D.

SELVAKUMARAN
SENIOR SECTON ENGINEER/AWTI
 ISO-3834 –Quality
requirements for fusion welding
of metallic materials.
 EN -15085- Quality
requirements of Welding of
railway vehicles and
components.
 IRIS- International Railway
Industry Standard
 Company Certification Standards
in Welding
 ISO 3834-1 Quality requirements
for fusion welding of metallic
materials
 It is an international standard created by the
welding professional
 ISO 3834 - quality requirements of welding
 not a product standard
 requirements to ensure good practice in the welding
 to prevent premature failures.
 Competing in European and World wide markets.
ISO 9001 - quality management system

 ISO 9000 : 7 - Product realization

 7.5 Production and service provision

 7.5.2 Validation of processes for production and service

provision

◦ where the quality cannot be verified by measurement.

◦ deficiencies appear only in service condition.
◦ special processes are to validated.
 Personnel
qualification

ISO 9001 - 7.5.2

- Validation ISO 3834 Process
requirements qualification

Equipment
Qualification
 Welder ISO 9606
qualification EN 287

Welding
ISO 14732
operator
EN 1418
qualification
Welding IWE, IWP,
coordinator ISO 14731
(WC + RWC) IWT, IWS

ISO 9712 IWIP,

NDT personnel Level II -
EN 473 ISNT/ASNT

Welding- ISO 15607

procedure
specifications ISO 15609
 • Criteria for the selection of the appropriate level of quality
Part-1 requirements

• Comprehensive quality requirements

Part 2

• Standard quality requirements

Part 3

• Elementary quality requirements

Part-4

•Documents necessary to conform to claim conformity to the

Part 5 quality requirements of ISO 3834-2, ISO 3834-3 or ISO 3834-4.

•Guidelines on implementing ISO 3834

Part 6
Criteria 3834 – 2 3834 – 3 3834 – 4
comprehensive Standard Elementary
product failure total product impair the Not
failure intended use of fundamentally
construction. impair the
intended use.

financial loss with significant Financial losses Minor financial

financial loss not extreme. consequences

Safety consequences Normal safety No adverse

risk/injury. Major injury. risk effects on safety
of people

loading dynamic loading - -

in addition to
high static
loading.
 1. Scope - part of ISO 3834
 (2. Normative references, 3. terms and references,
 4. Use of this part of ISO 3834) 5Ms
 5. Review of requirements and
 MEN
technical review (Measurement)
 MATERIAL
 6. Sub-contracting (Method)
 7. Welding personnel (Men)  MACHINE

 8. Inspection and testing personnel (Men)  METHOD

 9. Equipment (Machine)  MEASUREMENT

 10. Welding and related activities (Method)

 11. Welding consumables (Material)
 12. Storage of parent materials (Material)
 13. Post-weld heat treatment (Method)
 14. Inspection and testing (Method)
 15. Non-conformance and corrective actions (Method)
 16. Calibration and validation of measuring,
inspection and testing equipment (Method)
 17. Identification and traceability (Method)
 18. Quality records (Method)
 Requirement
 Review of requirement
 to verify that the work content is within its
capability to perform,
 that sufficient resources are available to
achieve delivery schedules,
 and that documentation is clear and
unambiguous.
shall include

a) the product standard to be used, together

with any supplementary requirements;
b) statutory and regulatory requirements;
c) any additional requirement determined by
the manufacturer;
d) the capability of the manufacturer to meet
the prescribed requirements.
 Technical requirements to be considered shall include the following:

o Parent Material(s) specification

o Qualification of personnel;
o Welding procedure specifications
o Non-destructive testing procedures
o Heat-treatment procedures
o Inspection and testing
o sub-contracting
o details of joint preparation
o environmental conditions
o handling of non-conformances.
o selection, identification and/or traceability (e.g. for materials,
welds, documents);
 Procedure for subcontracting
 Sub contractors should follow Manufacturer
requirements
 Compliance to requirements of ISO 3834.

 The sub-contractor’s
 review of requirements ( 5.2)
 technical review ( 5.3)
7.1 General
 The manufacturer shall have sufficient and
competent personnel for the
 planning,
 performing and
 supervising of the welding production
according to specified requirements.
7.2 Welders and welding operators
Welders and welding operators shall be qualified
by an appropriate test.

ISO 3834-5:2005, Table 1,

Essential variables and range of qualification
 welding process
 The parent material group(s) and subgroup(s), in
accordance with ISO/TR 15608
 product type (plate or pipe)
 material thickness / outside pipe diameter)
 type of weld (butt or fillet)
 filler material group
 filler material type
 welding position
 weld detail(s) (material backing, gas backing, flux backing,
consumable insert, single side welding, both side welding,
single layer, multi-layer, leftward welding, rightward
welding)
 Range of qualification is applicable for certain variables
 all slag and spatters are removed;
 no grinding on the root and the face
side of the weld
 stop and restart in the root run and in
the capping run are identified
 to be assessed in accordance with ISO
5817 (Quality levels for
imperfections).
 Visual, radiography, bend test &
fracture test
7.3 Welding coordination personnel
monitoring all welding & related activities
RWC May be responsible for the work of other
welding co-ordinators in the in the same
department / site.
The tasks and responsibilities of such persons
shall be clearly defined.
competent to make decisions and sign on behalf of
the manufacturer.
ISO 3834 Part REQUIREMENT OF RESPONSIBLE WELDING C
OORDINATOR

ISO 14731 Grade 1 Comprehensive

ISO 3834-2
(IWE/ IWT)

ISO 14731 Grade 2 Specific

ISO 3834-3
(IWT/IWS)

ISO 14731 Grade 3 Basic

ISO 3834-4
(IWT/IWP)
 8.1 General
 The manufacturer shall have at his disposal sufficient
and competent personnel for planning, performing,
and supervising the inspection and testing of the
welding production according to specified
requirements.
 8.2 Non-destructive testing personnel
 The non-destructive testing personnel shall be qualified.
 ISO 3834-5:2005, Table 3
9.1 Production and testing equipment

 The following equipment shall be available, when necessary:

⎯ power sources and other machines;
⎯ equipment for joint and surface preparation and for
cutting, including thermal cutting;
⎯ equipment for preheating and post-heat treatment
including temperature indicator;
⎯ jigs and fixtures;
⎯ cranes and handling equipment used for the production;
⎯ PPEs: personal protective equipment and other safety
equipment, directly associated with the applicable
manufacturing process;
⎯ ovens, quivers, etc. used for treatment of welding
consumables;
⎯ facilities for surface cleaning;
⎯ DT, NDT: destructive and non-destructive testing facilities.
 9.2 Description of equipment
 shall maintain a list of essential equipments
 shall identify items of major equipment, essential for an
evaluation of workshop capacity and capability.
 9.3 Suitability of equipment
◦ The equipment shall be adequate for the application
concerned.
 9.4 New equipment
◦ For new (or refurbished) equipment, appropriate tests of
the equipment shall be performed.
 9.5 Equipment maintenance
o documented plans for the maintenance of equipment.
o ensure maintenance checks of those items in the
equipment which control variables listed in the relevant
procedure specifications.
 10.1 Production planning
 10.2 Welding-procedure specifications
 10.3 Qualification of the welding
procedures
 10.4 Work instructions
 10.5 Procedures for preparation and
control of documents
 10.1 Production planning
The manufacturer shall carry out adequate production planning.
Items to be considered shall include at least:
⎯ sequence manufacturing (e.g. as single parts or sub-assemblies,
and the order of subsequent final assembly);
⎯ identification of the individual processes required to manufacture
the construction;
⎯ Welding Procedure specifications
⎯ Welding sequence
⎯ specification for inspection and testing
⎯ environmental conditions (e.g. protection from wind and rain);
⎯ identification by batches, components or parts, as appropriate;
⎯ allocation of qualified personnel;
⎯ arrangement for any production test.
10.2 Welding-procedure specifications
The manufacturer shall prepare the welding-
procedure specification(s) and shall ensure that
these are used correctly in production.
ISO 3834-5:2005, Table 4
10.2 Welding-procedure specifications
ISO 15607
 BS EN ISO 15607:2003 - Specification and qualification of welding
procedures for metallic materials — General rules
Standards for various processes

BS EN ISO 15609-1:2004 - Specification and qualification of

welding procedures for metallic materials — Welding procedure
specification — Part 1: Arc welding
WPS Format & variables

BS EN ISO 15614-1:2004 - Specification and qualification of welding

procedures for metallic materials — Welding procedure Test — Part 1:
Arc and Gas welding of Steels and arc welding of Nickel alloys
Qualification procedures (test & evaluation)
range of qualification
10.2 Welding-procedure specifications
ISO 15609

(to be contd..)
10.2 Welding-procedure specifications
ISO 15609

(to be contd..)
10.2 Welding-procedure specifications
ISO 15609

(to be contd..)
10.2 Welding-procedure specifications
ISO 15609
 10.3 Qualification of the welding procedures
 Welding procedures shall be qualified prior to production.
 General
- Responsibilities and procedures for control
of welding consumables shall be specified.
Storage and handling
◦ procedures for storage, handling, identification and
use of welding consumables which avoid moisture
pick-up, oxidation, damage, etc.

◦ Identification
◦ Proper Storage to avoid damage & corrosion
◦ Separate place for Stainless Steel to avoid contamination
 The procedure shall be compatible with the parent
material, welded joint, construction, etc. and shall be in
accordance with the product standard and/or specified
requirements.
 A record of the heat treatment shall be made during the
process. The record shall demonstrate that the
specification has been followed and shall be traceable to
the particular product.
14.1 General
◦ Location and frequency of such inspections and/or tests
◦ Welding Inspection to be done in 3 stages.
 Before the start of welding, the following shall
be checked:
operators’ qualification certificates;
⎯ suitability of welding-procedure specification - WPS;
⎯ identity of parent material;
⎯ identity of welding consumables;
⎯ joint preparation (e.g. shape and dimensions);
⎯ fit-up, jigging and tacking;
⎯ any special requirements in the welding-procedure
specification (e.g. prevention of distortion);
⎯ suitability of working conditions for welding, including
environment.
During welding, the following shall be checked at
suitable intervals or by continuous monitoring:
⎯ essential welding parameters (e.g. welding current,
arc voltage and travel speed);
⎯ preheating/interpass temperature;
⎯ cleaning and shape of runs and layers of weld metal;
⎯ back gouging;
⎯ welding sequence;
⎯ correct use and handling of welding consumables;
⎯ control of distortion;
⎯ any intermediate examination (e.g. checking of
dimensions).
The ISO documents to which it is required to conform to
fulfil the quality requirements are specified in ISO 3834-
5:2005, Table 7, for arc welding, electron beam welding,
laser beam welding and gas welding, and in ISO 3834-
5:2005, Table 10, for other fusion welding processes.
After welding, the compliance with relevant
acceptance criteria shall be checked:
⎯ by visual inspection;
⎯ by non-destructive testing;
⎯ by destructive testing;
⎯ form, shape and dimensions of the construction;
⎯ results and records of post-weld operations (e.g.
post-weld heat treatment, ageing).

The ISO documents to which it is required to conform to fulfil

the quality requirements are specified in ISO 3834-5:2005,
Table 8, for arc welding, electron beam welding, laser
beam welding and gas welding, and in ISO 3834-5:2005,
Table 10, for other fusion welding processes.
 Measures shall be taken, as appropriate, to
indicate, e.g. by marking of the item or a
routing card, the status of inspection and
test of the welded construction.
 Measures shall be implemented to control
items or activities which do not conform to
specified requirements in order to prevent
their inadvertent acceptance.
 When repair and/or rectification is undertaken
by the manufacturer, descriptions of
appropriate procedures shall be available at all
workstations where repair or rectification is
performed.
 When repair is carried out, the items shall be
re-inspected, tested and examined in
accordance with the original requirements.
 Measures shall also be implemented to avoid
recurrence of nonconformances.
 appropriate calibration or validation of
measuring, inspection and testing equipment.
 All equipment used to assess the quality of
the construction shall be suitably controlled
and shall be calibrated or validated at
specified intervals.
 ISO 17662
Identification and/or traceability
• Documents
• Procedures
• parent material (e.g. type, cast
number);
• consumables ( batch no., test
certificate)
• location of repairs;
Quality records shall include, when applicable:
⎯ record of requirement/technical review;
⎯ production plan;
⎯ welding-procedure specifications; (WPS)
⎯ welding-procedure qualification records (WPQR);
⎯ welder or welding-operator qualification certificates;(WPQ)
⎯ equipment maintenance records;
⎯ NDT personnel certificates;
⎯ heat-treatment procedure specification and records;
⎯ DT & NDT procedures and reports;
⎯ material inspection documents;
⎯ welding consumable inspection documents;
⎯ dimensional reports;
⎯ records of repairs and non-conformance reports;
⎯ other documents, if required.
Quality records shall be retained for a minimum period of five years in
the absence of any other specified requirements.
EN 15085
EN 15085 - parts
Anyquestions
please?
Thank You