Welding QA Quidelines for Fabrication

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Welding Quality Assurance Guideline for Fabricators

Abstract This document provides a basic outline for small to medium fabricators to develop a new welding quality assurance system or to enhance an existing system.

American Welding Society 550 N.W. LeJeune Road, Miami, Florida 33126

COPYRIGHT 2003; American Welding Society, Inc.

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STDmAWS WQAG-ENGL 07842b5 05L43Bb 784 - Key Words Quality assurance, quality system,

qualification document control, material control weldhg procedure, nonconformance, inspection, NDE

Welding Quality Assurance Guideline for Fabricators

Prepared by AWS Fabricator Recognition Task Group

Approved by AWS Board of Directors

Abstract This document provides a basic outline for small to medium fabricators to develop a new welding quality assurance system or to enhance an existing system.

American Welding Society 550 N.W. LeJeune Road, Miami, Florida 33126



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Foreword: An appropriate quality system is the foundation of delivering a quality product or service. When designed for the Fabricator‘s unique products and suitably committed to paper and practice, the daily practices of the Fabricator are more consistent and traceable when problems arise. I t is an increasing trend tha t custumers want t o see t h a t a welding quality a~surance system is documented and demonstrated. They are concerned with the Fabricator’s, and the Fabricator’s subcontractors’ capability of producing products t h a t meet specifications. Many customers look for a systematic quality improvement process.

The quality rianual will identify duties and responsibilities of management. supervisors and craftspersons, and will provide the customer with better information about who is responsible to ensure t h a t the product me&s specifications. Medium-sized and small companies with a5 few a5 three employees can use this Guideline t o develop an effective welding quality assurance system,

The intent of this Guideline i5 t o assist; fabricators in developing their first welding quality a55urance system or refining an existing system. The Fabricator chooses a level of welding quality as~urance t h a t i5 appropriate for the size r% the organization and the type of welded products they produce. This Guideline can provide an opportunity to review existing practices. Each section of this Guideline addresses a specific topic, yet not all the il;erns in this Guideline will necessarily apply to all Fabricators’ scope of work. Appropriate selections should be made based on the Fabricator’s size and the nature of the products made or repaired a t the facility(ies). The guidelines presented here can be modified and applied t o most any facility size.

The welding quality assurance system and the quality manual must actually reflect how things are done. When there is a difference between what is written and what is done, one must change. The Fabricator can discover differences during their own internal audit of the system. The less favorable alternative may be a defect found by the Customer. The audit is the checks and balance part of a quality system. The process of reviewing and writing the Fabricatm’s quality documents can be a valuable opportunity to take a firm look a t the way the company’s products are produced. Use this opportunity t o improve and eliminate redundant pra~ücea.

This Guideline is the first step in creating a welding quality assurance system which can be used t o satisfy some registration requlrernents. More detailed requirements for specific industries may be found in such documents as: 150 3834, Quality Kequirerilentz for Welding: C5A 47.1, Certification of Companies for Fusion Welding of Steel 5tmctures- Welding; and the Ai5C Quality Certification Program.



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Chair

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Fabricator Recognition Committee

Ann (Anna) Petroski Valmet lnc., Bill Myers Phil Grimm Richard Arn Ernest Levert, 5r

ioneycomb Division Dresser Rand Turbo Products Oiv.

Modem Welding Glunt Machine & Fabricating

Lockheed Martin Vought 5ysterns



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a This Guideline i s for the use of weldment fabricators to assist them in developing,

This Guideline is for the use of purchasers of weldrnents to aqsess the welding quality improving and maintaining a welding quality assurance system.

assurance programs of their suppliers.

This Guideline i s limited to describing a recommended welding quality assurance for small to medium sized weldment Fabricators. The scope does not include guidance on weldment design, design control or design review. Although some elements of a quality system are applied to weldment fabrication in this Guideline, it docs not constitute the description of a full, company wide quality system. Notes:

In the event that this Guideline is used by the customer to qualify a Fabricator as a supplier, this Guideline is written in an auditable format. As used here the term Fabricaior refers to the organization supplying weldments to the Customer. Each element of this Guideline should be addressed in the Fabricator's Quality Assurance Manual. If the Fabricator is not sufficiently large to benefit from instituting a particular element of this program, a nor appficuble statement should address the item in the quality system manual.

covered by an existing industry specific certification program, such as AISC for buildings, or ASME for pressure vessels.

nationally recognized standard or customer specification is designated in contract documents, then the rules regarding welding quality in those standards apply. The Fabricator may elect to create a system that complies with one of those standards or may create an appropriate one of their own.

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0

a This Guideline may be used for any material or type weidment not

This Guideline references the term Governing Specification. If a

3.1 . Responsibility and Organization 3.1. I . Personnel whose work affects the quality of the product will be

adequately qualified.' The duties, interrelationships and limits of responsibility of welding, and welding quality assurance personnel will be clearly defined.

3.1.2. it is desirable that persanne1 responsible for weldment quality control (QC) and weldment quality assurance (QA) have defined roles separate from the responsibility for fabrication and delivery.

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3.2.

3.3.

3.4.

3.5.

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A statement in the welding quality assurance will specify to which codefs) or standard(s) or governing specification the welding will conform.

A written welding quality a5surance manual’. that describes the Fabricator’s QA system and includes a written policy describing the Fabricator’s commitment to (weldment) quality. Also define ... 3.3.1.

3.3.2.

3.3.3.

3.3.4.

... who is responsible for the management and implementation of weldment QNQC. ... who is responsible for the prepmation and revision of the Quality Assurance manual. ... how appropriate welding procedures are selected for fabrication work, or how customers’ procedures are used and controlled.' ,’ ... how the delegation of authority is carried out when persons listed within the Quality Assurance manual arc unavailable.

A statement will indikate that responsible QNQC reprtsentative(s) have full support of upper management, (an owner or officer of the company), and identify the person responsible to resolve disputes between QAIQC and other department heads. This statement should include the statement that Quality Control has the authority to identify quality problems and initiate, recommend, or provide solutions. QC may verify implementations of solutions and limit or control further processing and delivery of nonconforming items, until proper disposition has occurred. These decisions will involve the fabricator’s engineering group, or the customer’s engineer when appropriate. It is preferable that these limits be defined.

The QA Manual should include an organization chart showing the relationship between management, purchasing, quality assurance, quality control, receiving. production welding and shipping. If field work is within the scope of work, then the addition of field construction, qualification and inspection may need to be included.

4.1. The Fabricator will maintain a description of their facility(ies) and a list of esseatial equipment and resourus used for weldment fabrication. This list will serve to describe the Fabricator’s capabilities to potential customers. Include information applicable to the Fabricator’s unique product or service-suggested items could inclu de... e number and level of qualified welders, a welding process capability,

e capacity of largest cranes, facility square footage,

e

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size of the largest fabrications possible in the workshop, capacities of rolling, bending, cutting equipment, typicai items fabricated or customers previously served. number of engineers, designers, draftsmen,

e precision level attainable

4.2. The Fabricator should plan an appropriate equipment maintenance program that ensures continuing process capability.

5.1, Notification will be given in writing and accepted by the customer before services are subcontracted.

The Fabricator must address by written practice how the quality of subcontracted services is assured. For sewices that the Fabricator would regularly supply, but

5.2.

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due to capacity requirements or other reasons must subcontract, the Fabricator must especially address how the quality will meet or exceed the quality of the item or service as if it had been supplied by the Fabncalor. This could include in- process, final or receipt inspections.

The level of control of subcontracted services must be appropriate for the criticality and risk of the weldment as assessed by the Fabricator or the customer.

The level of personnel qualification requirements for NDE services must be specified in the contract to the subcontractor and available to the ~ustomer.~

5.3.

5.4.

6 . I . The Fabricator will establish and demonstrate a system of defining how their work concerning weldments is performed. These documents will include, but are not limited to the following:

Fabrication Drawings (supplied by the Fabricator)

Specifications that define elements of the Fabricator's welding quality control or quality assurance system

Fabrication or Layout Drawings (provided by the customer) o

Work Instructions WPSs (welding procedure specifications)

O Purchasing procedures for base material and welding consummables

6.2. Written documentation will show how the system assures that the lotest applicable drawings, specifications and instructions required are used for welding, inspection and testing. The documents are controlled by revision, and are located where the work is performed, and accessible to personnel with responsibility to perform work. The system will identify who is responsible for issue and review, Obsolete documents will be removed or otherwise prevented from inadvertent use. Changes are clearly identified.

Customer Documents include all forms of information (communications, drawings, etc.) received from the customer. "hm will be a clear system to track changes that result from written or oral communication with the customer.

6.3.

Quality Records should include, but are not limited to: WPQR (welder performance qualification records)

o Nondestructive examination (NDE) reports PQR (procedure qualification records) Manufacturer test reports (if required for traceability)

O Mill test reports (if required for traceability) O Records from subcontractors.

8. I . The fabricator must define when traceability is required by internal processes. code comdiance or by the customer. An adequate continuity involving drawings,-purchase orbers. part marking and work records must be id&tified.

The purchase of ali base materials, welding materials, and related parts that will be attached by welding will be controlled by a defined system. This system will provide procedures assuring that all applicable specifications, (which may include mill test certification), are used when ordering materials.

8.2.

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8.3.

8.4.

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The system will include a description of how materials are. received. stored and issued in purchasing procedures. Also include the title of the individual and their responsibilities for the purchasing of material.

Procedures will define how materials or parts are identified and how identity is maintained throughout fabrication. As appropriate for the Fabricator's product or service, incoming materials will be checked for conformance with the purchase order, material specifications andior drawings where applicable.

9.1.

9.2.

9.3.

9.4.

9.5.

9.6.

9.7.

The Fabricator will have WPSs for production welding.

When required by the governing specification, or appropriate to the Fabricator's product or service, WPSs will be written to include essential and non-essential variables'. Variations from an accepted industry practice must be justifiable for the Fabricator's application.

Although strongly suggested, supporting PQRs are not required by this Guideline. When the governing specification requires that welding procedures be qualified by testing, the Fabricator will have supporting PQRs that support all WPSs, except pre-qualified W p s s as allowed by AWS DI. 1, the governing specification or the Fabricator's standard.

All WPSs (and PQRS when required by the Fabricator's welding quality assurance system), will be reviewed and approved for use by the Welding Coordinator (see qi 1 . I ) before being used in production welding operations.

All welding procedures will be available to welders or welding operators during testing and during production welding?

Welding procedures should be qualified by an AWS Accredited Test Facility, or by the Fabricator's Welding Coordinator. Other test facilities may be used provided they have been reviewed to assure that they can perform the required testing in accordance with appropriate or governing specifications. The welding quality assurance system should specify who is responsible for evaluating the test facility, and test results to assure compliance. Regardless of the choice of facility used to conduct qualification testing, the results must be certified by the Fabricator.

Welding procedures are most effective when they provide complete information to the welder." WPSs must be revised when essential variables are changed and should be revised when nonessential variables are changed and improved. New or additional PQR(s) may be required.

1 O. 1. Controls must be in place to assure that the proper filler material is used. The welding quality assurance system should specify how welders obtain filler material and who is responsible to assure that the proper filler material is used.

The Fabricator will purchase the welding consumable$ to appropriate AWS Filler Metal Specifications whenever possible. AMs and/or MIL specifications may be used if there are no equivalent AWS specifications. Proprietary filler material names may be used in the absence of any applicable specification.

10.2.

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10.3. Storage and reconditioning of low hydrogen electrodes will meet the requirements of the electrode manufacturer" as a minimum. The welding quality assurance system should document how this precaution is handled. The exposure of low hydrogen'? filler materials and fluxes to ambient air and humidity must be controlled. The welding quality assurance system must specify how this exposure is controlled and limited.

10.4. Contaminated filler materials/flux must be kept from inadvertent use until it is reconditioned or disposed.

For gas shielded processes, gases should be supplied in a safe and efficient manner to eliminate contamination.

10.5.

1 1. I . We ld iw Coo rdinator

appropriate for the-

1 1 . l . 1. As a minimum, the Fabricator will appoint an employee who, irrespective of other responsibilities, is charged with understanding how the Fabricator's welding quality assurance system functions, and must be available during all phases during which welding is performed. The Welding Coordinator is responsible for implementation of the Fabricator's welding quality assurance system. The Welding Coordinator (or an individual in their department) should be an ANSIIAWS Certified Welding Inspector" or other international equivalent.

1 1.1.2. The Welding Coordinator may or may not have direct responsibility for the design and revision of the welding quality assurance system.

1 1.1.3. The Welding Coordinator is responsible for assuring that only qualified welders are used. Although this responsibility may be shared by foremen, welding inspectors or other direct supervisors, the Coordinator must maintain responsibility for the system irrespective of production schedules.

1 1.1.4. The Fabricator must have available an individual who possesses the basic knowledge required to develop, qualify, and specify the appropriate welding procedures for the fabrication work performed in the Fabricator's shop Or under the Fabricator's control. This individual may be the same individual who functions as the Welding Coordinator, or may be contracted for the function.

1 1.2. Welding Inspecto rs The Fabricator should have at least one employee who is an AWS Senior Certified Welding Inspector (SCWI), or AWS Certified Welding Inspector (CWI), The welding inspector should be familiar with the codes or specifications which apply to the fabrication work performed. Alternatively, the Fabricator must designate a welding inspector who can demonstrate their ability to inspect weldments to the requirements of the applicable codes or specifications. This individual may be the Welding Coordinator. 1 i .2. I . Inspection may include receipt inspection of raw materiais (plate,

sheet, pipe, etc.) and/or welding consumables. (see 113.3)

Employees who perform non-destructive inspection operations, such as magnetic particle testing (MT), dye penetrant testing (PT), ultrasonic testing (UT), radiographic testing (RT), radiographic interpretation (RI), etc. should be qualified using a program comparable to SNT-TC-1 A level II or AWS NDE Certification Program or equivalent nationally recognized standard or one required by the governing specification as a minimum.

i 1.3.

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11.4. lydders and Wel-rs Welderr; and welding operators will be qualified to verify their ability to make sound welds when following an appropriate WPS".

Welders should have an identifying number, letter or symbol for the purpose of identification. Responsibility for issuing this identification and how this identification is used on uie weldment should be defined.

1 1.5.

12.1.

12.2.

12.3.

12.4.

12.5.

12.6.

12.7.

12.8.

12.9.

The Fabricator must qualify all welders that will perform work on weldments for which the Fabricator is responsible. The welding quality assurance system should specify to what extent welders should be qualified and who is responsible for signing certification documents.

The welding quality assurance system will detail how welders' activities are monitored and documented and who is responsible. Performance Testing will be supervised by the Welding Coordinator or their designee. Where possible. it is preferable that the test supervisor is not the welder's supervisor.

It is recommended that the Fabricator use AWS QC7 or QC3" certified welders. The Fabricator may accept qualifications done by subcontractors or other agencies; however, acceptance does not absolve the Fabricator of the responsibility to employ qualified welders who can provide acceptable weldments.

All welder performancdqualification records, will be reviewed and approved by the Welding Coordinator before welders begin production welding operations.

Unless the governing specification requires specific forms, forms provided in appropriate AWS codes may be used or may be designed by the Fabricator. If non-standard forms are used, they will include the essential variables identified in the appropriate code of construction or Fabricator's standard. Samples of the forms used should be included the welding quality assurance manual.

The performance qualification of a welder or welding operator will remain valid unless.. . 12.6.1. the welder has not welded in production with the qualified process

during a period of six months or more, (unless otherwise specified by the governing specification) or,

12.6.2. there is specific reason to question the welder's ability to make welds that meet the specifications. The qualifications which support the welding heishe is doing will be revoked. All other qualifications not questioned remain in effect.

The Fabricator should keep a log or roster of qualified welders and devise a method to maintain their qualifications.

The welding quality assurance system should specify how certified welders or welding operators are assigned to a job and who is responsible for assuring that only qualified welders are used. Some codes may require that tack welders be qualified and other codes may not require qualification if the tack weld is removed prior to final welding. The welding quality assurance system should specify the extent of tack welders' qualifications. If unqualified tack welders inadvertently perform tack welds, controls are in place to assure that the tack weld is removed before final welding.

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13.1.

13.2.

Weldrnent inspection may be performed by the Fabricator and/or contracted.

The Fabricator must create a system that clearly defines acceptance criteria. This criteria may be derived from the Fabricator's customer, codes, standards or if created by the fabricator, should reference the basis used to derive the criteria.

The Fabricator must define what inspections (what parts, at what frequency, at what stage of production) are necessary and how the required inspections am documented.

Inspection may include receipt inspection of raw materiais (plate, sheet, pipe, etc.) andíor welding consumables. This inspection may be done by welders and fitters or by specifically designated quality control personnel.

i 3.3.

13.4.

14.1.

14.2.

14.3.

14.4.

When the required weldment quality-as defined by 113.2 is not met, there is a nonconformance. The Fabricator will have a system to identify nonconformities to prevent the item's inadvertent use in the final product. A nonconformity could occur, but IS -ed to the follo w k , when _.. . . O base material identification and inspection before welding is not

preparation of the base material andor consumable control is not

the procedure is not followed during welding or, final weldment acceptance criteria is not met.

performed or,

followed before welding or. 0

Additionally. a nonconformance may be related to a nonconformity in the normal procedures required for quality assurance and quality control. The Fabricator's quality system must identify who has the responsibility to approve the disposition of a nonconformance.

The Fabricator's quality assurance system will identify nonconformities and assign a disposition of., . 14.3. i . deviation-accept the part as is. 14.3.2. rework-correct the nonconformance to bring the part to full

compliance with the original specification. 14.3.3. repair- modify the part ta bring it back to acceptable quality which

may not be in full compliance with the original acceptance criteria. 14.3.4. scrap-discard the nonconforming part and remake.

The Fabricator's nonconformance. system will include a method to identify, investigate and address the mot cause of the nonconformance.

15. I , The Fabricator should demonstrate that adequate resources. including equipment and the assignment of trained personnel to manage, perform and inspect weldments to the appropriate quality level, are available.

The Fabricator should demonstrate a suitable system of equipment maintenance to ensure continuing process capability.

15.2.

16.1. The Fabricator should identify a method of assurhg that welding procedure parameters are maintained dunng welding.

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16.2. A method of calibration for welding machines or for an appropriate calibrated measurement device must be determined. The Fabricator must select a frequency to check calibration of identified devices and create a log that identifies the status of calibration of welding related devices.

Reference D o c u m e n t s nie elements of uli5 Guideline may satis@ in patt or whole. the welding quality assurance system requirements of these documents ...

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ANSVAWS Di .X ANSUAWS 02. I ANSIIAWS QC 1 AWS W, QC3 AWS Qc4 ASME Boiler and Pressure Vessel Code, Section IX API 1104 MIL Specification 248 Earthmoving Equipment D14.3 ANSYAWS D14.6 Rotating Equipment ANSVAWS D15. i Railroad IS0 97 12

It is suggested that the Fabricator refer to this document for a more detailed presentation of the qualification and certification of NDE personnel.

It is suggested that the Fabricator refer to this document for a more detailed presentation of the duties of a Welding Coordinator.

It is suggested that the Fabricator refer to this document for an alternate presentation of a welding quality assurance system when a quality system conforming to IS0 9001 or IS0 9002 is required.

It is suggested chat the Fabricator reference these documents for n detailed description of the elements of document control, quality records and process control.

I S 0 14731 Welding Coordination

IS0 3834

IS0 9001/9004-1994

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Welding QA Quidelines for Fabrication

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