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“Invent a New India Using Knowledge”

है”ह”ह

IS 15326-2 (2003): Quality Requirements for Welding -Fusion Welding of Metallic Materials, Part 2: ComprehensiveQuality Requirements [MTD 12: Welding Applications]

IS 15326 (Part 2) :2003ISO 3834-2:1994

w-P-r2giRigTmTati

Indian Standard

QUALITY REQUIREMENTS FOR WELDING —FUSION WELDING OF METALLIC MATERIALS

PART 2 COMPREHENSIVE QUALITY REQUIREMENTS

ICS 25.160.10

@ BIS 2003

BUREAU OF INDIAN STANDARDSMANAK BHAVAN, 9 BAHADUR SHAH ZAFAR MARG

NEW DELHI 110002

June 2003 Price Group 4

Welding Applications Sectional Committee, MTD 12

NATlONAL FOREWORD

This Indian Standard ( Part 2 ) which is identical with ISO 3834-2 : 1994 ‘Quality requirements forwelding — Fusion welding of metallic materials — Part 2: Comprehensive quality requirements’ issuedby the International Organization for Standardization ( ISO ) was adopted by the Bureau of IndianStandards on the recommendations of the Welding Applications Sectional Committee and approval ofthe Metallurgical Engineering Division Council.

In this adopted standard, some terminology and conventions are, however, not identical to those usedin Indian Standards. Attention is especially drawn to the following:

a) Wherever the words ‘International Standard’ appear referring to this standard, they should beread as ‘Indian Standard’.

b) Comma ( , ) has been used as a decimal marker while in Indian Standards, the current practiceis to use a point ( ) as the decimal marker.

In this adopted standard, reference appears to certain International Standards for which Indian Standardsalso exist. The corresponding Indian Standards which are to be substituted in their place are listedbelow along with their degree ~f equivalence for the editions indicated:

International Standard Corresponding Indian Standard

ISO 3834-1:1994 IS 15326 ( Part 1 ) :2003 Quality requirementsfor welding — Fusion welding of metallicmaterials : Part 1 Guidelines for selection anduse

ISO 3834-3:1994 IS 15326 ( Part 3 ) :2003 Quality requirementsfor welding — Fusion welding of metallicmaterials : Part 3 Standards quality requirements

ISO 3834-4:1994 IS 15326 ( Part 4 ) :2003 Quality requirementsfor welding – Fusion welding of metallicmaterials : Part 4 Elementary quality requirements

ISO 9606-1:1994 IS731O (Part 1 ) : 1974 Approval tests forwelders working to approved welding procedures:Part 1 Fusion welding of steel

IS 7318 (Part 1 ) : 1974 Approval tests forwelders when welding procedure approval is notrequired : Part 1 Fusion welding of steel

ISO 9606-2:1994 IS 7318 (Part 2) : 1974 Approval tests forwelders when welding procedure approval is notrequired : Part 2 TIG or MIG welding of aluminiumand its alloys

ISO 9712:1999 IS 13805:1993 General standard for qualificationand certification of non-destructive testingpersonnel

Degree of Equivalence

Technically equivalent

do

do

Partially equivalent

do

do

do

( Continued on third cover)

IS 15326 (Part 2):2003ISO 3834-2:1994

Indian Standard

QUALITY REQUIREMENTS FOR WELDING —FUSION WELDING OF METALLIC MATERIALS

PART 2 COMPREHENSIVE QUALITY REQUIREMENTS

1 Scope

This part of ISO 3834 has

.

—

—

—

it is independent of

been prepared such that

the type of welded con-struction to be manufactured;

it defines quality requirements for welding both inworkshops and on site;

it provides guidance for describing a manufac-turer’s capability to produce welded constructionsto meet specified requirements;

it may also be used as a basis for assessing themanufacturer with respect to his welding capa-bility.

This part of ISO 3834 is appropriate when demon-stration of a manufacturer’s capability to producewelding constructions and to fulfill specified qualityrequirements, are specified in one or more of the fol-lowing:

— a contract between involved

— an application standard;

— a regulatory requirement.

The requirements contained

parties;

within this part ofISO 3834 may be adopted in full or may be selectivelydeleted by the manufacturer if not applicable to theconstruction concerned. They provide a flexibleframework for the control of welding in the followingcases:

Case1

To provide specific requirements for fusion welding incontracts which require the manufacturer to have aquality system in accordance with ISO 9001 orISO 9002.

Case2

To provide specific requirements for fusion welding incontracts which require the manufacturer to have a

quality system other than ISO 9001 or ISO 9002.

Case3

To provide specific requirements for fusion weldingas guidance to a manufacturer developing a qualitysystem.

Case4

To provide specific requirements for references inapplication standards which uses fusion welding aspart of its requirements or in a contract between rel-evant parties. It may however be more appropriate forISO 3834-3 or ISO 3834-4 to be used in such cases.

2 Normative references

The following standards contain provisions which,through reference in this text, constitute provisionsof this part of ISO 3834. At the time of publication, theeditions indicated were valid. All standards are subjectto revision, and parties to agreements based on thispart of ISO 3834 are encouraged to investigate thepossibility of applying the most recent editions of the

1

IS 15326 (Part 2) :2003ISO 3834-2: 1994

standards indicated below. Members of IEC and ISOmaintain registers of currently valid InternationalStandards.

ISO 3834-1:1994, Quality requirements for welding— Fusion welding of metallic materials — Part 1:Guidelines for selection and use.

ISO 9606-1:1994, Approval testing of welders —Fusion welding — Part 1: Steels.

ISO 9606-2:1994, Approva/ testing of we/ders —Fusion welding — Part 2: Aluminium and aluminiumalloys.

ISO 9712:1992, Non-destructive testing — Qualifica-tion and certification of personnel.

ISO 9956-1: 19951), Specification and approval ofwelding procedures for metallic materiak — Part 1.“General rules for fusion welding.

ISO 9956-2:1995]), Specification and approval ofwelding procedures for metallic materials — Part 2.”Welding procedure specification for arc welding.

ISO 9956-3:1995’1, Specification and approval ofwelding procedures for metallic materials — Part 3:Welding procedure tests for the arc welding ofsteels.

ISO 9956-4:199511, Specification and approval ofwelding procedures for metallic materials — Part 4.”Welding procedure tests for the arc welding of a/u-minium and its alloys.

ISO 13916:—’1, We/ding — Measurement of preheat-ing temperature, interpass temperature and preheatmaintenance temperature during welding.

3 Definitions

For the purposes of this part of ISO 3834, the defi-nitions given in ISO 3834-1 apply.

4 Contract and design review

4.1 General

The manufacturer shall review the contractual re-quirements and the design data provided by the pur-chaser or in-house data for construction designed bythe manufacturer. This is to ensure that all information

1) To be published.

necessary to carry out the fabrication operations isavailable prior to the commencement of the work. Themanufacturer shall affirm his capability to meet allwelding contract requirements and ensure adequateplanning of all quality related activities.

Contract review is carried out by the manufacturer toverify that the contract is within his capability to per-form, that sufficient resources are available to achievedelivery schedules and that documentation is clearand unambiguous. The manufacturer should ensureany variations between the contract and previoustender documentation are identified and the pur-chaser notified of any programme, cost or engineeringchanges that may result.

The items in 4.2 are typically considered at or beforethe time of the contract review. The items in 4.3usually form part of the design review and should betaken into account during the contract review if thedesign is not carried out by the fabricator. It shall beensured that all relevant information has been sup-plied by the purchaser.

When a contract does not exist, e.g. items made forstock, the manufacturer is required to take into con-sideration the requirements of 4.2 whilst carrying outhis design review (4.3).

4.2 Application— Contractreview

Contractual requirements to be considered should in-clude:

a)

b)

c)

d)

e)

f)

g)

h)

the application standard to be used, together withany supplementary requirements;

the specification of welding procedures, non-destructive testing procedures and heat treatmentprocedures;

the approach to be used for welding procedureapproval;

the approval of personnel;

post-weld heat treatment;

inspection and testing;

selection, identification and/or traceability, e.g. formaterials, welders and welds (see clause 16);

quality control arrangements, including any in-volvement of an independent inspection body;

2

IS 15326 (Part 2) :2003

ISO 3834-2:1994

i)

j)

k)

1)

other welding requirements, e.g. batch testing ofconsumables, ferrite content of weld metal, age-ing, hydrogen content;

environmental conditions relevant to welding onsite, e.g. very low temperature ambient conditionsor any necessity to provide protection against ad-verse weather conditions;

subcontracting;

handling of nonconformances.

4.3 Application— Designreview

Design requirements to be considered should include:

a)

b)

c)

d)

e)

f)

g)

h)

i)

5

location, accessibility and sequence of all welds;

surface finish and the weld profile;

parent metal(s) specification and welded jointproperties;

permanent backing;

welds which are to be made in the workshop, orelsewhere;

dimensions and details of joint preparation andcompleted joint;

use of special methods, e.g. to achieve full pen-etration without backing when welded from oneside only;

quality and acceptance requirements for welds;

other special requirements, e.g. acceptability ofpeening, heat treatment.

Subcontracting

When a manufacturer intends to use subcontractedservices (e.g. welding, inspection, non-destructivetesting, heat treatment), all relevant specifications andrequirements shall be supplied by the manufacturerto the subcontractor. The subcontractor shall providesuch records and documentation of his work as maybe specified by the manufacturer.

Any subcontractor shall work under the order and re-sponsibility of the manufacturer and fully comply withthe relevant requirements of this part of ISO 3834.

The manufacturer shall ensure that the subcontractorcan comply with the quality requirements of the con-tract.

The information to be provided by the manufacturerto the sub-contractor shall include all relevant datafrom the contract review (see 4.2) and the design re-view (see 4.3). Additional requirements may need tobe specified if the design of a structure is to be sub-contracted.

6 Welding personnel

6.1 General

The manufacturer shall have at his disposal sufficientand competent personnel for the planning, perform-ance and supervision of the welding production ac-cording to specified requirements.

6.2 Welders

All welders and welding operators shall be approvedby an appropriate test according to the relevant partof ISO 9606.

All records of approval shall be maintained up to date.

6.3 Welding coordination personnel

The manufacturer shall have at his disposal appropri-ate welding coordination personnel, e.g. according toEN 719, such that the welding personnel can be sup-plied with the necessary welding procedure specifi-cation or work instructions and that the work can beproperly performed and controlled. Such personshaving responsibility for quality activities shall havesufficient authority to enable any necessary action tobe taken. The duties, interrelationships and limits ofresponsibility of such persons should be clearly de-fined.

7 Inspection,testing and examinationpersonnel

7.1 General

The manufacturer shall have at his disposal sufficientand competent personnel for planning and perform-ance, supervision and inspection, testing and exam-ination of the welding production according tospecified requirements.

7.2 Non-destructive-testing personnel

The non-destructive-testing personnelproved in accordance with ISO 9712.

shall be ap-

3

IS 15326 {Part 2) :2003

ISO 3834-2:1994

8 Equipment

8.1 Production and testing facilities

The following equipment shall be available whennecessary:

—

—

—

—

—

—

—

—

—

welding power sources and other machines;

equipment for joint preparation and cutting, in-cluding thermal cutting;

equipment for preheating and post-weld heattreatment including temperature indicator;

jigs and fixtures;

cranes and handling equipment used for weldingproduction;

personnel protective equipment and other safetyequipment, directly associated with welding;

ovens, quivers etc. used for treatment of weldingconsumables;

cleaning facilities;

destructive and non-destructive-testing facilities.

8.2 Description of facilities

The manufacturer shall maintain a list of essentialequipment, used for welding production. This list shallidentify items of major equipment, essential for anevaluation of workshop capacity and capability. Thisincludes, for example:

— capacity of largest cranes;

— size of components the workshop is able to han-dle;

— capability of mechanized or automatic weldingequipment;

— dimensions and maximum temperature of fur-naces for post-weld heat treatment;

— capacities of rolling, bending and cutting equip-ment.

Other equipment only needs to be specified by ap-proximate total numbers which cover each generaltype (e.g. total number of power sources for the dif-ferent welding processes).

8.3 Suitability of equipment

The equipment shall be adequate for the applicationconcerned. Approval of welding and heating equip-ment is not normally required unless specified in thecontract.

8.4 New equipment

After installation of new (or refurbished) equipmentappropriate tests of the equipment shall be per-formed. The tests shall verify the correct function ofthe equipment. The tests shall be carried out in ac-cordance with appropriate standards, whenever rel-evant. Records shall be maintained of such tests.

8.5 Maintenance

The manufacturer shall have documented plans forthe maintenance of equipment. The plan shall ensuremaintenance checks of those items in the equipmentwhich controls variables listed in the relevant weldingprocedure specifications. The plans may be limited tothose items which are essential for assuring thequality of the welded construction.

Examples of those items are:

—

—

—

—

—

—

condition of guides in equipment for thermal cut-ting, mechanized welding fixtures etc.;

condition of ammeters and voltmeters,flowmeters etc. used for the operation of thewelding machines;

condition of cables, hoses, connectors, etc.;

condition of control system in mechanized and/orautomatic welding equipment;

condition of thermocouples and other temperaturemeasurement instruments;

condition of wire feeders and conduits.

Defective equipment shall not be used.

9 Welding activities

9.1 Production plan

The manufacturer shall carry out adequate productionplanning, compatible with facilities as in 8.1. This shallinclude at least:

— specification of the sequence by which the con-struction shall be manufactured, e.g. as single

4

IS 15326 (Part 2) :2003ISO 3834-2:1994

—

—

—

—

—

t

—

—

parts or subassemblies, and the order of sub-sequent final assembly;

identification of the individual processes requiredto manufacture the construction;

reference to the appropriate procedure specifi-cations for welding and allied processes;

sequence in which the welds are to be made, ifapplicable;

order and timing in which the individual processesare to be performed;

specification for inspection and testing, includingthe involvement of any independent inspectionbody;

environment conditions, e.g. protection from windand rain;

item identification by batches, components orparts as appropriate,

9.2 Welding procedure specification (WPS)

The manufacturer shall prepare welding procedurespecification in accordance with the appropriate partof ISO 9956 and shall ensure that these are usedcorrectly in production.

9.3 Welding procedure approval

Welding procedures shall be approved prior to pro-duction in accordance with the appropriate part ofISO 9956. The method of approval shall be in accord-ance with the relevant application standards or asstated in the contract.

!.Other procedures, e.g. procedure for heat treatment,should only be approved if stated in the relevant ap-plication standards and/or in the contract.

9.4 Work instructions

The manufacturer may use the welding procedurespecification directly in the workshop for instructionpurposes to the welder. Alternatively, he may usededicated work instructions. Such dedicated work in-structions shall be prepared from an approved weld-ing procedure specification and do not requireseparate approval (see ISO 9956-1).

9.5 Documentation

The manufacturer shall establish and maintain pro-cedures for the control of relevant quality documents,e.g. welding procedure specification, welding pro-cedure approval record, welder approval certificate.

10 Welding consumables

10.1 General

Responsibilities and procedures involved in the con-trol of welding consumables shall be specified by themanufacturer.

10.2 Batch testing

Batch testing of consumables shall be required onlyif stated in the contract.

10.3 Storage and handling

The manufacturer shall produce and implement pro-cedures for storage, handling and use of consumableswhich avoid moisture pickup, oxidation, damage, etc.The procedures shall be in accordance with the sup-plier’s recommendations.

11 Storage of parent materials

Storage shall be such that the material will not beadversely affected. Identification shall be maintainedduring storage.

12 Post-weld heat treatment

The manufacturer shall be fully responsible for thespecification and the performance of any post-weldheat treatment. The procedure shall be compatiblewith the parent metal, welded joint, construction etc.and in accordance with the application standard and/orspecified requirements. A record of the heat treat-ment shall be made during the process. The recordshall demonstrate that the specification has been fol- .lowed and shall be traceable to the particular heattreatment operation.

5’

IS 15326 (Part 2) :2003

ISO 3834-2:1994

13 Welding-related inspection andtesting

13.1 General

Inspection and testing shall be implemented at ap-propriate points in the manufacturing process to as-sure conformity with contract requirements. Locationand frequency of such inspection and/or testing willdepend on the contract and/or application standard,the welding process and the type of construction (see4.2 and 4.3).

The manufacturer may carry out additional testswithout restriction. Reporting of such tests is not re-quired.

13.2 Inspection and testing before welding

Before the start of welding, the following shall bechecked, when necessary:

—

—

—

—

—

—

—

—

—

suitability and validity of welders’ approval certifi-cates (see ISO 9606);

suitability of welding procedure specification (seethe appropriate part of ISO 9956);

identity of parent material;

identity of welding consumables;

joint preparation (e.g. shape and dimensions inaccordance with ISO 9692);

fit-up, jigging and tacking;

any special requirements in welding procedurespecification, e.g. prevention of distortion;

arrangement for any production test;

suitability of working conditions for welding, in-cluding environment.

13.3 Inspection and testing during welding

During welding, the following shall be checked atsuitable intervals or by continuous parameter, whennecessary:

—

—

6

essential welding parameters (e.g. welding cur-rent, arc voltage and travel speed);

preheating/interpass temperature (see ISO 13916);

— cleaning and shape of runs and layers of weldmetal;

— back gouging;

— welding sequence;

— correct use and handling of consumables;

— control of distortion;

— any intermediate examination, e.g. checking di-mensions,

13.4 Inspection and testingafterwelding

After welding, the compliance with relevant accept-ance criteria shall be checked, when necessary:

—

—

—

—

.

by visual inspection;

by non-destructive testing, e.g. according toISO 9712;

by destructive testing according to relevant ISOstandards;

form, shape and dimensions of the welded con-struction;

results and records of ~ost-weld operations, e.g.grinding, post-weld heat treatment, ageing.

13.5 Inspectionand test status

Measures shall be taken as appropriate to indicatee.g. by marking of the item or a routing card, the sta-tus of inspection and test of the welded construction.

14 Nonconformance and correctiveaction

Measures shall be implemented to control itemswhich do not conform to s~ecified requirements inorder to prevent their inadvertent use. When repairand/or rectification is undertaken by the manufacturer,appropriate procedures shall be available at all work-stations where repair or rectification is performed.When repair or rectification is carried out,’ the itemsshall be re-inspected, tested and examined in accord-ance with the original requirements. Measures shallalso be implemented to ensure that conditions ad-verse to quality of the welded construction arepromptly identified and corrected.

IS 15326 (Pati 2) :2003ISO 3834-2:1994

15 Calibration

The manufacturer shall be responsible for the appro-priate calibration of inspection, measuring and testingequipment. All equipment used to assess the qualityof the welded construction shall be suitably controlledand shall be calibrated at specified intervals.

16 Identification and traceability

Identification and traceability shall be maintainedthroughout the manufacturing process, where appro-priate.

Documented systems to ensure identification andtraceability of welding operations should include,when necessary:

P — production plans;

— routing cards;

— records of weld locations in construction;

— weld marking, stamping, labels etc.;

— traceability (for fully mechanized and automaticweld-equipment including welder and welding op-erator) to specific welds;

— welder and procedure approvals;

— non-destructive-testing procedures and personnel;

— welding consumables, e.g. type, batch or castnumbers;

— parent material, e.g. type, batch;

— location of repairs.

17 Quality records

Quality records, according to the contract require-ments, should include, when necessary:

— record of contract/design review;

— materials certificates;

— consumables certificates;

— welding procedure specification;

— welding procedure approval test records;

— welder or welding operator approval certificates;

— non-destructive testing personnel certificates;

— heat treatment and procedure specification rec-ords;

— non-destructive testing and destructive testingprocedures and reports;

— dimensional reports;

— records of repairs and other non-conformity re-ports.

Quality records shall be retained for a minimum periodof 5 years in the absence of any other specified re-quirements.

IS 15326 (Part2) :2003

ISO 3834-2: 1994

Annex A(informative)

Bibliography

[1] ISO 3834-3:1994, Quality requirements forwelding — Fusion welding of metallic materials— Part 3: Standards quality requirements.

[2] ISO 3834-4:1994, Qua/ity requirements forwelding — Fusion welding of metallic materials— Part 4: Elementary quality requirements.

[3] ISO 9001:1994, Qua/ity systems — Mode/ forquality assurance in design, development, pro-duction, installation and servicing.

[4] ISO 9002:1994, Qua/ity systems — Mode/ forquality assurance in production, installation andservicing.

[5] ISO 9692:1992, Metal-arc welding with coveredelectrode, gas-shie/ded metal-arc welding andgas welding — Joint preparations for steel.

[6] EN 719:1994, We/ding coordination — Tasksand responsibilities.

( Continued from second cover)

International Standard Corresponding Indian Standard

ISO 9956-1:1995 1

ISO 9956-2:1995

ISO 9656-3:1995 No IS exists

Degree of Equivalence

—

ISO 9656-4:1995 IISO 13916:1996 J

1s0 9001:2000 1s/1s0 9001 : 2000 Quality management Technically equivalentsystems — Requirements

ISO 9002:1994 1S/1S0 9002: 1994 Quality systems — Model do

for quality assurance in production, installationand servicing

ISO 9692:1992 No IS exists —

EN 719:1994 IS 15327:2003 Welding coordination — Tasks Technically equivalent

and responsibilities

IS 15326/1S0 3834, consists of the following parts, under the general title ‘Quality requirements forwelding — Fusion welding of metallic materials’:

Part 1 Guidelines for selection and use

Part 2 Comprehensive quality requirements

Part 3 Standards quality requirements

Part 4 Elementary quality requirements

Annex A, of this part of IS 15326AS0 3834 is for information only.

In reporting the results of a test or analysis, made in accordance with this standard, if the final value,observed or calculated, is to be rounded off, it shall be done in accordance with IS 2:1960 ‘Rules forrounding off numerical values ( revised )’.

Bu]eau of Indian Standards

B IS is a statutory institution established under the Bureau of Indian Standards A et, 1986 to promoteharmonious development of the activities of standardization, marking and quality certification of goods andattending to connected matters in the country.

Copyright

B 1S has the copyright of all its publications, No part of these publications maybe reproduced in any form withoutthe prior permission in writing of BIS. This does not preclude the free use, in the course of implementing the

standard, of necessary details, such as symbols and sizes, type or grade designations. Enquiries relating tocopyright be addressed to the Director (Publications), BIS.

Review of Indian Standards

Amendments are issued to standards as the need arises on the basis of comments. Standards are also reviewed

periodical ly; a standard along with amendments is reaffirmed when such review indicates that no changes areneeded; if the review indicates that changes are needed, it is taken up for revision. Users of Indian Standardsshould ascertain that they are in possession of the latest amendments or edition by referring to the latest issueof ‘BIS Catalogue’ and ‘Standards : Monthly Additions’.

This Indian Standard has been developed from Doc : No. MTD 12( 4362),

Amendments Issued Since Publication

Amend No. Date of Issue Text Affected

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