
necessary with the authorities (or equivalent)?

12) Other information

Design data
The sub-contractor shall be provided with clear workshop drawings and instructions, such
as the following:
material backing
details and dimensions of joint preparations
permitted welding processes and consumables
where necessary, welding sequence
specification of parent material and characteristics of welded joints

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quality of the welds and acceptance requirements
possible special instructions

Quality records
When required by the main company, the subcontractor shall provide or present
documents such as the following:
welding procedure specifications
welding procedure qualification records
welders' qualification test certificates
measurement records
test reports from NDT and possible destructive testing
records of repairs and other non-conformance reports
documents related to the delivery

The quality documents to be filed either by the sub-contractor or by the main company as
agreed.

4.6.2 Sub-contracting of heat treatment
An assessment of the sub-contractor will be performed during which the items listed in
clause 4.13 will be checked.

4.6.3 Sub-contracting of inspection and testing
An assessment of the sub-contractors will be performed during which the items listed
below will be checked.
a) Sub-contractors competence
are there any requirements for accreditation?

b) Inspection plan
see clause 4.14.5

c) Qualification of NDT personnel (ISO 9712 or EN 473)

4.6.4 Sub-contracting of maintenance works
An assessment of the sub-contractor will be performed during which the items listed in
clause 4.9.5 will be checked.

4.6.5 Sub-contracting of calibration
An assessment of the subcontractor will be performed during which the items listed in
clause 4.16 will be checked.

4.7 Welding and the associated personnel

4.7.1 General
The purpose of the procedure is to ensure that the company has the required competent
personnel capable to fulfil the tasks required by the contract, by the regulatory
requirements, and by codes and orders of other bodies concerned.

The procedures apply to qualification of personnel and their various tasks.

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The responsibility for the skill of the personnel can, for example, be allocated to the
companys HR manager or production manager. In the welding matters, the responsible
welding co-ordinator will be contacted.

At technical reviews, personnel required for various projects are discussed along with
their qualifications.

4.7.2 Welders and welding operators
Those doing welding work are required to be qualified according to the relevant part of
ISO 9606-1 or EN 287, ISO 14732 or EN 1418 unless otherwise required by the product
standard or in the contract. The procedures show how qualifications and possible
renewal including possible special requirements are to be dealt with. In some cases, a
production test on site is required before the welder can start to work.

The welder's job description could also include the following activities:
joint preparation (according to instructions)
fitting (according to instructions)
maintenance (according to instructions).

4.7.3 Welding coordinator
The company shall nominate at least one welding coordinator (responsible), who has the
overall welding responsibility and the necessary authorisations (e.g. to stop production).
It is possible for one responsible welding coordinator to be responsible for several sub-
contractors.

If the field of activities of the company is broad, the tasks can be shared, e.g. between
the lead welding coordinator and other welding coordinators or welding foremen. Where
necessary, the welding coordinators and welding foremen report to the lead coordinator.
The qualifications of the welding coordinators need to be demonstrated through sufficient
experience or training (e.g. International Institute of Wleding).

ISO 14731 shall be taken into consideration for the choice of welding coordinators' tasks.

Responsible welding coordinator (often the only welding coordinator in a company)

When defining tasks for the responsible welding coordinator, the following list can be
used as guidance (see also ISO 14731):
organising of welding quality management according to ISO 3834
coordination of qualification of welding procedures
updating and distribution of files with welding procedure qualification records
preparation and signing of welding procedure specifications
publication of a table with qualified welding procedure specifications
general instructions for welders' qualification
updating and publication of a centralised welder register
expert tasks connected to purchasing of welding equipment and materials
coordination of welder's training
training of examiners for welder's qualification tests

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technical welding expert services for different departments and units in the company
(including the Design Department and Requirements Review).

Where necessary, a competence requirement may be specified for the responsible
welding coordinator (e.g. IWE/IWT/IWS).

Welding coordinator (can also be responsible)
When preparing procedures for assisting welding coordinators, the following list can be
used as guidance (see also ISO 14731):
department-specific organising and preparation of procedures and forms
concerning quality management in welding
acting as the responsible welding coordinator of various projects
having welding tests done according to the needs of the department
preparing and releasing of welding and heat-treatment procedure specifications to be
used
ensuring functioning of welders' qualification systems
welders training
nominating of personnel for transfer marking on materials
controlling validity of welders' qualifications
controlling to ensure that transfer of markings takes place according to instructions
reserving of welding equipment
reserving of welding consumables

Where necessary, a competence requirement may be specified for the welding
coordinator (e.g. IWT).

Welding foreman
A welding foremans tasks include:
work planning
organising and control of welding work
ensuring welding is carried out in accordance with WPS
organising and control of heat treatment
organising and control of inspections.

Where necessary, a competence requirement may be specified for the welding
coordinator (e.g. IWS).

4.7.4 Other personnel
(not in ISO 3834)

Designer
Designers tasks include, e.g.:
preparation of manufacturing and welding drawings
design of welded joints
preparation of prefabrication drawings
determination of manufacturing tolerances and appropriate choice of reference points
and reference levels for dimensioning.

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Heat-treatment personnel
The heat-treatment operators tasks include, e.g.:
heat treatment according to specifications
calibration of temperature measuring and recording equipment
validation of the furnace controlled temperature zone
control of temperatures
documentation of heat treatments
loading, supporting, protection, installation of measurement sensors, insulators and
heating elements.

4.8 Inspection and testing personnel
The purpose of the procedure is to ensure that the qualifications of the NDT personnel
are of a required level and in accordance with the ISO 9712 or EN 473 or as specified in
the product standard or contract.

4.9 Equipment

4.9.1 General
The purpose of the procedures is to ensure that the welding equipment can be used as
required by the welding procedure specifications. Defective equipment shall not be used.

The procedures apply to description, acceptance, use and maintenance of equipment.
Machine cards shall be kept of each equipment item showing the following:
type and capacity
manufacturer and machine number
machine number used by the company or some other unique mark
acceptance tests
regular maintenance.

The responsibility for the maintenance of the equipment could be given to the
maintenance manager or service manager. The responsibility may also be delegated to
users.

4.9.2 Procedure for capacity and capability of equipment
The procedure dealing with the description of the equipment shall specify what the
capacity list includes, e.g. number and capacity of welding equipment, such as maximum
welding current.

4.9.3 Procedure for acceptance of equipment
Before equipments are accepted, it may be necessary to perform an acceptance test. If
no acceptance standard is available, the necessary procedures may be prepared
together with the equipment supplier.

4.9.4 Procedure for starting to use equipment and recording
Before the use of new or refurbished equipment, the following checks are necessary:
external integrity
condition of cables
operating functions.

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Furthermore, a welding test should be performed to ensure that the equipment functions
normally.

4.9.5 Procedure for maintenance of equipment
a) Maintenance interval, responsible person and the person performing the maintenance.
The maintenance report of a welding machine may show the following, for example:
inspections related to electrical safety
condition of welding cables
condition of wire feeding devices
condition of welding gun or welding torch
output capacity
condition of measuring devices.

b) In daily maintenance of welding machines the following shall be observed:
condition of wire feed roller and correct compressive force
condition of current and gas nozzles
condition of insulator sleeve of gas nozzle
condition of protection hose of welding gun
condition of earthing
gas flow of shielding gas
condition of valves.

4.10 Welding and related activities
The purpose of the procedures is to ensure that welding and the related activities take
place as planned.

The responsibility for welding activities may be given to the responsible welding
coordinator, production manager, manufacturing manager or the welding foreman.

The procedures may apply to the production plan, preparation and qualification of
welding procedures, preparation of work instructions, maintenance work and auxiliary
work, daily planning and performance of welding, maintenance or supporting activities.

4.10.1 Procedures for preparing the production plan
ISO 3834-2 can be applied as such for procedures concerning the production plan.
Separate procedures could be prepared for individual work stages, e.g. cleaning,
nestling, joint preparation, post-weld treatment and inspection of welds. A routing card
can also be used to assist the preparation of the production plan.

4.10.2 Procedures for preparation of welding procedure specifications
The procedure for preparing of welding procedure specifications may include the
following:
which items shall be included and to what degree of accuracy?
tolerances (for joint preparations; for welding parameters)
for which products may the procedures be used?
method of qualification
choice of welding consumables (based on performed tests, experience or customer's

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requirements taking into account additional recommendations given by the
consumable manufacturer and possible authority requirements)
who has the right to sign welding procedure specifications?
special procedures
- Cleaning
- tacking
- buttering
- root opening
- pre-heating (measurement according to ISO 13916)?
- repair welding.

4.10.3 Procedures for qualification of welding procedures
The preparation of welding procedure qualification records (WPQR) shall be included in
the procedure for qualification of welding procedures.

a) The WPQR for qualification by tested welding consumables (ISO 15610) may be
based on the following:
inspection body's (e.g. TTK, TV, DNV, Lloyds, etc.) lists of parent materials and filler
materials
welding consumable manufacturers list (e.g. Esab, Elga, Bhler, etc.), which may
include filler material specific approvals.

b) The WPQR for qualification by previous experience (ISO 15611) may consist of the
following:
test reports
customer's statement that the product has been in use the last five years without any
need for weld repair. This statement may be done e.g. in connection with maintenance
at the customer.

c) Standard welding procedure (ISO 15612):
WPQR prepared by the organization which performed the welding procedure test (if
available).

d) Welding procedure tests (ISO 15614) and pre-production tests (ISO 15613):
procedures for examination of tests (what to do before, during test, and after the tests)
inspection and test reports.

The signatory of the qualification will be nominated in all cases.

4.10.4 Work instructions
The procedure for preparing of work instructions may include the following:
which items of the welding procedure specification and to what extent?
who has the right to sign the work instructions?
who may use work instructions?

4.10.5 Procedure for welding maintenance and supporting activities
The welder shall be able to understand the maintenance procedures (daily maintenance
and periodic maintenance) for the equipment and its parts. See clause 4.9.5.

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4.11 Storage and handling of welding consumables
The purpose of the procedure is to ensure that the handling and storage of welding
consumables has been sufficiently addressed in order to prevent them from becoming
moist, oxidised and damaged or mixed with one another. The procedure for storage,
drying, baking and handling needs to comply with the recommendations of the
manufacturer of welding consumables.

Responsibility
The person responsible for the storage and handling of the welding consumables is the
person in charge of welding in the company, e.g. responsible welding coordinator or a
person authorised by the coordinator, e.g. the stock keeper.

Contents
The procedure for storage of welding consumables may include the following:

a) Sufficiently detailed information for ordering welding consumables:
is it enough to use the classification and then choosing other welding consumables
with the same classification?
is it mandatory to purchase only welding consumables with specific trade names?
is, in special cases, a material certificate necessary?

b) Acceptance of welding consumables:
conforming that the purchased welding consumable is what was ordered
check that sufficient markings are in place.

c) Storage of welding consumables:
temperature range in the storehouse shall be defined
existing maximum relative humidity in the storehouse shall be defined
where necessary, other conditions in the storehouse shall be reported
consumables to be stored in unopened original packages, and opened packages
always to be used first
sequence of giving out of consumables from the storehouse: oldest consumables to
be used first (first in, first out)
the number of consumables that can be given out from the storehouse for use at the
work place shall be specified.

d) Handling of welding consumables:
the consumables shall not become mixed up during use
where necessary, they shall be marked, e.g. with stickers or colored markings
where necessary, the welding consumables shall be dried
where necessary, holding ovens or quivers shall be used
where necessary, the maximum storage time at the work place shall be specified after
which the consumables need to be re-dried or scrapped
a minimum number of opened packages shall be permitted at the work place
proper discipline required on the work place: e.g. covered electrodes shall not be left
around.

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e) Drying and storage of welding consumables:
devices used for drying need to be available
consumable specific instructions for drying based on the consumable
manufacturer's instructions (temperature and drying time) shall be given
the maximum holding time in holding oven shall be taken into account
mixing of welding consumables shall not be possible.

4.12 Storage of parent materials
The purpose of the procedure is to ensure that the parent materials used for welded
products meet the requirements specified for the product.

The procedure applies to the storage and handling of the parent materials.

The person responsible for manufacturing in the company is responsible for the storage
of parent materials. The person responsible organises and ensures that the storage of
parent materials does not cause damage or that they become mixed during storage.

It is important to prevent wrong materials from being used.

Contents
The requirements specified for a product, or by a contract or a standard or the authorities
shall be observed in the identification of materials.

a) If the material supplier provides or is required to provide an order confirmation, this
shall be checked with care and expertise also in regard to its technical part.

b) Care shall be taken during acceptance inspections to ensure that all of the
requirements in the order have been fulfilled and that all of the markings are as
required.

c) Care shall be taken in the storage that the materials will not be damaged or mixed up.

d) In nestling, care shall be taken in marking to ensure that the materials will not become
mixed up. The marking system shall correspond to the product standards. Marks
made using crayons, paint or stamps or batch-specific identifier cards may be used as
necessary. For example, the transfer of the markings of the pressure vessel materials
shall be made before nestling. A person appropriately trained will transfer the following
markings:
material quality
cast and test numbers
stamp of the person transferring the markings.

Small parts may be marked using code markings.

e) During manufacturing care shall be taken to ensure that the identification of the
materials is retained.

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f) Where necessary, and according to the product standard, the customer shall be
provided with information about the materials used, and as necessary also with
material certificates.

4.13 Post-weld heat treatment
The purpose of the procedure is to ensure that the welds are heat-treated in a specified
manner in order to fulfil the requirements of the welded product.

The procedure applies to the heat treatment after welding.

The responsibility for the heat treatment can be allocated to the person responsible for
manufacturing or to the welding coordinator.

Contents
ISO 17663 describes heat treatment as a special process. It includes the following:
review of requirements and technical review
subcontracting
personnel
inspection and testing
equipment for heat-treatment
heat treatment activities
heat treatment records
non-conformance and corrective actions
quality records

4.14 Inspection and testing

4.14.1 Contents
The purpose of the procedure (Inspection and Testing Plan) is mainly to ensure that
quality control is in place before welding, during welding, and after welding.

Procedures are prepared for visual inspection and for both destructive and non-
destructive testing.

The overall responsibility for inspections lies with a person who is independent of
production, e.g. the quality manager. The person or organisation performing the
inspection is responsible for the actual inspection work and its results. The inspectors'
visual acuity should be checked at regular intervals. The majority of inspections do not
require an outside inspector, e.g. a welder trained for inspection tasks can do the visual
inspection of the welds he has made. The general principle is that the person doing the
work is responsible for that work.

4.14.2 Inspection and testing before welding
The procedure may include:

a) Inspection of the welders qualifications:
validity
suitability (range of qualification)

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b) Welding procedure specifications/work instructions:
necessity
suitability
correct welding procedure specification
parent material and material thickness
identity of parent material
welding consumable(s) (marking, storage, and condition)
dimensions of joint preparations (method of preparation, bevel angle, gap, depth of
root face)
fit-up, jigging and tacking
setting of welding parameters (welding current, voltage, wire feed rate)
measurement of preheating temperature
environmental conditions (e.g. temperature and draught)

c) Production tests:
extension parts to be welded for destructive testing

d) Non-conformances

4.14.2 Inspection during welding

a) Control of welding parameters (that they are in use):
welding current
arc voltage
travel speed
gas flow rate
contact tube distance

b) Temperature measurements:
ISO 13916 may be used when measuring the pre-heating temperature, the interpass
temperature, and preheat maintenance temperature.

c) Use and handling of welding consumables

d) Cleaning, shape and number of runs

e) Welding sequence

f) Back gouging

g) Control of distortion

h) Required intermediate examinations

i) Non-conformances

4.14.3 Inspection after welding

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a) Implementation of the testing plan (destructive and non-destructive testing)

b) Checking of test reports:
written instructions (e.g. a specific standard)
acceptance levels
qualifications of inspection personnel

c) Checking the shape, profile and dimensions of the structure d) Results of post-
treatment:
grinding
post-heating-treatment record
ageing

e) Non-conformances

Sometimes there could be a need to prepare testing plan (ITP). It might include:
test object
extent of testing
testing time
test methods/equipment
subcontracting
test instructions
testing conditions (e.g. lighting, viewing angle, viewing distance)
acceptance levels (e.g. corresponding to quality levels)
recording instructions or report forms.

4.14.4 Inspection and testing status
The inspection or test status of the welded structure is given in an appropriate manner,
e.g. by means of a marking on the object itself or a traceability card.

4.15 Non-conformances and corrective actions
The purpose of procedures is to ensure that
a nonconforming product does not go forward into production, for use or to be
delivered to the customer
correction is taken to correct the nonconformance
corrective actions are taken to avoid repetition of the fault.

The procedures concern welding, inspection and non-conformances found after delivery.
It is important to define what a non-conformance is.

All parties are obliged to report of any non-conformance they have noted. Depending on
the nature of the non-conformance, the welder shall have the right, if necessary, to
interrupt his/her work.

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A designated person shall be given the responsibility for ensuring that the
corrections/repairs are made according to instructions and completed, and that the
required quality has been reached.

4.15.1 Procedures when the welding procedure specification has not been
followed or is impossible to follow
If the welding procedure specifications/work instruction was not followed, the welder shall
inform e.g. the foreman/responsible welding coordinator about it. A non-conformance
report shall be made of this type of non-conformance.

The contents of the report should include e.g. of the following items:
description of the non-conformance
proposed action (correction of welding procedure specifications or work instructions?)
decision
control of implementation
corrective action.

The procedure should describe how to proceed, e.g.

a) No action

b) Correction without permission

c) Correction with permission from a certain person d) Classification for alternative use

e) Scrapping.

Any repair welding shall be done according to the qualified welding procedures.

4.15.2 Procedures for non-conformances found during inspection
The following may be mentioned in procedures for how to handle weld imperfections
found during inspection:
the way in which the imperfection has to be marked
acceptance of the non-conformance
increasing the extent of testing and additional test methods (see, technical review)
corrective actions (see, technical review)
reporting (see 4.15.1).

4.15.3 Procedures for non-conformances found after delivery
Procedures for dealing with non-conformances found after delivery may include the
following:
classification of the non-conformance
NDT
heat treatment
does the welding procedure specification really meet the requirements for the work to
be done?
has the welding procedure specification been wrongly prepared?

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has the welding procedure specification been qualified by previous welding
experience according EN ISO 15611 (the qualification of WPS to be withdrawn?)
what method has to be followed in corrective and preventive actions?
reporting
others

4.16 Calibration and validation of measuring, inspection and testing equipment
The purpose of the procedures is to ensure that the measurement instruments and
equipment in use meet the required technical and other criteria for fulfilling the
requirements specified by the customer. Requirements for calibration and validation of
equipment used for welding, including ancillary activities are given in ISO 17662.

The procedures refer to the measurement instruments and equipment used in
manufacture and inspection.

The company shall nominate a person responsible for calibration and validation. The
company is responsible for the appropriate calibration or validation of inspection,
measurement and testing equipment for welded products. The extent and level of
accuracy of the calibration or validation and the interval between these activities shall be
defined by the company according to required product standards. It shall be observed
that tight production tolerances cause a greater need for accuracy of calibrated or
validated equipment. Generally, calibration concerns instruments and equipment (master
instruments) used for validation of instruments used in testing the final properties of a
product. For products requiring great accuracy, the degree of measurement uncertainty
(accuracy) shall be known and it is necessary to ensure the companys own
measurement equipment is traceable to international measurement standards.

The company shall prepare the necessary calibration or validation procedures for
instruments and equipment.

The most common objects of calibration or validation in the welding industry include:

a) The equipment required for inspection by measuring of finished products or, if
necessary, parts, e.g.:
measuring tapes for final inspections
caliper gauges and micrometers
gauge blocks
dial indicators
angle gauges
measuring instruments for throat thicknesses
rulers
matrices
thickness gauges
theodolites and measuring machines

b) Gauges and meters used in welding and flame cutting, e.g.:
ammeters and voltmeters
tachometers

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gas flow meters (rotameter)
wire feed regulator

c) Measurement equipment required in heat treatment and pre-heating, e.g.:
plotters
regulators
thermoelements
thermometers
pyrometers

d) Equipment used in non-destructive testing, e.g.:
magnetization equipment
magnetic field gauge
light intensity meters
x-ray equipment
viewing devices
densitometers
ultrasonic equipment and calibration blocks

e) Destructive testing:
the equipment should be subject to official calibration inspection, e.g. hardness,
tensile testing machines and impact hammers.

4.17 Identification and traceability
The purpose of the procedures is to ensure that the identification and traceability of the
welded product or its parts are maintained throughout the whole manufacturing process.

The procedures concern organizing and documenting the identification and traceability of
welding and related activities.

The company is responsible for planning, managing and documenting identification and
traceability at the product level.

Identification and traceability relating to welding should include, if necessary, depending
on the structure and its application:
identification of production plans (see also clause 4.10.1)
identification of routing cards or a list
identification of weld locations, e.g. by a drawing of the actual situation
identification of non-destructive testing procedures and personnel (for which object?)
identification of welding consumables, e.g. designation, trade name, manufacturer of
welding consumables and batch or cast number, if required
identification and/or traceability of parent material, e.g. type, cast number, if required
identification of location of weld repairs
identification of location of temporary attachments
traceability for fully mechanized or automatic welding units to specific welds
traceability of welders and welding operators to specific welds
traceability of welding procedure specifications to specific welds.

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4.18 Quality records

4.18.1 General
The quality records are an essential part of the companys quality assurance system.
They provide the basis for its quality policy, quality objectives and working methods and
they ensure the repeatability of procedures. With the help of the quality records and
systematic working methods, it is possible to get customers and possible third parties,
already interested at the first contact. At the same time they may also be convinced of
the companys ability to manufacture and deliver the required product.

The records should be used by all those whose work is affected by the document in
question. The quality records can be divided into two groups:

1) The documents relating to the companys own activities e.g. operational and work
instructions for the organization, distribution of responsibilities and operations of the
company.

2) Quality files derived from the documents, reports and check lists (forms) on actions
relating to the product and documents delivered to the customer together with the
product.

4.18.2 Records relating to the companys own operations
In a welding company records are, for example, the organizational description/chart,
responsibilities and authorizations within the organization, the equipment list and
documents specified in ISO 3834-2.

These include instructions relating to document management and procedures for:
how perform certain operations
references to standards, if possible
the person performing the operation
the timing of the operation
signing the completion of operation.

In addition to table 2 the following records may be useful:
correspondence with the customer, inquiries, offers/tenders, orders, confirmations of
orders
documents and confirmations of orders relating to purchasing
drawings
approved subcontractors
non-destructive and destructive testing procedures and reports
procedures for acceptance of parent materials and transfer of marks
material certificates

4.18.3 Quality files regarding a specific product
A contract, product standard or law may require that certain quality records have to be
delivered together with the product to the purchaser and in some cases also to the
relevant authorities.

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Quality files should also be retained in order to demonstrate the achievement of the
required quality and the efficient functioning of the quality procedures.

The documents should be prepared at the stage of manufacture or inspection concerned
and collected so that they can be collected immediately when the product has been
completed. The welding coordinator or the person responsible for quality should check
and approve the documents before sending them to the customer.

The documents should be sufficiently clear, accurate and easily identifiable as belonging
to a specific product, so that it can be proved afterwards that the requirements of
manufacture and inspections have been fulfilled.

The manufacturer files the documents in accordance with its own archiving procedures.

Another way of ensuring that the necessary documents are created on schedule is to
have a production or quality plan covering the stages and operations involved in the
products manufacture and inspection, signed by the responsible person when the
required actions have been completed.

The documents specified in the contract shall be submitted together with the product.
The documents to be delivered may include the following:
records of requirement/technical reviews
production/quality plan
material certificates
information on welding consumables
reports of material testing
routing cards relating to inspection
measurement and other test reports
list of welding procedure specifications used
list of qualified welders used
heat treatment procedure specifications and reports
records of repairs and non-conformance reports.

The periods for retention of individual records shall be defined and documented and the
record holders identified.

4.18.4 Document management
The manufacturer should create an easily usable list-based or other equivalent procedure
for document control, in order to verify their validity and to prevent the use of invalid
and/or outdated documents.

The documents shall be provided with an identification number, a revision number,
signature and date of approval. The persons to whom the documents have been
delivered to shall be listed, and at the same time it is ensured that all have the latest
revised version at their disposal. The documents may be filed as a hard copy or in an
electronic format, for example for 10 years. The person who has approved the original
document should also approve any changes made. The points changed are to be marked
in a suitable manner.

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1) Need for certification
Fulfillment of the requirements of ISO 3834 can be demonstrated in different ways. Often
the requirement may be a certification of the system. The company should be able to
choose itself whether it wants certification to promote marketing, to improve overall
quality and efficiency and to increase the credibility of its operations from the customers
or stakeholders perspective.
There are several ways of showing the customer or a potential customer that the
companys welding quality requirements have been met. These are:
a method bilaterally agreed on between the customer and the company
auditing by the customer
auditing by a third party chosen by the customer.

Quality is always a question of agreement between the customer and the supplier, which
does not necessarily require certification.

2) Adoption of ISO 3834 in a company
The adoption of ISO 3834 in a company may, for example, be carried out in as a project
in three stages.

At the first stage the company has to carry out a survey of the current situation. This
stage should be performed with great care and sufficient time should be spent on it, as it
forms the basis for the success of the whole project. The current situation should be
examined as thoroughly and as truthfully as possible. It is human at this stage to
embellish the actual situation in the company. Such embellishment, however, makes
the actual advantage gained from the project smaller than expected. Very often only the
requirements of the standard will be met, but the possibilities for improving the quality
and efficiency of the production will be lost already at the beginning of the project.

In many cases the examination of the initial situation is useful, if consultation with an
outside expert is used, because the expert has no need to describe the situation as
better than it actually is. Neither is an outside expert subject to workplace blindness,
which is only human for people who have worked for a long time at the same workplace.

When real quality improvement is defined as the goal, it is important to gain the
commitment of personnel at all levels in the companys hierarchy to the project. The
executive management of the company shall give and demonstrate its full support for the
project from the beginning to the end. This is supported by informing and training the
personnel at the earliest possible stage.

It has been found useful to arrange training of the stuff in connection with the survey of the
current situation. The number of companys staff, products and company culture are
important factors making the organizing of a training event beneficial. Separate training
events can be organized for clerical staff and welding personnel, or all personnel groups
can be gathered together in one event. The advantage of the first alternative is that the
content of the training can be tailored accurately to meet the needs of target group. For
example, for welders, the items of the standard on Equipment, Welding activities and
Welding consumables can be highlighted. For the clerical staff it would be useful to
concentrate, for example, the item Requirement and technical reviews.

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The advantage of a common training event organized for the whole personnel would be
that it would be possible to examine matters from different perspectives. The various
personnel groups would gain an overall picture of all the operations affecting quality
management in welding as required by the standard. The personnel groups would get
knowledge of items dealt with in other groups areas of responsibility and understand the
actions required by themselves and others and the linkages and dependencies between
them.

The number of participants in the training events should be restricted to enable an open
and controlled discussion of matters. In large enterprises it is better to arrange several
events than to bring together the whole personnel or personnel group in one training
event. There is no reason to underestimate the importance of training or information
events, because the basic requirement for a successful project is that the whole personnel
are involved in developing the activities.

The main objective of the first stage is to identify and record items needing improvement.
After this stage it is often useful to update the project plan, in order to ensure a realistic
schedule for implementation.

At the second stage, on the basis of the initial survey, an action plan shall be prepared
for addressing the items needing development and the planned actions shall be
performed. These actions may be split into separate tasks, for example, according to the
list of contents in the standard or to the companies own quality manual. Chronologically
the separate tasks may be carried out either simultaneously or successively. The
method of implementation depends on the resources available for the project and how
responsibilities are assigned in the company. At latest at this stage of the project, it is
recommended to nominate a responsible person(s) for each item to be developed.

Training of the companys personnel continues at this stage. While the first stage mainly
gives information on the content of ISO 3834 and the actions regarding needed
procedures and documentation to meet the requirements, at this stage the objective is
focused on the technical content of actions and procedures. Activities and training
given at this stage are to a large extent decisive as regards the technical and
economic benefits that adopting ISO 3834 will bring the company.

When the items according to ISO 3834 are used as a tool for measuring the quality
producing capacity of the company, and the weaknesses and disadvantages found as a
result of using the standard are addressed properly, the productivity of welding can be
improved and quality costs cut, so that the expenditure and effort put into the ISO 3834
project will be found as an excellent investment.

The duration of the second stage depends very much on the size and initial situation of the
company. If the company has a certified ISO 9001 quality system in place and it has, for
example, successfully manufactured standardized products, it has in practice already had
to operate according to many of the items of ISO 3834-2. Readiness for certification can in
this case be achieved quite quickly and with a very reasonable amount of work. The
additional work may be limited to revising of a few operational procedures to bring them
into the form required by ISO 3834.

Project n:
Edition: Rev. 1
Date:30/11/11
Page: 34 from 34

LEONARDO DA VINCI
The work is considerably more demanding if the company does not have a certified quality
system, or a well documented quality management system has not been required for the
products it manufactures, especially as regards welding. The work of preparing
procedures is in any case quite extensive even though an effort is made to minimize the
number of procedures to what is appropriate. Time and resources shall also be reserved
for understanding the purpose of the procedures and for learning the tasks involved in
practice and establishing them on all levels of production.

Typically, 618 months shall be reserved for the second stage. In order to achieve a
timetable of 6 months, the ISO 3834 work shall be done by teams of several (>3) people
simultaneously in the different areas of operations. If the implementation of the standard
will be done in a team, as small as possible, (e.g. in addition to normal workload), the
project will easily take more than a year.

The estimates above mainly concern companies with a wide production program. If the
company manufactures a clearly limited range of products, where the welding work is
similar, and the requirements are clearly established, the timetable for adopting ISO 3834
may be much shorter.

The third stage involves checking the functional effectiveness of the quality management
system for welding and its compliance with standards, so that any remaining
disadvantages are found before the real audit by an external party. This pre-audit could
be carried out by an expert in the project, who has not participated in developing the
procedures of the company concerned. The pre-audit could also be done by an outside
expert familiar with ISO 3834. The idea here is to avoid a situation where a person could
assess the results of his or her own work. Any disadvantages found will, of course, be
corrected, after which the company can ask for an audit by an accredited certificating
body. The end goal is an effectively functioning quality management system for welding,
and at this stage all the procedures will comply with the appropriate requirements
according to ISO 3834.

Problems
The most common problems occurring with the implementation of ISO 3834 are:
purchasing or ordering
status of the responsible welding coordinator in the company
handling of welding consumables
following the welding procedure specifications
validation of ammeters and voltmeters
range of qualifications.

Implement ISO 3834 welding standards

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Implement ISO 3834 welding standards

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EUROPEAN TRAINING PROGRAMME FOR COMPLETING

THE REQUIREMENTS FOR QUALITY WELDING

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