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

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


Mr. R.D.Pennathur Mr. R.D.Pennathur
Codes & Standards

Welding Process Qualification

Mechanical Testing

Safe Practice

Stainless Steel Welding
Mr. R.D.Pennathur
CODES & STANDARDS
The 3 agencies generally identified in a
code or standard:
The customer, or client
The manufacturer, or contractor
The 3
rd
party inspection, or clients
representative
Codes often do not contain all relevant
data, but may refer to other standards
Mr. R.D.Pennathur
5 of
691
Standard/Codes/Specifications
Standards
Specifications
Examples:
Plate, Pipe,
Forgings,
Castings, Valves,
Electrodes
Codes
Examples:
Pressure vessels,
Bridges,
Pipelines, Tanks
Mr. R.D.Pennathur Mr. R.D.Pennathur
Welding is the most widely employed
fabrication process in building of bridges,
flyovers, automobiles, railways and loco-
carriages, ships, machineries, power plant,
refineries, petro-chemical plant, defense
items, consumer products, etc.

Welding - The Major Process for
Fabrication
Mr. R.D.Pennathur Mr. R.D.Pennathur
Steel is the major material used for fabrication and
construction and steel consumption considered a
major index for the nations growth

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

For every ton of steel consumed, on average about 5
kg of weld metal is required to be deposited
through different welding processes.
Welding Steel Consumption
Mr. R.D.Pennathur
MATERIALS OF CONSTRUCTION
All general engg.,
Infrastructure,
Automotive,
Shipbuilding,
Railways
Mild Steel, High Strength
Low Alloy Steels
Defense,
Penstocks for hydel plants
High tensile steels
Boilers and piping in thermal power plants
Creep resisting steels
Light structures
Boats
Dairy Equipment
Buzz bars
Aluminium
Chemical & Petrochemical Plant
Refineries,
Cryogenic plant,
Food processing,
Pharmaceuticals
Stainless steels -
Austenitic
Vessel,
Piping & Heat Exchangers in Chemicals & Food
Copper, Nickel and
alloys, Titanium
Mr. R.D.Pennathur
CONCEPT OF QA & QC SOME DEFINITIONS
Quality- The totality of features
and characteristics of a product
or service that bear on its ability
to satisfy stated and implied
needs.

Quality Management- That
aspect of overall management
functions that determines and
implement Quality System &
Policy.
Mr. R.D.Pennathur
Quality System- The organisational
structure, responsibilities,
procedures, processes and resources
for implementing Quality
Management.

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


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

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

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

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

Mr. R.D.Pennathur
QUALITY STANDARDS
Basic Standards
Specifying general requirements with basic
significance eg.Quality Management Systems,
drawings & tolerances ISO 9000 ff, EN 4500 ff, ISO
17000 series

Special Basic Standards
Specifying matters for several applications eg. Test
procedures, welding requirements materials ISO 3834

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


Mr. R.D.Pennathur
QUALITY MANAGEMENT IN
WELDING
Basic Standard for QMS
ISO 9001 -2000
Manufacturing

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

Procedures
ISO 15607 15614

Testing and Inspection Personnel
ISO 9712, EN 1289
Mr. R.D.Pennathur
WHAT IS ISO 3834?
It is an international standard created by
welding professionals to guide the manufacturer
in managing his welding fabrication process

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

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

ISO 3834 was developed to identify all factors
that could affect the quality of welded product
and which need to be controlled at all stages,
before, during and after welding.
Mr. R.D.Pennathur
WHY ADOPT ISO 3834 WHEN WE HAVE
ISO 9001?

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

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

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

WHAT IS THE DEFINITION OF A
MANUFACTURER?

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

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

A manufacturer may be involved in manufacture,
fabrication, construction, repair or maintenance.
Mr. R.D.Pennathur
HOW DOES ISO 3834 LINK IN WITH ISO
9001?

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

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

The specific complementary elements of ISO
9001 are detailed in ISO 3834
Mr. R.D.Pennathur
Areas/aspects of improvement can be identified
Ensures focus on
market needs
More competitive
Optimizes the
manufacturing time
Reduction in cost,
wastage & repairs
Measure of
performance
Induce more organized
way of thinking
Provide
motivation
Recognition &
customer confidence
BENEFITS OF ADOPTING ISO 3834 QUALITY
ASSURANCE SYSTEM
Quality
Assurance
system
Mr. R.D.Pennathur
HOW MANY PARTS DOES ISO 3834
HAVE?
ISO 3834: 2005 Quality requirements for fusion
welding of metallic materials consists of 6 parts:
ISO 3834-1:2005, Criteria for the selection of the
appropriate level of quality requirements
ISO 3834-2:2005, Comprehensive quality
requirements
ISO 3834-3:2005, Standard quality requirements
ISO 3834-4:2005, Elementary quality requirements
ISO 3834-5:2005, Applicable documentation (not
full title)
ISO/TR 3834-6:2007, Guidelines on implementing
ISO 3834
Mr. R.D.Pennathur
ISO 3834-2 COMPREHENSIVE
QUALITY LEVEL
Applied to constructions in which the
failure of welds may lead to total product
failure with successive significant
financial consequences and a major risk
of human injury

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

Manufacture would require enhanced
controls to avoid the occurrence of
harmful imperfections
Mr. R.D.Pennathur
ISO 3834-3 STANDARD QUALITY
LEVEL
Applied to constructions in which the
failure of welds could impair the intended
use of the construction & the operational
unit in which it forms a part.

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

Manufacture would be conventional without
reliance of high performance materials &
the production processes would be well
established.
Mr. R.D.Pennathur
ISO 3834-4 ELEMENTARY QUALITY LEVEL
Applied to constructions in which the
failure of welds would not
fundamentally impair the intended use
of the constructions.

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

The materials used would be simple as
well as the manufacturing technique.
Mr. R.D.Pennathur Mr. R.D.Pennathur
SELECTION OF WELDING QUALITY
REQUIREMENT AS PER ISO:3834
Contract Welding
Requirement
Quality Requirement
When quality system
conforming to ISO
9001 is required
When quality system
conforming to ISO 9001
is not required
Comprehensive
quality requirement
Use ISO 3834-2 Use ISO 3834-2
Standard quality
requirement
Use ISO 3834-2 Use ISO 3834-3
Elementary quality
requirement
Use ISO 3834-2 Use ISO 3834-4
Mr. R.D.Pennathur
HOW IMPORTANT ARE WELDING PERSONNEL?
A key feature of ISO 3834 is the requirement
to ensure that people with welding
responsibilities are competent to discharge
those responsibilities

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

The specifying of minimum requirements for
personnel dealing with welding coordination
and welding inspection personnel
Mr. R.D.Pennathur
THE HUMAN RESOURCE
Without an appropriate specific
technical competence intended as a
combination of knowledge, experience and
attitude) no management system can be
successful in the manufacturing of any
product

A great importance has been entrusted to
the Welding Coordinator, who has
become the real key element around
whom all the welding production process
works.
Mr. R.D.Pennathur
ROLE OF THE RESPONSIBLE WELDING
CO-ORDINATOR
The company shall nominate at least one Responsible Welding
Coordinator ( RWC )

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

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

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

RWC maybe to an individuals normal job title eg, Technical
Manager, QC Manager, Production Manager etc.
Mr. R.D.Pennathur Mr. R.D.Pennathur
ISO 14731 GRADATION OF
RESPONSIBLE WELDING COORDINATORS
Three different levels of RWC are given. The selection of
RWC depends mainly on the variability and technical
complexity of the welding procedures required
1 Grade 1 With Comprehensive Technical
Knowledge as specified in ISO 14731
Evidence of experience in welding in similar
product & process

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

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

IWS
IWP
Mr. R.D.Pennathur
MAIN RESPONSIBILITIES
Code compliance
Workmanship control
Documentation control
Mr. R.D.Pennathur
PERSONAL ATTRIBUTES
Important qualities that good Inspectors are
expected to have are:
Honesty
Integrity
Knowledge
Good communicator
Physical fitness
Good eyesight
Mr. R.D.Pennathur
STANDARD FOR VISUAL INSPECTION
BASIC REQUIREMENTS
BS EN 970 - Non-destructive examination
of fusion welds - Visual examination
Welding Inspection Personnel should:
be familiar with relevant standards, rules and
specifications applicable to the fabrication
work to be undertaken
be informed about the welding procedures to
be used
have good vision (which should be checked
every 12 months)
Mr. R.D.Pennathur
WELDING INSPECTION


Conditions for Visual Inspection (to BS EN 970)
Illumination:
350 lux minimum required
(recommends 500 lux - normal shop or office lighting)
Vision Access:
eye should be within 600mm of the surface
viewing angle (line from eye to surface) to be not less
than 30
30
600mm
Mr. R.D.Pennathur
WELDING INSPECTION
Aids to Visual Inspection (to BS EN 970)

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

Other aids:
welding gauges (for checking bevel angles, weld
profile, fillet sizing, undercut depth)
dedicated weld-gap gauges and linear misalignment
(high-low) gauges
straight edges and measuring tapes
magnifying lens (if magnification lens used it
should have magnification between X2 to X5)
usually by
agreement
}
Mr. R.D.Pennathur
WELDING INSPECTORS
EQUIPMENT
Measuring devices:
Flexible tape, steel rule
Temperature indicating crayons
Welding gauges
Voltmeter
Ammeter
Magnifying glass
Torch / flash light
Gas flow-meter
Mr. R.D.Pennathur
WELDING INSPECTORS GAUGES
TWI Multi-purpose Welding
Gauge
Misalignment Gauges
Hi-Lo Gauge
Fillet Weld Gauges
G.A.L.
S.T.D.
10mm
16mm
L
G.A.L.
S.T.D.
10mm
16mm
0
1/4 1/2 3/4
IN
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2
3
4
5
6
Mr. R.D.Pennathur
WELDING INSPECTORS EQUIPMENT
Tong Tester
Ammeter Voltmeter
Mr. R.D.Pennathur
WELDING INSPECTION
Stages of Visual Inspection (to BS EN 970)
Extent of examination and when required
should be defined in the application standard
or by agreement between the contracting
parties

For high integrity fabrications inspection
required throughout the fabrication process:
Before welding
(Before assemble & After Assembly)
During welding
After welding

Mr. R.D.Pennathur
BEFORE WELDING
Preparation: Familiarisation with relevant
documents
Welding Procedures
Welder Qualifications
Equipment:
Materials
Consumables
Weld Preparations
Welding Equipment
Fit-up
Pre-heat



Mr. R.D.Pennathur
DURING WELDING

Weather conditions
Welding Process(es)
Welder
Pre-heat (if required)
Welding consumables
Welding Parameters
Root runs
Inter-run cleaning
Distortion control

Mr. R.D.Pennathur
AFTER WELDING

Weld Identification
Visual Inspection
Dimensional Survey
Other NDT
Repairs
Pressure / Load Test
Documentation


Mr. R.D.Pennathur
SUMMARY OF DUTIES
A Welding Inspector must:
Observe
To observe all relevant actions related to weld quality throughout
production.

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

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