INTERNATIONAL TRAINING INSTITUTE For the Sheet · PDF fileD15.1 AWS D15.1, Railroad Welding...

“Printed versions of this document are uncontrolled” INTERNATIONAL TRAINING INSTITUTE QUALITY ASSURANCE MANUAL APPROVED BY: QA TEAM

PAGE 1 of 50 ISSUE DATE: 8/10/98

LEVEL THREE REV. DATE: 1/1/10

INTERNATIONAL TRAINING INSTITUTE For the

Sheet Metal and Air Conditioning Industry

LEVEL THREE

This Level Three document applies to the training, education, and certification of welders who are members of the Sheet Metal Workers’ International Association (SMWIA).




TABLE OF CONTENTS

EXB# TITLE DESCRIPTION REVISION DATE PAGE #

Title Page Level Three Title Page 4/8/2003 1

Table of Contents Level Three TOC 4/8/2003 2-3

1* Lab Check List & Maintenance Log

Pre-Test Checklist 1/1/2009 4

2 WAIT Video 19 Min. Video Original 5

3 Method Sheet Test Procedure Description Original 6

4 Application (deleted 11/20/04) AWS Certification deleted 11/20/04

5* Routing Sheet (Front/Back) Step By Step Testing Procedures 1/1/2009 7-8

6* Destructive Testing Check List Step By Step Coupon Procedures 4/29/2000 9

7* Verification Form Welder Practice, Training Form 4/29/2000 10

8* CWI Status Verification Copies of CWI’s wallet card or Certificate Sample 11

*** Exhibits 9 and 10 have been deleted from the Quality Assurance Manual

11 AWS Maintenance of Certification (Renewals) 1/1/2009 12

12 Accreditation Procedure Procedures for Facility Certification 1/1/2009 13 - 14

13* Accreditation Application ATF Application For Facility Accreditation 1/1/2009 15

13A Self Audit Confirmation Annual ATF Renewal 1/1/2009 16 - 17

14 TS/WS Training Course Supervisor Training Content & Schedule Sample 18 - 19

15 Assessor Flow Chart ITI Assessors Flow Chart 1/1/2009 20

16 ATF Flow Chart Accredited Test Facility Flow Chart 1/12/2009 21

17 Welding Program Contacts Welding Contacts 1/1/2010 22

18 Audit Plan Audit Sequence AWS Document 23

19* On Site Audit Check Lit Assessment Questionnaire AWS Document 24 - 36

20 All Audit Reports Results of Assessment AWS Document 37

21** All CAR Corrective Action Request AWS Document 38




TABLE OF CONTENTS CONT.

EXB# TITLE DESCRIPTION REVISION DATE PAGE #

Exhibits 22 thru 24 have been deleted from the Quality Assurance Manual

25 Job Description for WS/TS & FR

ATF Personnel Job Descriptions 1/1/2010 39

26 QAM History Log Revision Log 1/1/2010 40

27 Equipment Maintenance Record A Check Off Sheet To Track Equipment Maintenance 4/29/2000 41

28 WS On-Site Audit Check List WS Assessment Questionnaire 4/8/2003 42 - 50

* MUST BE A PART OF THE QUALITY RECORDS RETAINED. (Consult Level Two Section 16.01, for exact time these records must be retained.)




EXHIBIT #1 *

LAB CHECK LIST AND MAINTENCE LOG

LOCATION____________________________________________ DATE _________________

1. Safety equipment available.

2. Welding and cutting equipment in accordance with ITI QA Manual.

3. Ventilation.

4. Welding consumables and materials have been properly stored in accordance with ITI QA Manual.

⋅ Base Metal MTR’s

⋅ Electrodes Traceability

⋅ Gases

5. Check test equipment for current calibration tag.

Meter ID#:________________________ Meter Calibration Expiration Date:______________________

6. Code, Proper Standard, or Specification

7. Written test

8. WPS

9. Visual calibration inspection of measuring equipment.

TEST SUPERVISOR SIGNATURE ______________________________________________________ COMMENTS:




EXHIBIT # 2

WAIT VIDEO

This video is part of your orientation if you decide not to use the Method Sheet. Total run time is 19 min



LEVEL THREE REV. DATE: Original

EXHIBIT # 3

METHOD SHEET

INFORMATION ROUTING SHEET

Describe the step-by-step instructions and Hold Points on Routing Sheet. Review the WPS. ASK THE TEST SUPERVISOR (TS) ANY QUESTIONS you may have pertaining to the weld test. Passing a mandatory hold point is an automatic failure. You must have the approval and initialing of the TS at every hold point on the routing sheet. NO EXCEPTIONS!

WELDER IDENTIFICATION

Make sure the TS has all the correct information needed to complete paperwork and mark test coupon. SAFETY EQUIPMENT

You are required to use and wear proper safety equipment. POWER TOOLS

In some situations, power tools such as power grinder, power brush and power chipper is not allowed in the test booth. However, hand tools such as files, chisels, chipping hammer, wire brush and flashlight will be allowed. Check with TS before starting.

POWER SOURCES

All welding machines shall be set at zero or minimum setting prior to testing. PRACTICE MATERIAL

Reasonable practice time will be allotted. All practice material will be furnished. TACKING

Tacking of coupons may be done in any position. CLEANING

All in process welding and cleaning must be done in the test position. REMOVAL

Do not remove test coupon from test position without all hold points initialed and the TS’s approval.



LEVEL THREE REV. DATE: 1/1/09 Make as many photocopies as needed.

EXHIBIT # 5 *

ROUTING SHEET Test Supervisor’s Testing Instructions (For use during testing)

WPS # _________ WELDERS NAME ________________________________________ IA#__________________________

DATE __________ LOCAL # /CITY _________________________________________ SSN#__________________________

HAVE Y0U RECEIVED YOUR ORIENTATION? YES ______ NO ______

PREPARING COUPONS ARE THE WELDERS RESPONSIBILY NOTE: Place Thickness Material, and Position Tested on the Diagonal Line. (EX. 10ga SS-4G)

HOLD POINT #1 A. Proper safety equipment

B. Proper tools C. Proper consumables per WPS D. Machine setting zero or minimum setting

E. Coupons size cleaned and degree of bevel correct F. Proper backing if applicable G. Test coupons marked with proper identification

TEST SUPERVISOR initials

HOLD POINT #2 A. Set welding machine per WPS requirements – Amps: ________ B. Practice time Volts: _________ TEST SUPERVISOR initials

HOLD POINT #3 A. Fit up inspection of test coupons BEFORE TACKING TEST SUPERVISOR initials

HOLD POINT #4 A. Tack weld test coupon B. Fit up inspection of test coupon AFTER TACKING C. Position test coupon per WPS. TEST SUPERVISOR initials

HOLD POINT #5 A. Root pass TEST SUPERVISOR initials

HOLD POINT #6 A. Fill pass TEST SUPERVISOR initials

HOLD POINT #7 A. FINAL VISUAL TEST SUPERVISOR initials

Visual Acceptable (YES/NO)

Photo ID: YES_____ NO______ Power Tools Used: YES_____ NO______

Knowledge Test: YES_____ NO______ Score: ______ Eye Correction Used: YES_____ NO ______ Reading Glasses ________ Cheaper: ________ Prescription:________ Test Supervisor’s Signature: _____________________________________________________

I have reviewed and understand my test records limitations.

Welder’s Signature: ___________________________________________________________

Notes: _______________________________________________

_____________________________________________________

_____________________________________________________

Base Metal 1 Heat#:______________ Base Metal 2 Heat#:______________ Filler Metal 1: ___________________ Filler Metal 2:____________________ Shielding Gas:____________________


PAGE 8 of 50 LEVEL THREE PAGE 8 OF 50

EXHIBIT #5* ISSUE DATE: 8/10/98REV. DATE: 11/20/04

Make as many photocopies as needed.

GUIDE TO INTERPRETING ABBREVIATIONS ON AWSCERTIFIED WELDER CARD

EXAMPLE:

AWS Supplements Filler MetalC Sheet Metal Welding (AWS D9.1) (AWS CLASSIFICATION NUMBER)F Chemical Plan and Petroleum Piping ER309-L

(ASME B31.1 and Sec. IX) E7018-A1G Generic Supplement (Company-furnished ER70X-2

WPS) E71T-1

Codes (For Supplement G only, reference Base MetalAcceptance criteria.) AXXX ASTM Designations (I.e., A36)

M Material Numbers from B2B2.1 AWS B2.1, Standard for Welding Procedure SAXXX (SA106, SA105, SA304L, etc.)

And Performance Qualification PX (P1, P8, P44, etc.)D1.1 AWS D1.1, Structural Welding Code-SteelD1.2 AWS D1.2, Structural Welding Code -

Aluminum PositionD9.1 AWS D9.1 Sheet Metal Welding Code 1G Groove Weld, FlatASME IX ASME Section IX, Qualification Standard for 2G Groove Weld, Horizontal

Welding and Brazing Procedures, Welders, 3G Groove Weld, VerticalBrazers, and Welding and Brazing Operators 4G Groove Weld, Overhead

ASME ASME B31.3, Process Piping 5G Groove Weld, (Pipe) VerticalD15.1 AWS D15.1, Railroad Welding Specification- 6G Groove Weld, (Pipe) 45 deg. Vertical

Cars and Locomotives 1F Fillet Weld, FlatAPI API 1104, Welding of Pipelines and Related 2F Fillet Weld, Horizontal

Facilities 3F Fillet Weld, Vertical4F Fillet Weld, Overhead

Processes U Vertical Progression UpSMAW Shielding Metal Arc Welding (SMAW) D Vertical Progression DownGMAW Gas Metal Arc Welding (GMAW)GMAW-S Gas Metal Arc Welding - Short Circuit ThicknessFCAW Flux Cored Arc Welding (FCAW) U Unlimited (1/8 " to Unlimited)GTAW Gas Tungsten Arc Welding (GTAW) L LimitedSAW Submerged Arc Welding (SAW) xx-xx Range in sheet gauges (i.e., 11 - 18)BZ Brazing x/x Thickness in fractions of an inch (i.e.

3/8")SCH Schedule listing for pipe thickness

Gas WB With backingAR Argon WOB Without backing75-25 75% Argon 25% Co2

G D1.1 A36SMAW E7018 3/8"3G - 4G

Supplement Filler M etal ThicknessBase M etal Posit ionProcessCode



LEVEL THREE REV. DATE: 11/20/04 EXHIBIT # 6 *

Destructive Testing Check List

WPS # SSN

WELDERS NAME IA #

SPECIMEN REMOVAL (Preparing of test specimen is the responsibility of the Welder)

A. Locate coupon layout and preparation standard for test per applicable Code, Standard orSpecification (i.e. D1.1, ASME IX etc.)'

B. Transfer welder's identification per QA MANUAL and QC-4 3.7C. Grind specimens to meet the requirements of the Applicable Code, Standard or

Specification D. Check for longitudinal proper grind directionE. Maintained specimen thicknessF. Radius edge specimen to meet the Applicable Code, Standard or SpecificationG. Polish to proper finish (80 Grit or Finer)

Test Supervisor's Initials SPECIMEN BENDING

A. Check bending dies for calibrationB. Determine bend direction and bend specimen

Test Supervisor's Initials BEND SPECIMEN INSPECTION

A. Locate bend specimen acceptance criteria per Applicable Code, Standard or SpecificationB. Apply criteria to specimens using proper scales or other measuring devisesC. Test Supervisor may use magnification as needed

Test Supervisor's Initials X Indicates Acceptable

Root Bend1G ____

1G ____

2G ____

2G ____

3G ____

3G ____

4G ____

4G ____

5G ____

5G ____

6G ____

6G ____

Face Bend ____ ____ ____ ____ ____ ____ ____ ____ ____ ____ ____ ____

Side Bend ____ ____ ____ ____ ____ ____ ____ ____ ____ ____ ____ ____

Test Supervisor DATE

Comments




EXHIBIT # 7 *

WELDER RETEST PRACTICE AND/OR TRAINING VERIFICATION FORM I hereby verify that ________________________________ has met the requirements of ______________________________

(Welders Name) (Applicable Code) concerning welder/operator re-testing. Date of Training: ______________________________________________

Trainer Signature: ______________________________________________

Comments: ______________________________________________________________________________________

______________________________________________________________________________________

______________________________________________________________________________________

______________________________________________________________________________________

______________________________________________________________________________________

______________________________________________________________________________________

______________________________________________________________________________________



LEVEL THREE REV. DATE: Sample

EXHIBIT # 8 *

CWI Status Verification




EXHIBIT # 11 *

Procedure for Renewing an AWS Welder Certification

1. The WS, TS, or FR must verify the dates for the maintenance of certification. 2. The WS, TS, or FR must then enter the maintenance dates into the ITI Database.

a. This is done by logging into the ITI Welding Database and going to WQTR Renewals b. Enter the Welder’s SS# c. Enter his renewal date and check the process he is renewing (Note: you may renew more than

one process at a time as long as the dates are the same.) d. Click “Renew at the Bottom of the page.

3. The WS, TS, or FR must then print out the AWS Welder Maintenance form from the ITI Welding

Database (found in the References part of the website), fill it out and forward it to the AWS along with the appropriate payment. The cost of maintenance is $10.00 per person per form.

Any ATF not forwarding the forms and payment to the AWS may have their accreditation revoked!!




EXHIBIT # 12 *

TEST FACILITY ACCREDITATION

1.0 PURPOSE To define ITI’s Process for Requesting Initial Test Facility Accreditation.

2.0 APPLICATION

Applies to all test facilities under the ITI program. 3.0 PROCEDURE

3.1 INFORMATION The forms necessary to make application for Test Facility Accreditation may be obtained from Exhibit 13.

3.2 APPLICATION

An application for accreditation will be made by completing the appropriate ITI form and submitting them to the ITI main office with CC to ITI ASSESSOR. Accreditation will be granted only for those Supplements and Welding Procedure Specifications of AWS QC-7 for which the Test Facility has demonstrated the capacity to conduct the required qualification function, i.e. welding and testing. Accreditation is granted for a one-year period.

3.3 ON-SITE ASSESSMENT The QA Manager shall designate the ITI ASSESSOR to perform on-site assessments. Assessments may take from one to several days.

3.4 CHECKLIST ITI ASSESSORS use an audit plan (Exhibit 18) and checklist (Exhibit 19) to follow when performing an assessment. These documents are intended to ensure that assessments are conducted as uniformly and completely as possible among the ITI ASSESSORS from Test Facility to Test Facility. The assessment generally involves:

A. An entry briefing with Test Facility management B. Review of quality assurance system manual C. Interviews with staff D. Observation of selected tests E. Examination of equipment and calibration records F. An exit briefing of assessor findings

3.5 OBJECTIVES

The objective of an assessment is to establish whether a Test Facility complies with the AWS criteria for accreditation and the requirements within the ITI QA Manual. ITI ASSESSORS may provide advice in response to questions or on the basis of observations in order to provide help to improve the Test Facility’s potential of being in compliance.




EXHIBIT # 12 *

TEST FACILITY ACCREDITATION (CONT.)

3.6 ASSESSMENT REPORT At the conclusion of an assessment, the ASSESSOR will prepare a report of findings, identifying deficiencies (i.e., deviations from the criteria and test method procedures for which accreditation is requested) which, in the opinion of the ASSESSOR, the Test Facility must correct in order to be accredited. After the exit briefing , the FACILITY REPRESENTATIVE is asked to sign the deficiency report to attest that he has reviewed the deficiency report with the ASSESSOR. If any deficiencies are noted on the deficiency report, the Test Facility is requested to respond within 30 Days of the date of the exit briefing. In the event that the Test Facility disagrees with the ASSESSOR's findings, the Test Facility is requested to

write to the ITI explaining why it disagrees with the ASSESSOR. SUBMITTAL The Assessors report, communications from the Test Facility, and other information from the application is to be submitted to the QA Manager.

3.7 GRANT If accreditation is granted, the ITI office shall prepare and forward a certificate of accreditation to the Test Facility.




EXHIBIT # 13 *

APPLICATION TO BECOME AN ACCREDITIED TEST FACILITY Mail Application to ITI Main office ATTN: Michael T. Harris

CC: Regional Assessor

DATE: ___________________________ TO: International Training Institute

601 North Fairfax Street Suite 240 Alexandria, Virginia 22314

ATTENTION: MICHAEL T. HARRIS We request the International Training Institute (ITI) to accredit the following facility as a participant in the Certified Welder Program in accordance with the provisions of AWS QC 4-89 Standard for Accreditation of Test Facilities for the ITI Certified Welder Program. NAME OF FACILITY: ______________________________________________________________________

STREET ADDRESS: ______________________________________________________________________

CITY, STATE, ZIP: ______________________________________________________________________

PHONE NO: ______________________________________________________________________

FAX NO: ______________________________________________________________________

PREFERED ASSESSMENT DATES: 1)______________________ 2)_______________________

3)______________________ 4)_______________________

SIGNATURE: _______________________________________________________________________________

NAME (PRINT): _______________________________________________________________________________

TITLE: _______________________________________________________________________________

CC: Regional Assessor




EXHIBIT # 13A *

SELF AUDIT CONFIRMATION

Send Confirmation to ITI Assessor

We have completed the required annual self-audit in accordance with the provisions of AWS QC 4-89 Standard for Accreditation of Test Facilities for the ITI Certified Welder Program:

No changes

Changes Attached (send appropriate sheets from Audit Checklist).

NAME OF FACILITY: ______________________________________________________________________

STREET ADDRESS: ______________________________________________________________________

CITY, STATE, ZIP: ______________________________________________________________________

PHONE NO: ______________________________________________________________________

FAX NO: ______________________________________________________________________

EMAIL: __________________________________________________________________________ Test Supervisor: ________________________ __________________________ ________________________ ________________________ __________________________ ________________________ ________________________ __________________________ ________________________ Welding Supervisor: ______________________________________ Audit conducted by: Name (print): ______________________________ Signature: __________________________Audit date: ____________ Audit accepted by: Facility Representative (print): ______________________________ Signature: ___________________________Date: ____________ ITI Assessor:___________________________________ Approval date: ___________________ Attach a copy of Quality Records retained for welder tested since last audit (per Level Two Section 16.01), a copy of calibration records, and proof of current CWI status. (See the following page for procedures on how to perform your self audit and for the proper records to send to your assessor)



LEVEL THREE REV. DATE: Original

EXHIBIT # 13A (CONT.)

SELF AUDIT Procedure and Checklist

For ATF Facility Representatives

The following is a list of steps to follow and documents that you must submit to your ITI Welding Assessor in order to complete the self-audit requirement of the QA Manual.

1. Review your audit checklist from the last audit and make any changes that are necessary (If anything has changed since your last audit).

2. Fill out Exhibit 13A of the QA Manual), this form must be completely filled out and returned to your ITI Welding Assessor.

a. If their have been no changes to your audit checklist since the last audit, simply check “No Changes” on Exhibit 13A.

b. If their have been changes to your audit checklist since the last audit, check the box “Changes Attached” and send the appropriate corrected pages from your audit checklist to your ITI welding Assessor.

3. Send copies of all Test Supervisors’ current CWI cards or certificates. 4. Send copies of the current Volt/Amp meter Calibration certificate for all of the meters used in your ATF. 5. You must send in all Quality Records for one welder tested since the last audit. If you have not tested any

welders since the last audit, please write “No Welders Tested” at the bottom of Exhibit 13A. The quality records include but are not limited to the following:

a. Lab Sheet. b. Routing Sheet. c. Destructive Testing Checklist (If Applicable) d. Volt/Amp Meter Calibration Records for the given certification test. e. Purchase Orders and MTRs for all base material and filler material use for that test. f. Copy of the Written test that was given to the welder.

Please follow these steps and send all appropriate documents to your ITI Welding Assessor 30 days prior to your expiration date as per the QA Manual. If you have any questions regarding this process, please feel free to call your ITI Assessor.




EXHIBIT # 14

SAMPLE


of 50Issue Date: 8/1/98Rev Date: 1/1/09

ASSESSORFLOW CHART

Provides assessment ofcompliance to quality

system

Level ThreeEXHIBIT # 15

Headquarters Operation

Provides assessment of compliance to quality system

ITI ExecutiveAdministrator

ITI Administrator

of Training

AWS

QAT

ITI Assessor

ATF

ATF Welding Supervisor Contractors




EXHIBIT # 16

Records

WSQuality PQR's & WPS's

iTi ATF (Assessors)

ATFPerformance Test

& Maintenance

iTi

AWS

Computer Data

ATF(Keep Original records)

Maintenance to AWS




EXHIBIT # 17

WELDING PROGRAM CONTACTS

Steve Kowats – QA Manager/ ITI Welding Assessor (MAIN Contact) Phone: (703) 624-0892 Email: [email protected] Michael Sloan –ITI Welding Assessor Phone: (703) 623-5814 Email: [email protected] George Donovan –ITI Welding Assessor Phone: (703) 627-2720 Email: [email protected] Michael Miller –ITI Welding Assessor Phone: (703) 626-8773 Email: [email protected]

“Printed versions of this document are uncontrolled” INTERNATIONAL TRAINING INSTITUTE QUALITY ASSURANCE MANUAL APPROVED BY: QA TEAM PAGE 23 of 50

ISSUE DATE: 8/10/98 LEVEL THREE REV. DATE: AWS DOCUMENT

EXHIBIT # 18

Audit Plan Audit Plan # _________

Date of this Plan _________

Facility to be Audited

Purpose/Scope

Determine compliance with: • AWS QC4-89 Standard for Accreditation of Test Facilities for AWS Certified Welder Program • AWS QC7-93 Standard for AWS Certified Welders • ITI Quality Assurance Manual

Anticipated Documents and References to be Audited

Period Since Last Audit

Assessor

Personnel To Be Notified

Date and Time of Audit

Personnel (expected involvement)

Reporting Requirements (copies to)

Reporting Schedule

It is the responsibility of the manager to provide feedback on the results of this audit to the personnel having responsibility in the area assessed.



LEVEL THREE REV. DATE: AWS DOCUMENT

EXHIBIT # 19

On Site Audit Checklist

TEST FACILITY ______________________________________________________________

TEST FACILITY NUMBER _____________________________________________________

TEST FACILITY REPRESENTATIVE ____________________________________________

ADDRESS ___________________________________________________________________

PHONE NO FAX. NO. _________________________________________________________

EMAIL ______________________________________________________________________

ASSESSOR DATE ____________________________________________________________

PERSONNEL INTERVIEWED __________________________________________________

Part I – Procedures

1. Please describe the procedure for procurement of materials including filler metals. ______________________________________________________________________

a. Is there a purchase order on file? b. Does the P.O. require material test reports on base metal and certificates of conformance on filler metals? c. Is the material and certifications checked on receipt? d. Are the mill test reports and certificates of conformance on file?

Rev 02/28/03




EXHIBIT # 19

2. Please describe the initial discussions with candidate certified welders.

a. Is a sample application available? b. Is it filled out so that is may be used as a sample? c. Is the welder advised of the testing procedures including safety rules, fit up tolerances, and

testing requirements?

3. Please describe the procedure for traceability of materials. Begin with use of certified materials through welding of test coupons and visual examination, mechanical or radiographic testing, and recording of results.

Rev 02/28/03




EXHIBIT # 19

a. Is the candidate welder assigned an identification code? How?

b. Is the identification code recorded on the coupon and the paper work?

c Does the Test Supervisor verify that certified materials are used? How?

d. Are the test materials identification recorded on the test records?

e. Is the welder identification code transferred to the bend specimens?

f. Is the identification code shown on the x-ray film when radiography is used?

Part II – Personnel

1. Are the inspection and testing services of the Test Facility under the authority of a FR?

2. Are the Test Supervisors employees or contractors?

3. Are they currently certified as CWI’s under AWS QC 1?

4. Who are the Test Supervisors and what are their Certificate numbers?

5. If radiography is used, are the NDE personnel employees or contractors?

6. Is ASNT Recommended Practice SNT-TC-1A followed in the qualification of NDE personnel?

7. Is the film interpreter a Level II in accordance with SNT-TC-1A?

Rev 02/28/03




EXHIBIT # 19

8. Are job descriptions or job duties available for the Facility Representative, the Test Supervisors, QA

Manager, and Test Technicians and NDE Personnel?

9. Are there sufficient staff to assure adequate supervision?

10. Who performs function of “Quality Assurance Manager?

Part III – Operations

1. Are written instructions and sketches available for the candidate to use in fitting the test assembly?

2. Is the fit up inspected prior to welding? How is it documented?

3. Are the Welding Procedures available for use by the candidate?

4. Are written procedures or checklists available for preparation and inspection of bend specimens?

5. Are radiographic acceptance criteria available to the x-ray interpreter?

6. Are the results of the bend test or film interpretation recorded on the test records?

7. Does the welders file consist of:

a. The welders initial application.

b. The material withdrawal form.

c. The bend test report or the radiograph and the radiographers report.

Rev 02/28/03




EXHIBIT # 19

d. The Performance Qualification Test Record.

8. Will welders be tested off site?

9. If welders are to be tested off site, have written procedures or checklists been prepared?

10. If welders are to be tested off site is it covered in the QA manual?

11. If off-site-bend test are being performed are the requirements of Section I and II being met.

Part IV – Reference Documents 1. Does the Test Facility maintain a library?

2. Are there current copies of applicable Welder Qualification Codes available?

3. Does the library contain the following: (Please check ones you have)

WELDING CODES AND SPECIFICATIONS

AWS D1.1 Structural Welding Code-Steel

AWS D1.2 Structural Welding Code-Aluminum

AWS D1.3 Structural Welding Code-Sheet Steel

AWS D1.6 Structural Welding Code – Stainless Steel

AWS D9.1 Welding of Sheet Metal

AWS D10.9 Qualification of Welding Procedures and Welders for Piping and Tubing Specifications

Rev 02/28/03




EXHIBIT # 19

AWS B2.1 Welding Procedure and Performance Qualification Standard

AWS B2.1.005 Standard WPS for GMAW of Austenitic Stainless Steel

AWS B2.2 Brazing Procedure and Performance Qualification Standard

ASME Sec IX Qualification Standard for Welding and Brazing Procedures, Welders, Braziers and Welding and Brazing Operators

ASME B31-1 Power Piping

ASME B31-2 Fuel Gas Piping

ASME B31-3 Chemical Plant and Petroleum Refinery Piping Others

MECHANICAL TESTING

AWS B4.0 Mechanical Testing of Welds, Standard For Mechanical Tests for Welded Joints.

QUALIFICATION AND CERTIFICATION * AWS QC 1 Standard for Certification of Inspectors & Supplements

* AWS QC4 Standard for Certification of Accredited Test Facilities

* AWS QC7 Standard for Certification of Certified Welders

* ITI QAM International Training Institute Quality Assurance Manual SAFETY AND HEALTH * ASC Z49 Safety in Welding and Cutting

Mandatory Documents Other Documents Available (Specify) Rev 02/28/03




EXHIBIT # 19

Part V – General

1. Does the Test Facility do testing for any other organization?

2. Are there written procedures or checklists to engage outside Test Supervisor (CWI)?

3. What are the CWI Certification Nos.?

4. Are their training programs to maintain and improve skills?

5. Is Test Facility involved in training welders?

6. Does management review QA Program on a routine basis? If yes, how often?

7. Who is responsible for review?

8. Is the welder informed that he may use his own torch, tools, or other related accessory equipment?

Part VI – Welding Tests 1. Does the Test Supervisor have a checklist for the set-up and administration of the welding test?

2. Are WPS’s posted in the work area or otherwise available to the welder?

3. Is safety equipment verified?

Rev 02/28/03




EXHIBIT # 19

4. Is eye correction verified? Is the type recorded? 5. Is fit-up verified? 6. How do you verify that the test plates are not repositioned without approval?

Part VII – Welded Test Assembly Handling 1. Are written procedures or other methods available to define the visual inspection criteria to be applied to

test assemblies? 2. Are written procedures or other methods available to define the steps and examinations to be performed

to comply with the Supplements? 3. Are nondestructive test methods controlled by written procedure? 4. Are contracted nondestructive testing methods properly defined in purchase orders to assure accurate

testing and the application of the proper acceptance standards? 5. Are sketches, drawings, etc. used to define the steps in performing the cutting, and preparation of

destructive testing (bends, nick-breaks, etc.?) 6. Is there proper documentation as to the disposal of test specimens? 7. Are nondestructive technicians trained, tested, and certified to SNT-TC-IA? 8. Is there a written practice for qualification of in-house or subcontract NDE technicians? Rev 02/28/03




EXHIBIT # 19

Part VIII – Final Disposition 1. What records are placed in the welder’s file? 2. What records are forwarded to AWS Q&C Department?

Part IX –Welding Equipment and Controls 1. SMAW

a. Number of units b. Number of AC c. Number of DC d. Number of AC/DC

2. GMAW a. Number of units b. Number of pulse GMAW

3. GTAW a. Number of units b. Number of AC HF c. Number of DC d. Number of AC/DC

4. FCAW a. Number of units

5. Other processes – (list each) Rev 02/28/03




EXHIBIT # 19

Part X – Cutting Equipment 1. OFC

a. Number of stations b. Type fuel gas utilized

2. CAC a. Number of units

3. PAC a. Number of units

4. Mechanical cutting a. Mechanical b. Milling Machines c. Angle grinder d. Lathe e. Other equipment (list each)

Part XI – Measuring & Testing Equipment 1. Measuring/Testing item – (For each item of equipment used in welder qualification, the following

information shall be provided). a. Is a maintenance procedure or schedules established?

b. Is maintenance log up to date?

c. Does equipment appear abused?

d. Are proper equipment records maintained?

Rev 02/28/03




EXHIBIT # 19

i. Is equipment identified?

ii. Does it have a calibration tag (if required volt/amp etc,)?

iii. Are operating manuals available? (example Power Sources, volt/amp meter and etc.) e. Are calibration methods defined?

2. Bend Testing Equipment

a. Wrap-around fixture?

b. Die & plunger fixture?

b. Adjustable radius fixture?

3. Other Testing Equipment

a. Fillet break/nick break fixture?

b. Tensile test machine?

c. Impact Testing Machine

d. Other Testing Equipment

4. Other measuring equipment available:

(Check all available) a. Tape measure b. Micrometers c. Calipers d. Scales e. Optical aids f. Fillet weld gauge g. Weld reinforcement gauge h. Hi-Low gauge i. Under-cut gauge j. Protractor

Rev 02/28/03




EXHIBIT # 19

5. Does facility perform any chemical tests?

a. Mass spectrometer analysis? b. Wet chemical method? c. Macro etch? d. Are written procedures available?

6. If the above tests are performed, are the applicable standards form AWS, ASME and ASTM available

for control of procedures?

Part XII – Records and Test Reports 1. Are written procedures on file for record retention?

2. Are records retained for the 5-year requirement per ASWQC-4-89?

3. Are records secured?

Rev 02/28/03




EXHIBIT # 19

ASSESSORS SUMMARY Accredited Test Facility:______________________________________________________________

Date:______________________________________________________________________________

Facility Representative:_______________________________________________________________

Assessor:___________________________________________________________________________

Total Findings:_______________________________________________________________________

Total Concerns:______________________________________________________________________

Total Deficiencies:____________________________________________________________________

See attached Audit Report for details on Findings, Concerns and Deficiencies. _______________________________ _________________________________ ASSESSOR: Date ________________________________ _______________________________ FACILITY REPRESENTATIVE: Date Rev 02/28/03




EXHIBIT # 20 WS Report

Audit # ________________ Date of this Report ________________

Remote Testing Location Audited

Purpose

Determine compliance with: • AWS QC4-89 Standard for Accreditation of Test Facilities for AWS Certified Welder Program • AWS QC7-93 Standard for AWS Certified Welders • AWS QC7-93 Supplement G • ITI Quality Assurance Manual

Date and Time of Audit

Date of the last audit or period since last audit

Auditor (report by)

Personnel Involvement During Audit

Documents and References reviewed during the audit

Reporting Requirements (copy to)

FR TS ON FILE

It is the responsibility of the Welding Supervisor to provide feedback on the results of this audit to the personnel Having responsibility in the area assessed.

AUDIT SUMMARY

COMMENDATIONS:

CONCERNS:

FINDINGS:




EXHIBIT # 21

Corrective Action Request (CAR) Part #1 (Completed by Welding Assessor/ WS, add appropriate paragraph reference if known.)

Description of Condition:

Signature: /s/ Date:

Notes: All listed potential test supervisors have been examined for this certification and await results

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Part #2 (Completed by the Test Supervisor, response received completed by Certification Director)

Date Received: Responsibility: CAR # Response Due Date: Response Received:

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Part #3 (Completed by the Test Supervisor by the response due date.)

Probable Root Cause of Condition (or sources of information for a preventative action):

Action to Prevent Recurrence (determination of steps necessary to prevent a potential problem):

This recommended action is by: Scheduled Completion Date:

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Part #4 Corrective Action Closeout (Completed by the Welding Supervisor)

The corrective action has been completed (controls have been effective to prevent): Comments Completion Date:

Further Verification needed? ________ Verification Date: ____________ After 'x' cycles?

Signature: Closure Date:

Copy to originator of closed out CAR Date:




EXHIBIT # 25

JOBDESCRIPTIONFORFACILITYREPRESENTATIVE,WELDING SUPERVISOR AND TEST SUPERVISOR

FACILITY REPRESENTATIVE must have knowledge of welding in the Sheet Metal Industry and be in good Standing with his or her Local Union. The Facility Representative shall have no fewer than five years experience in construction, production, and design, functions that have a direct relationship to the welding assemblies fabricated to national or international standards. The Facility Representative shall be trained by an ITI Assessor in ATF’s responsibility, complete the ITI’s Test Supervisor Course, and be in a position to make legal binding commitments and statements on behalf of the Test Facility. WELDING SUPERVISOR must have knowledge of welding in the Sheet Metal Industry and be in good standing with his or her Local Union. The WS must have completed the ITI’s TS and WS Training courses and be a current Certified Welding Inspector under AWS QC-1 Program. The WS shall have no fewer than five years experience in construction, production, and design, functions that have a direct relationship to the welding assemblies fabricated to national or international standards. The WS shall have no fewer that two years experience as an ITI Test Supervisor. This two year requirement may be waived for the initial WS with approval from the QAT. The WS is encouraged to be a full time employee of the ATF. The WS would provide the following:

Oversee welding activities performed by the ATF Contact person for all TS and/or Contractors in the ATF jurisdiction Technical support for TS, Contractors and Local Unions Documents PQR’s Writes WPS’s Check welding database entries made by the TS Confirms all TS paperwork is filled out at the ATF and agrees with the welding database Audits any location that remote AWS welder qualification has been performed prior to the annual ATF

Audit by the ITI. Generates WS Reports for each audit performed Insures each CAR is resolved Contacts ITI Assessor for Technical support after all resources are exhausted

TEST SUPERVISORS must have knowledge of welding in the Sheet Metal Industry and be in good standing with his or her Local Union. The Test Supervisor must have completed the ITI’s Test Supervisor training course and be a current Certified Welding Inspector under AWS QC-1 Program. The Test Supervisor shall have no fewer than five years experience in construction, production, and design, functions that have a direct relationship to the welding assemblies fabricated to national or international standards.

Work under the supervision of the ITI unless a WS exist Work under the supervision of the WS if the WS exist Can record PQR data with the approval and supervision (within visible and auditable range) of the WS

and/or ITI Assessor




EXHIBIT # 26

Quality Assurance Manual History Log

All versions may be found on the ITI welding database at www.sheetmetal-iti.org.

New versions of the QA Manual were published in for the following years and may be viewed on the ITI welding database:

2010 2008 2007 2006 2005 2004 2003 2002

2000-2001 1998-1999


PAGE 41 of 50 LEVEL THREE REV. DATE: 4/29/00

EXHIBIT # 27

EQUIPMENT MAINTENANCE RECORD

Wiring** Clamps Amperage Voltage Machine Location

Date Inspected Plug Ground Leads Ground Electrode Machine Setting Amprobe Reading Machine Setting Amprobe Reading

Comments & Recommendations

Welding Lab

Welding Lab

Welding Lab

Welding Lab

Welding Lab

Welding Lab

Welding Lab

Welding Lab

Welding Lab

Sheet Metal Shop

Sheet Metal Shop

Sheet Metal Shop

Tool Room

Sheet Metal Shop

Sheet Metal Shop

** Legend - O.K. - No Repair Required R2 - Replaced R1 - Repaired N/A - Not applicable to this machine




EXHIBIT # 28

WS On Site Audit Checklist

REMOTE TEST LOCATION ____________________________________________________

ADDRESS ___________________________________________________________________

PHONE NO ________________________ FAX. NO. _________________________________

EMAIL ADDRESS _____________________________________________________________

WELDING SUPERVISOR _________________________DATE ________________________

TEST SUPERVISOR ____________________________________________________________

PERSONNEL INTERVIEWED____________________________________________________

Part I – Procedures 1. Please describe the procedure for procurement of materials including filler metals.

Materials and filler metal required for testing are purchased and stored with correct markings and documentation to maintain traceability to supplier certification. All materials and filler metal are in full compliance with applicable standards and codes. (see QAM sec. 8 & 15)

a. Is there a purchase order on file? YES, on file in Facility office

b. Does the P.O. require material test reports on base metal and certificates of conformance on filler metals? YES, Base metal and filler metals are purchased by the TS, (MTR’s are specified on all PO’s or verbal orders. c. Is the material and certifications checked on receipt? Yes, and they are checked again, just prior to certification testing by TS. d. Are the mill test reports and certificates of conformance on file? YES, maintained in Facility office.




EXHIBIT # 28 2. Please describe the initial discussions with candidate certified welders. Candidates are given oral instructions and/or view the W.A.I.T. Video that provides an excellent orientation on Certified Welding Procedures. Test Supervisor will check I.A. #, picture I.D. and Eye Correction. The welder is given a review of: Safety Procedures, Filler Material Requirements, Method Sheet, Routing Sheet, Welding Procedure Specification (WP S), and be advised of the Criteria for Visual Inspection and the criteria for Destructive Tests, if required by the code. A ten question written test to follow the hands-on welding test.

a. Is a sample application available? Yes, see Procedure Instructions Manual, QAM(Exhibit #5)

b. Is it filled out so that is may be used as a sample? Yes, on file.

c. Is the welder advised of the testing procedures including safety rules, fit up tolerances, and testing requirements? YES, Test procedures provided by QA Manual and safety is addressed in the WAIT video & QA Manual and the Welder’s Orientation

3. Please describe the procedure for traceability of materials. Begin with use of certified materials through welding of test coupons and visual examination, mechanical or radiographic testing, and recording of results.

QAM- Section 8.01 provides detailed procedures for traceability of materials and filler metals. Upon receipt the from the supplier the traceability is checked and material is assigned and given a color code identifier. Uncut test material is banded with the proper identification numbers and color code. Test coupons are cut from certified material and the color code is transferred to the individual test coupons. T he Test Supervisor upon issue, places the welder’s identification code onto the test coupon. Test Supervisor will assign the welders SSN as the permanent identification code to the test coupon to successful Visual and Bend Test Specimens and document that number on the Routing Sheet.

a. Is the candidate welder assigned an identification code? How? Yes, welder’s SS # as stated above.

b. Is the identification code recorded on the coupon and the paper work? YES

c. Does the Test Supervisor verify that certified materials are used? How? YES, Test Supervisor issues all test material and verifies material to MTR’s.

d. Are the test materials identification recorded on the test records? YES, on WPQ

e. Is the welder identification code transferred to the bend specimens? YES, transferred by welder and witnessed by Test Supervisor

f. Is the identification code shown on the x-ray film when radiography is used? Yes, when applicable




EXHIBIT # 28

Part II – Personnel

1. Are the inspection and testing services of the Remote Test Location under the authority of a WS? YES.

2. Are the Test Supervisors employees or contractors? Employees.

3. Are they currently certified as CWI’s under AWS QC 1? YES.

4. Who are the Test Supervisors and what are their Certificate numbers?

5. If radiography is used, are the NDE personnel employees or contractors?

Contractors.

6. Is ASNT Recommended Practice SNT-TC-1A followed in the qualification of NDE personnel? YES, see QA Manual.

7. Are there sufficient staff to assure adequate supervision? YES.

Part III – Operations

1. Are written instructions and sketches available for the candidate to use in fitting the test assembly? Yes, Exhibit (#2)Wait Video, and as shown on WPS per applicable code

2. Is the fit up inspected prior to welding? How is it documented? YES, Exhibit (#5) By initialing the Routing sheet

3. Are the Welding Procedures available for use by the candidate? YES.

4. Are written procedures or checklists available for preparation and inspection of bend specimens? YES, Destructive Testing Checklist, see Exhibit (#6)

5. Are radiographic acceptance criteria available to the x-ray interpreter? Yes, when applicable

6. Are the results of the bend test or film interpretation recorded on the test records? YES,WQTR.




EXHIBIT # 28

7. Does the welders file consist of: a. The welders initial application.

YES.

b. The material withdrawal form. No dedicated form is used but Test Supervisor issues all material by hand to each candidate.

c. The bend test report or the radiograph and the radiographers report. YES, on WQTR.

d. The Performance Qualification Test Record. YES.

8. Will the contractors TS be testing welders at remote locations? Yes, only in Local Union’s area.

9. If welders are to be tested at a remote location, have written procedures or checklists been prepared? Yes, QAM is always followed.

10. If welders are to be tested at a remote location is it covered in the QA manual? Yes.

11. If bend test are being performed at a remote location are the requirements of the Codes, specifications and standards being met. Yes.

Part IV – Reference Documents 1. Does TS have access to a library?

Yes, ATF office. 2. Are applicable Codes, specifications and standards available?

Yes.

Part V – General 1. Does the TS do testing for any organization other than SMWIA?

No. 2. Does management have a QA Manual?

Yes. If yes, how often is it reviewed? Minimum Annually.

3. Who is responsible for review? Management.




EXHIBIT # 28

Part VI –Welding Tests 1. Does the Test Supervisor have a checklist for the set-up and administration of the welding test?

Yes, Routing Sheet, Exhibit (#5)

2. Are WPS’s posted in the work area or otherwise available to the welder? Yes.

3. Is safety equipment verified? Yes, See Routing Sheet ,video or lab sheet.

4. Is eye correction verified? Is the type recorded? Yes, per Routing Sheet

5. Is fit-up verified? Yes, see Routing Sheet

6. How do you verify that the test plates are not repositioned without approval? By visual inspection and initial Hold Points on Routing Sheet, Exhibit (#5)

Part VII –Welded Test Assembly Handling

1. Are written procedures or other methods available to define the visual inspection criteria to be applied to test assemblies? Yes, see applicable code

2. Are written procedures or other methods available to define the steps and examinations to be performed to comply with the Supplements? Yes.

3. Are nondestructive test methods controlled by written procedure? Yes, when applicable.

4. Are contracted nondestructive testing methods properly defined to assure accurate testing and the application of the proper acceptance standards? Yes

5. Are sketches, drawings, etc. used to define the steps in performing the cutting, and preparation of destructive testing (bends, nick-breaks, etc.?) Yes, also applicable to code, Exhibit (#6)

6. Is there proper documentation as to the disposal of test specimens? Yes, successful test coupons are stored for a minimum of one year (QAM Sec. 16.01 Paragraph 3.1) TS will dispose of successful test coupons after one year by permanently de-facing with file, saw or similar manner through the weld area before disposal.




EXHIBIT # 28

Part VIII – Final Disposition

1. What records are placed in the welder’s file at the ATF? In accordance with the Table of contents in Procedure Instruction Manual. (also Level 2 Section 16.01)

2. What records are forwarded to AWS Certification Department? AWS Application and payment.

Part IX –Welding and Cutting Equipment List of equipment to be used for testing. 1. SMAW

a. Number of units

2. GMAW

a. Number of units

3. GTAW

a. Number of units

4. FCAW

a. Number of units

5. OFC

a. Number of stations

6. CAC

a. Number of units

7. PAC

a. Number of units

Part X – Measuring & Testing Equipment

1. Measuring/Testing item – (For each item of equipment used in welder qualification, the following information shall be provided). a. Is a maintenance procedure or schedules established?

Yes.




EXHIBIT # 28

b. Is maintenance log up to date? Yes.

c. Does equipment appear abused? No.

d. Are proper equipment records maintained? Yes.

i. Is equipment identified? Yes.

ii. Does it have a calibration tag (if required volt/amp etc,)? Yes.

iii. Are operating manuals available? (example Power Sources, volt/amp meter and etc.) Yes, on file in Welding Shop office.

e. Are calibration methods defined? Yes, to National Standard.

2. Bend Testing Equipment

a. Wrap-around fixture? No

b. Die & plunger fixture? Yes, Fischer, Model BT1G, Serial #

c. Adjustable radius fixture? Yes.

3. Other Testing Equipment

4. Is applicable measuring equipment available: (Check all available) a. ____ Tape measure b. ____ Micrometers c. ____ Calipers d. ____ Scales e. ____ Optical aids f. ____ Fillet weld gauge g. ____ Weld reinforcement gauge h. ____ Hi-Low gauge i. ____ Under-cut gauge j. ____ Protractor




EXHIBIT # 28 5. Does facility perform any chemical tests? NO

a. Mass spectrometer analysis? NO b. Wet chemical method? NO c. Macro etch? NO d. Are written procedures available? N/A

6. If the above tests are performed, are the applicable standards form AWS, ASME and ASTM available for control of procedures? N/A

Part XII – Records and Test Reports 1. Are written procedures on file for record retention?

Yes. 2. Are records retained for the 5-year requirement per AWS QC-4-89?

Yes, at the ATF 3. Are records secured?

Yes, at the ATF




EXHIBIT # 28

Weld Supervisor’s Summary Remote Test Location:____________________________________________________ Date:__________________________________________________________________ Test Supervisor:_________________________________________________________ Welding Supervisor:______________________________________________________ Total Findings:__________________________________________________________ Total Concerns:__________________________________________________________ Total Deficiencies:_____________________________________________________________ See attached Audit Report for details on Findings, Concerns and Deficiencies. _____________________________ _________________________ WELDING SUPERVISOR: Date ______________________________ __________________________ TEST SUPERVISOR: Date

INTERNATIONAL TRAINING INSTITUTE For the Sheet · PDF fileD15.1 AWS D15.1, Railroad Welding...

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