Codes, Standards & Safety.pptx

Mr. R.D.PennathurMr. R.D.Pennathur


CODES,

SAFETY

STANDARDS&


Codes & Standards

Welding Process Qualification

Mechanical Testing

Safe Practice

Stainless Steel Welding

Mr. R.D.Pennathur

CODES & STANDARDS

The 3 agencies generally identified in a code or standard:

The customer, or clientThe manufacturer, or contractor

The 3rd party inspection, or clients representative

Codes often do not contain all relevant data, but may refer to other standards

Mr. R.D.Pennathur

5 of 691

Standard/Codes/Specifications

Standards

Specifications

Examples:Plate, Pipe, Forgings,

Castings, Valves, Electrodes

Codes

Examples:Pressure vessels,

Bridges, Pipelines, Tanks


Welding is the most widely employed fabrication process in building of bridges, flyovers, automobiles, railways and loco-carriages, ships, machineries, power plant, refineries, petro-chemical plant, defense items, consumer products, etc.

Welding - The Major Process for Fabrication


Steel is the major material used for fabrication and construction and steel consumption considered a major index for the nations growth

India at present consumes about 60 million tons of steel every year, most of which is used for fabrication and construction activities.

For every ton of steel consumed, on average about 5 kg of weld metal is required to be deposited through different welding processes.

Welding ∝ Steel Consumption

Mr. R.D.Pennathur

MATERIALS OF CONSTRUCTION•All general engg.,

• Infrastructure,• Automotive,

•Shipbuilding, •Railways

Mild Steel, High Strength Low Alloy Steels

•Defense,•Penstocks for hydel plants High tensile steels

•Boilers and piping in thermal power plantsCreep resisting steels

•Light structures •Boats•Dairy Equipment• Buzz bars

Aluminium

•Chemical & Petrochemical Plant•Refineries,•Cryogenic plant,•Food processing,•Pharmaceuticals

Stainless steels - Austenitic

• Vessel, • Piping & Heat Exchangers in Chemicals & Food

Copper, Nickel and alloys, Titanium

Mr. R.D.Pennathur

CONCEPT OF QA & QC SOME DEFINITIONS

Quality- The totality of features and characteristics of a product or service that bear on its ability to satisfy stated and implied needs.

Quality Management- That aspect of overall management functions that determines and implement Quality System & Policy.

Mr. R.D.Pennathur

Quality System- The organisational structure, responsibilities, procedures, processes and resources for implementing Quality Management.

Quality Assurance- All those systematic actions necessary to provide adequate confidence that a product or service will satisfy given requirement for quality.

Mr. R.D.Pennathur

Quality Control- The operational techniques and activities that are used to fulfill requirements for quality.

Quality Document- All necessary papers required to produce Quality Product/Service duly approved by respective authorities.

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Quality Records- All necessary papers to demonstrate the achievement of required quality and the effective operation of the quality system.

Quality Plan- A document setting out specific quality practices, resources and sequence of activities relevant to a particular product, service contract or project.

Mr. R.D.Pennathur

QUALITY STANDARDS

Basic StandardsSpecifying general requirements with basic significance eg.Quality Management Systems, drawings & tolerances ISO 9000 ff, EN 4500 ff, ISO 17000 series

Special Basic StandardsSpecifying matters for several applications eg. Testprocedures, welding requirements materials ISO 3834

Special StandardsProduct or application standards eg. Pressure vessels, piping, railway cars ISO 16528, EN 1090, ISO/DIS 10721, EN 15085, 15085

Mr. R.D.Pennathur

QUALITY MANAGEMENT IN WELDING Basic Standard for QMS ISO 9001 -2000

Manufacturing

ISO 3834, EN 1011, ISO 5817 Personnel ISO 9606, EN 287, ISO 14731, ISO 14732

Procedures ISO 15607 – 15614

Testing and Inspection Personnel ISO 9712, EN 1289

Mr. R.D.Pennathur

WHAT IS ISO 3834? It is an international standard created by

welding professionals to guide the manufacturer in managing his welding fabrication process

It encourages a proactive, process orientated approach to managing and controlling welding product quality in a workshop or on site

It is also a Factory Control System to control activities for the manufacture of the product

ISO 3834 was developed to identify all factors that could affect the quality of welded product and which need to be controlled at all stages, before, during and after welding.

Mr. R.D.Pennathur

WHY ADOPT ISO 3834 WHEN WE HAVE

ISO 9001?

ISO 9001 is a comprehensive standard that lays down quality management system requirements for any organisation

ISO 9001 however, does not prescribe specific details for “special processes”. Welding is regarded as a “special process”.

ISO 3834 was developed to identify all factors that could affect the quality of welded product and which need to be controlled at all stages, before, during and after welding.

Mr. R.D.Pennathur

WHAT IS THE DEFINITION OF A MANUFACTURER?

ISO 3834 defines a manufacturer as ‘person or organization responsible for welding Production’

The Standard uses this term to describe any such organisation, including manufacturing organisations supplying welding services, either for new products or for repair and maintenance, as well as other organisations where the application of the requirements of ISO 3834 are relevant

A manufacturer may be involved in manufacture, fabrication, construction, repair or maintenance.

Mr. R.D.Pennathur

HOW DOES ISO 3834 LINK IN WITH ISO 9001?

• ISO 3834 does not replace ISO 9001 as a quality management system however it contains many attributes that will be important for a welding manufacturer, in both workshops and at field installation sites, seeking ISO 9001 certification

• Elements of ISO 9001 should be considered when implementing ISO 3834 quality requirements and seeking ISO 3834 certification

• The specific complementary elements of ISO 9001 are detailed in ISO 3834

Mr. R.D.PennathurAreas/aspects of improvement can be identified

Ensures focus on market needs

More competitive

Optimizes the manufacturing time

Reduction in cost, wastage & repairs

Measure of performance

Induce more organized way of thinking

Provide motivation

Recognition & customer confidence

BENEFITS OF ADOPTING ISO 3834 QUALITY ASSURANCE SYSTEM

Quality Assurance system

Mr. R.D.Pennathur

HOW MANY PARTS DOES ISO 3834 HAVE?

ISO 3834: 2005 “Quality requirements for fusion welding of metallic materials” consists of 6 parts:

ISO 3834-1:2005, Criteria for the selection of the appropriate level of quality requirements

ISO 3834-2:2005, Comprehensive quality requirements

ISO 3834-3:2005, Standard quality requirements ISO 3834-4:2005, Elementary quality requirements ISO 3834-5:2005, Applicable documentation (not

full title) ISO/TR 3834-6:2007, Guidelines on implementing

ISO 3834

Mr. R.D.Pennathur

ISO 3834-2 – COMPREHENSIVE QUALITY LEVEL

Applied to constructions in which the failure of welds may lead to total product failure with successive significant financial consequences and a major risk of human injury

The product may be subject to pronounced dynamic loading in addition to high static loading

Manufacture would require enhanced controls to avoid the occurrence of harmful imperfections

Mr. R.D.Pennathur

ISO 3834-3 – STANDARD QUALITY LEVEL

Applied to constructions in which the failure of welds could impair the intended use of the construction & the operational unit in which it forms a part.

The product would have a normal safety risk & the financial consequences would not be extreme.

Manufacture would be conventional without reliance of high performance materials & the production processes would be well established.

Mr. R.D.Pennathur

ISO 3834-4 – ELEMENTARY QUALITY LEVEL

Applied to constructions in which the failure of welds would not fundamentally impair the intended use of the constructions.

Failure would not be expected to have any adverse effects on the safety of people & would only have minor financial consequences.

The materials used would be simple as well as the manufacturing technique.


SELECTION OF WELDING QUALITY REQUIREMENT AS PER ISO:3834

Contract Welding Requirement

Quality Requirement

When quality system conforming to ISO

9001 is required

When quality system conforming to ISO 9001

is not required

Comprehensive quality requirement Use ISO 3834-2 Use ISO 3834-2

Standard quality requirement Use ISO 3834-2 Use ISO 3834-3

Elementary quality requirement Use ISO 3834-2 Use ISO 3834-4

Mr. R.D.Pennathur

HOW IMPORTANT ARE WELDING PERSONNEL?

A key feature of ISO 3834 is the requirement to ensure that people with welding responsibilities are competent to discharge those responsibilities

This is achieved by incorporation of another standard, namely, ISO 14731 “Welding coordination– Tasks and responsibilities”

The specifying of minimum requirements for personnel dealing with welding coordination and welding inspection personnel

Mr. R.D.Pennathur

THE HUMAN RESOURCE

Without an appropriate specific technical competence intended as a combination of knowledge, experience and attitude) no management system can be successful in the manufacturing of any product

A great importance has been entrusted to the Welding Coordinator, who has become the real “key element” around whom all the welding production process works.

Mr. R.D.Pennathur

ROLE OF THE RESPONSIBLE WELDING CO-ORDINATOR

The company shall nominate at least one Responsible Welding Coordinator ( RWC )

The RWC must be competent to make decisions and sign on behalf of the manufacturer.

The RWC must be authorized with the overall responsibility for monitoring welding activities as well as taking action when welding has not been correctly performed.

The RWC may also be responsible for the work of other welding co-ordinators in the in the same department / site.

RWC maybe to an individuals normal job title eg, Technical Manager, QC Manager, Production Manager etc.


ISO 14731 GRADATION OF RESPONSIBLE WELDING

COORDINATORS Three different levels of RWC are given. The selection of

RWC depends mainly on the variability and technical complexity of the welding procedures required

1 Grade 1 With Comprehensive Technical Knowledge as specified in ISO 14731 Evidence of experience in welding in similar product & process

IWEIWT

2 Grade 2 With Specific Technical knowledge as specified in ISO 14731 and experience of many years in welding in similar product & process

IWTIWS

3 Grade 3 With Basic Technical knowledge as specified in ISO 14731 and experience over many years in welding in similar product & process

IWSIWP

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MAIN RESPONSIBILITIES

Code compliance

Workmanship control

Documentation control

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PERSONAL ATTRIBUTESImportant qualities that good Inspectors are expected to have are:

Honesty Integrity

Knowledge Good communicator

Physical fitness Good eyesight

Mr. R.D.Pennathur

STANDARD FOR VISUAL INSPECTIONBASIC REQUIREMENTS

BS EN 970 - Non-destructive examination of fusion welds - Visual examination

Welding Inspection Personnel should:

• be familiar with relevant standards, rules and specifications applicable to the fabrication work to be undertaken

• be informed about the welding procedures to be used

• have good vision (which should be checked every 12 months)

Mr. R.D.Pennathur

WELDING INSPECTION Conditions for Visual Inspection (to BS EN 970)Illumination:• 350 lux minimum required• (recommends 500 lux - normal shop or office lighting)

Vision Access:• eye should be within 600mm of the surface• viewing angle (line from eye to surface) to be not less

than 30°

30°

600mm

Mr. R.D.Pennathur

WELDING INSPECTION Aids to Visual Inspection (to BS EN 970)

When access is restricted may use: a mirrored boroscope a fibre optic viewing system

Other aids: welding gauges (for checking bevel angles, weld

profile, fillet sizing, undercut depth) dedicated weld-gap gauges and linear misalignment

(high-low) gauges straight edges and measuring tapes magnifying lens (if magnification lens used it

should have magnification between X2 to X5)

usually by agreement}

Mr. R.D.Pennathur

WELDING INSPECTORS EQUIPMENT

Measuring devices: Flexible tape, steel rule Temperature indicating crayons Welding gauges Voltmeter Ammeter Magnifying glass Torch / flash light Gas flow-meter

Mr. R.D.Pennathur

WELDING INSPECTORS GAUGES

TWI Multi-purpose Welding Gauge

Misalignment GaugesHi-Lo Gauge

Fillet Weld Gauges

G.A.L.

S.T.D.

10mm

12m

m

16mm

3mm

6mm

9mm

5mm4m

m

L

G.A.L.

S.T.D.

10mm

12mm

16mm

3mm

6mm

9mm5mm

4mm

T

605040

0 1/4 1/2 3/41

05

1015

20

IN

MM

MM15

1/2MMIN

HI-

LO

Sin

gle

Purp

ose

Wel

ding

Gau

ge

1

2

3

4

5

6

Mr. R.D.Pennathur

WELDING INSPECTORS EQUIPMENT

Tong Tester

AmmeterVoltmeter

Mr. R.D.Pennathur

WELDING INSPECTION Stages of Visual Inspection (to BS EN 970) Extent of examination and when required

should be defined in the application standard or by agreement between the contracting parties

For high integrity fabrications inspection required throughout the fabrication process:

Before welding (Before assemble & After Assembly) During welding After welding

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BEFORE WELDING

Preparation: Familiarisation with relevant ‘documents’…

Welding Procedures Welder Qualifications Equipment: Materials Consumables Weld Preparations Welding Equipment Fit-up Pre-heat

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DURING WELDING Weather conditions

Welding Process(es)

Welder

Pre-heat (if required)

Welding consumables

Welding Parameters

Root runs

Inter-run cleaning

Distortion control

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AFTER WELDING

Weld Identification

Visual Inspection

Dimensional Survey

Other NDT

Repairs

Pressure / Load Test

Documentation

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SUMMARY OF DUTIES

A Welding Inspector must: Observe

To observe all relevant actions related to weld quality throughout production.

RecordTo record, or log all production inspection points relevant to quality, including a final report showing all identified imperfections

CompareTo compare all recorded information with the acceptance criteria and any other relevant clauses in the applied application standard

It is the duty of a Welding Inspector to ensure all the welding and associated actions are carried out in accordance with the specification and any applicable procedures.

Mr. R.D.Pennathur

We are one of the renowned manufacturers of various grades of welding consumables which are second to none in terms of quality. We have the most modern manufacturing facility equipped with latest sophisticated machinery at Pondicherry, IndiaWe are manufacturing a vast range of Shielded Metal Arc Welding Electrodes and Flux Cored Arc Welding Electrodes. We also supply tested GMAW and GTAW welding consumables for all the applications.Our hardworking team would always be interested in any opportunity to cater your requirement of welding consumables.Currently we are supplying massive quantity of welding consumables to many world class EPC companies in various range of welding consumables including Carbon steel, Low Temperature Carbon Steel, Stainless Steel, Low alloy steel etc. If at all the need arises for a special consumable which is not in our arsenal, our R&D team is fully equipped in developing special electrodes to meet Service Requirements, Impact Test Requirements with strict chemistry controls and as welded hardness test criteria.We built quality and consistency in our consumables. Our manufacturing facility always had the market pulse to meet its demands and fast track delivery requirements without compromising quality and consistency.Willing to be a part of your esteemed organization, we took this privilege to approach and request your kind consideration for providing opportunity to MAILAM INDIA LTD for the following consumables.

Codes, Standards & Safety.pptx

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