En 15085 Design Module

Company Certification Standards in Welding

What is a code:

A systematic collection of regulations and rules of procedureIPC Indian Penal Code - It is a comprehensive code, intended to cover all substantive aspects of criminal law.

IBR Indian Boiler regulation - Regulations in respect of materials, design and construction, inspection and testing of boilers and boiler components for compliance by the manufacturer's and users of boilers in the country.

ASME BPVC Section IX - Welding and Brazing Qualifications

What is a standard:

A Standard can be defined as a set of technical definitions and guidelines that function as instructions for designers, manufacturers, operators, or users of equipment.

Different standards adopted :American Welding Society Standards (AWS)American petroleum institute standards (API)Australian / New zealand standards (AS/NZS)British Standards (BS)International Organisation for standardisation (ISO)European Union Standards (EN)German Standards (DIN)Bureau of Indian Standards (BIS)

Difference between a code and a standard

Acodeis a model, a set of rules that knowledgeable people recommend for others to follow. It is not a law, but can be adopted into law. Astandardtends be a more detailed elaboration, the nuts and bolts of meeting a code.

A standard becomes a Code when it has been adopted by one or more governmental bodies and is enforceable by law, or when it has been incorporated into a business contract.

SOME OF THE MANAGEMENT STANDARD.ISO 900O -QMSISO 14000 -EMSISO 18000-Occupational Health and Safety Management System (OH& S MS) And International Standard OHSAS 18001:1999ISO 27000-ISO/IEC 27002 provides best practice recommendations on IS security management systems (ISMS).

EMERGING STANDARDSISO-3834 Quality requirements for fusion welding of metallic materials.EN -15085- Welding of railway vehicles and components.IRIS- International Railway Industry Standard

Welding is a Special Process-Why

7 - Product realization 7.5 Production and service provision 7.5.2 Validation of processes for production and service provision The organization shall validate any processes for production and service provision where the resulting output cannot be verified by subsequent monitoring or measurement and as a consequence, deficiencies become apparent only after the product is in use or the service has been delivered.

What is ISO-3834&EN 15085It is an international standard created by the welding professionalISO 9001 defines requirements for quality management system ISO 3834 also defines the quality requirements, only welded products. EN 15085 for railway applications.

What is ISO-3834&EN 15085(contd)The standard specifies the requirements relating only to the welded structure.The standard can also be used as a production control system.ISO 3834 is not a product standard, but it is often cited as a requirement of various products to ensure good practice in the welding and to prevent premature failures.

What is ISO-3834&EN 15085(contd)The standards provides details of how to control the various welding and welding-related operations to achieve the desired quality consistentlyThe company that is certified according to this standard gains an advantage when competing with other companies in European and World wide markets.

What is ISO-3834&EN 15085(contd)Fusion welding processes are widely used in many products. In some companies it is a key manufacturing process. Products may be both simple and complex, for example, Pressure vessels, domestic and agricultural equipment, cranes, bridges, railway transport and other facilities.

What is ISO-3834&EN 15085(contd)These processes have a significant impact on production costs and product quality. It is important to ensure that these processes are carried out in the most efficient manner and that all transactions are properly controlled.

What is ISO-3834&EN 15085(contd)It is noted that ISO 3834 is not quality management system standard, which replaces ISO 9001:2000, but it may be beneficial to producers in the application of ISO 9001:2000.Description of the quality requirements of welding processes is important as the quality of these processes is not easy to verify, because they belong to the ISO 9000:2000 for special processes.

ISO 3834 part-1 to 4ISO 3834-1-General requirements

ISO 3834-2- Comprehensive quality requirementISO 3834-3- Standard quality requirementISO 3834-4 -elementary quality requirement

ISO 3834-2- Comprehensive quality requirement

Constructions in which the failure of welds may lead to total product failure with significant financial consequences Major injury. The product may be subject to dynamic loading In addition to high static loading.

ISO 3834-3- Standard quality requirement

Constructions in which failure of welds impair the intended use of construction.Normal safety risk Financial losses not extreme.

ISO 3834-4 elementary quality requirement

Constructions in which failure of welds Not fundamentally impair the intended use. No adverse effects on safety of people Minor financial consequences.

EN 15085Railway applications Welding of railway vehicles and componentsPart 1: GeneralPart 2: Quality requirements and certification of welding manufacturerPart 3: Design requirementsPart 4: Production requirements Part 5: Inspection, testing and documentation

EN 15085 Part 1: General

EN 15085 Part 1 provides an overview and scope of the 15085 series of standards and how it applies to the welding of metallic materials in the manufacture and maintenance of railway vehicles and their parts.

EN 15085 Part 2: Quality requirements and certification of welding manufacturer

EN 15085 Part 2 of the standard defines the certification and quality requirements for the welding manufacturer to undertake for new fabrication and repair work. It then provides an essential link between performance requirements defined during design to achieve the appropriate quality welds during production and the demonstration of the required quality by inspection

EN 15085 Part 3: Design requirements

EN 15085 Part 3 defines weld performance class during design, which is based on safety and stress factors relevant to railway operation. Quality levels of imperfections are assigned to weld performance classes to ensure a certain level of performance intended during design

EN 15085 Part 4: Production requirements

Based on the weld performance classes, certification levels for production, as well as inspection and testing and qualifications for welding personnel of the manufacturer are specified.

EN 15085 Part 5: Inspection, testing and documentation

This standard deals with inspections and testing to be executed on the welds, destructive as well as non-destructive tests to be performed and necessary documentation to issue to declare the conformity of the products.The EN 15085 series of standards does not deal with product qualification

Some important terms used in EN15085:

Certification level (CL): It is level to classify the welded railway vehicle or the welded component depending on the weld performance class (CP)The certification level is abbreviated by CL

CERTIFICATION LEVEL -1(CL-1)This level applies to welding manufacturers which manufacture welded railway vehicles or their welded partswithwelded joints classified inweld performance classes CP A to CP D. Certification level CL 2 to CL 4 is included.

Examples Of CL -1 level manufacturers. Bogie frames and bolsters;

Body shell components (e.g. under frames, structures);

Buffers and draw gear;

Wheel set components (e.g. wheel set mountings, axle boxes, spring supports);Brake equipment (e.g. magnetic track brake, brake rods, brake triangles, brake cylinders, brake cross beams);

Examples Of CL -1 level manufacturerswelded components for drag transmission from bogie to vehicle;

Vibration dampers and their link between bogie and vehicle or between vehicles;supporting frames for heavy components (e.g. traction units, pantographs);

finishing welding of castings within components indicated above;External fuel tanks

CERTIFICATION LEVEL -2(CL-2)This level applies to welding manufacturers which manufacture welded parts of railway vehicles with welded joints classified in weld performance classes CP C2 to CP D.Welded joints classified in weld performance class CP C1 are included if these welds are checked according to weld inspection class CT 1 according to EN 15085-5:2007, Table 1. Certification level CL 4 is onlyincludedaccordingtoweldedjointsof certification level CL 2 or CL 3.

CERTIFICATION LEVEL -3(CL-3)This level applies to welding manufacturers which manufacture welded parts of railway vehicles with welded joints classified in weld performance class CP D.

This level applies to manufacturers which do not weld but design railway vehicles and parts of rail vehicles or buy and assemble or sell them. Certification not required for welding works of certification level CL 3.

Weld performance class(CP)It is performance requirements of the welded joint as defined by the stress category and the safety category of the welded joint.Note:The weld performance class is abbreviated by CP (class of performance).

Weld performance classes

CP A (*) - Weld performance class CP A is a special class which applies only for welds with full penetration and full accessibility for inspection in production and maintenance

Stress categoriesSafetyHighMediumLowHighCP A (*)CP BCP C2MediumCP B bCP C2CP C3LowCP C1 dCP C3CP D

Weld inspection class(CT):defines the inspections to be carried out for a given weld with respect to the weld performance class.NOTEThe weld inspection class is abbreviated by CT (class of testing).

Correspondence between weld performance classes and inspection classes

Stress category:category determined by the stress factorStress factor: It is ratio of the calculated fatigue stress to the admissible fatigue stress of the joint type, adjusted by the appropriate safety factor

Safety categoriesThe safety category defines the consequences of failure of the single welded joint in respect to the effects on persons, facilities and the environment. The safety categories are differentiated as follows:

Low:Failure of the welded joint does not lead to any direct impairment of the overall function.Consequential events with personal injuries are unlikely.

Medium: Failure of the welded joint leads to an impairment of the overall function or can lead to consequential events with personal injuries.

High:Failure of the welded joint leads to consequential events with personal injuries and breakdown of the overall function

Relationship between

Stress category. Safety category.Weld performance class.Quality levels for imperfections.Inspection class and testing.

Given In Next Slide.

Stress categorySafety categoryWeld performance classQuality levels for imperfections EN ISO 5817Inspection classVolumetric testsRT or UTSurface testsMT or PTVisual examinationVTHighHighCP Asee Table 5 orTable 6CT 1100%100 %100 %HighMediumCP BBCT 210%10 %100 %HighLowCP C2CCT 3Not requiredNot required100 %

*Improvement is the Heart Of Any Standard

What does not get measuredCannot be RecordedWhat does not get RecordedCannot be MonitoredWhat does not get monitoredCannot be ControlledWhat does not get controlledCannot be Improved

Please stay on trackThank you for you attention

REQUIREMENTS TO IMPLEMENT ISO 3834&EN 15085

MENMATERIALMETHODMACHINEMONEY

Welding personnel(Men)

Welders and welding operatorsWelding co-ordination personnelInspection & testing personnelWelding inspection personnelNon-destructive testing personnel

Welder qualification standards

American standardsISO/EUROINDIANASME/Sec IXAWS D1.1BS EN 287ISO 9606IS 817IS 7318IS7310

What is the main reason for carrying out a Welding Procedure Qualification Test ?

To show that following a given set of parameters will produce a welded joint that has the properties that satisfy the design requirements

Welder Qualification

What is the main reason for carrying out a Welder Qualification Test?

To test the ability of a welder to follow verbal or written instructions and verification that the weld produced meets the required standard

TerminologyWPS - Weld Procedure Specification:Qualified instructions on how to complete the weld

PQR - Procedure Qualification Record (ASME) & WPAR - Weld Procedure Approval Record:Record of the welding parameters and test resultsWelders Qualification Test Certificate & Welders Performance Qualification (ASME)Record of Welder test results and ranges of approval

Terminology

Essential Variable:A parameter that when changed outside its permitted range requires requalificationNon Essential VariableA parameter that when changed does not require requalificationSupplementary Essential VariableIs an essential variable only when impact testing is required

Components of a welding procedure

Parent materialType (Grouping)ThicknessDiameter (Pipes)Surface condition

Components of a welding procedure

Welding processType of process (MMA, MAG, TIG, SAW etc)Equipment parametersAmps, Volts, Travel spee

Components of a welding procedure

Welding ConsumablesType of consumable/diameter of consumable Brand/classificationHeat treatments/ storage

Components of a welding procedure

Joint designEdge preparationRoot gap, root faceJigging and tackingType of baking

Welding PositionLocation, shop or siteWelding position e.g. 1G,2G, 3G etcAny weather precaution

Components of a welding procedureThermal heat treatmentsPreheat, tempsPost weld heat treatments e.g. stress relieving

EN 287-Part-1 -2011QUALIFICATION TEST OF WELDERS FUSION WELDINGPART-1- STEEL

Validity Of Approval

Valid for 2years, providing that the welders supervisor can confirm that at every six month period the welder has been working within his range of qualification.

Job knowledge for welders as per en 287Job knowledge test shall comprise: identification of the range of qualification based on the current qualification test, properties and identification of parent materials within the material groups or sub-groups of the test pieces, properties and identification of parent materials within the material groups orsub-groups covered by the range of the qualification certificate to be issued, characteristic features of the welding process being the subject of the qualifica- tion test, properties and identification of welding consumables used for the particular welding process, the principles of edge preparation for welding and pre-welding assembly, the principles of selecting proper welding parameters, the principles of pre-heating and pre-heating control, proper interpass temperatures and their control, weld imperfections and their causes, method of repair of the welds below the acceptance level.

Visual Testing

Each test piece shall be subjected to visual testing (VT): after the root run of the butt weld has been performed in the test piece, after completion of the test piece.Visual testing and its recording shall comply with the guidelines contained inEN ISO 17637.The quality level of the test pieces, based on type and size of imperfections, shall be assessed in accordance with EN ISO 5817 for steel test pieces and EN ISO10042 for the test pieces of aluminium or its alloys.Surface imperfections of the test piece shall be within quality level B.Only the following types of imperfections in quality level C are permitted: excess butt weld metal (502), excess fillet weld metal (503), excess throat of the fillet weld (5214), excessive penetration (504), incorrect weld toe (505), undercuts (501).The reference numbers given in brackets are in accordance with EN ISO 6520-1. In the assessment of the root run of the butt weld test piece welded from bothsides, weld root removed, surface imperfections shall not exceed limits for imper fections within quality level D.

Welder qualification designation

standardWelding processProduct typeWeld typeMaterial groupWelding consumablesMaterial thicknessPipe out side diameterWelding positionWeld detailsEN 287 -1111PBW1.1B10 mmD 60PAss nb1-SteelSMAWPLATEButt WeldSteel with steel classified based on yield strengthBasic coated electrode.plate thicknessout side diadown handsingle side with no backing

BS EN ISO 5817 -2007Welding-fusion welded joints in steel ,nickel,titanium and their alloys( beam welding excluded).

Quality levels for imperfections

Applicable above 0.5 mm parent metal thickness.Covers fully penetrated butt welded and all fillet welds.Principles of this standards can also be applied for partial penetration butt weld.

Different quality levels.Three quality levels are givenQuality level C -stringentQuality level C- IntermediateQuality level D- Moderate.

This International Standard applies to:unalloyed and alloy steels;nickel and nickel alloys; titanium and titanium alloys; manual, mechanized and automatic welding; all welding positions; all types of welds, e.g. butt welds, fillet welds and branch connections; the following welding processes and their defined sub-processes in accordance with ISO 4063:

BS EN ISO 4063-2009WELDING AND ALLIED PROCESSES NOMENCLATURE OF PROCESSES AND REFRENCE NUMBERS.

ISO 4063

Process number1 arc welding2- resistance welding3- gas welding5 beam welding8- cutting &gouging52Laser welding81 oxy fuel cutting83Plasma cutting

833 air plasma cutting84Laser beam welding

1 arc welding111- SMAW/MMAW12- Sub merged welding.(SAW)121- sub merged arc welding with solid wire electrode.13- GMAW131- MIG welding with solid wire135-MAG welding with solid wire136- MAG welding with flux core wire.

14- GTAW.141- TIG welding with solid filler material.142- Autogenous welding.15-PLASMA ARC WELDING

Resistance Welding2- Resistance welding21- resistance spot welding.211- indirect spot welding212- DIrect Spot Welding.22 Resistance seam welding225- foil butt seam welding

Beam welding5- beam welding52- laser beam welding521- solid state laser welding522-gas laser welding523- diode laser welding

Gas cutting and gouging81- oxy fuel/flame /oxygen cutting.83- plasma cutting.831- plasma cutting with oxidising gas.832- plasma cutting with out oxidising gas.833- air plasma cutting.84-laser beam cutting86- flame gouging

EN 287ESSENTIAL VARIABLES AND RANGE OF QUALIFICATION

the qualification of welders based on essential variables.each essential variable a range of qualification is required.all test pieces are to be welded within essential variable.any change in essential variable requires requalification.

List of essential variables Welding process(es)Product type(plate and pipe)Type of weld(butt and fillet)Material groupFiller material.Dimension(material thickness and outside pipe diameter)Welding position.Weld detail( backing, single side welding, both side welding, single layer, multi layer, leftward welding, rightward welding)

Welding processes Each qualification test qualifies only one welding process.Change in welding process requires a new qualification.Exceptions.Change from solid wire electrode 135 to metal cored wire 138 does not require requalification.

Type of weldBut welds do not qualify fillet weld and vice versa.

Equipment(machine)Production and testing equipmentDescription of equipmentSuitability of equipmentNew equipmentEquipment maintenance

Production planning(method)Welding procedure specifications (WPS)Qualification of the welding proceduresWork instructionsProcedures for preparation and control of documents

Welding Consumables(material)Batch testingStorage and handling

MaterialsStorage of parent materialsPost-weld heat treatment

Inspection & testing

Inspection & testing before welding Inspection & testing during weldingInspection & testing after weldingInspection & test status

OTHER REQUIREMENTS

Non-conformance and corrective actionsCalibration and validation of measuring, inspection and testing equipmentIdentification & traceabilityQuality records

What is IRIS CertificationWhat Is IRIS Certification ?IRIS Certification is associated with railway industryIRIS Certification comprise of ISO 9001 quality norms and a questionnaire in 4 different languagesIRIS Certification reduces the chances of multiple auditingIt also improves cost efficiencyIt also ensures high quality of audit records and audit results

What Is IRIS Certification(contd)Areas CoveredRailway equipmentsSignalingRolling stock Benefits Of IRIS CertificationEnsures improved quality across the supply chainOffers efficient evaluation and approval of manufacturing equipmentsReduces the cost for suppliers and manufacturersImproves the accessibility of comprehensive data

*THE QUALITY LADDERZeroDefectPreventAct in sucha way that the problemdoes not occur

Think3rd Ladder Eliminate cause of the problemImproveTake correctiveaction, analyseEstablish causesTemporaryeliminationSolve forlimited periodI am responsible2nd Ladder

RationaliseI dont have timeAccuseIt is others faultIt is nottrueIgnoreDont know 1st ladder

Quality ladder definedIs a overall picture of steps an Organization goes through while climbing a Quality Ladder for reaching peak performances. The peak performance is like the peak to be climbed. This peak has 3 plateau. Each plateau has to be climbed using the Quality ladder. At the top of each plateau the Organization has some respite before starting up the next ladder to climb up the next plateau. The first ladder is the rightmost ladder. Each step in the ladder is like an obstacle the organization has to overcome.

Quality ladder definedThe first obstacle is in the dont know barrier. People in the Organization use this term to give a reason for not involving themselves in a new concept.

Quality ladder defined(Contd)If this barrier is overcome the Organization enters the barrier ignore. People may learn about a new concept but then they tend to ignore it.

Quality ladder defined(Contd)If this barrier is over come then the next barrier is it is not true barrier. In other words I know about the new concept, I dont want to ignore it but I do not believe it, it is not true, I am not prepared to accept it.

Quality ladder defined(Contd)If this barrier is overcome the next barrier is the scapegoat culture. Somebody else is to be blamed for all failures in the Organization and accuse others.

Quality ladder defined(Contd)If this barrier is overcome and people are planned to accept that they are at fault, they take shelter under the most popular excuse I dont have time. I am too busy. Rationalization of the situation is the next barrier to overcome. If this barrier is overcome the Organization reaches the first plateau and there is some respite before you start climbing the second ladder.

The second and third ladders are self explanatory.

Any questions

*Is a overall picture of steps an Organization goes through while climbing a Quality Ladder for reaching peak performances. The peak performance is like the peak to be climbed. This peak has 3 plateau. Each plateau has to be climbed using the Quality ladder. At the top of each plateau the Organization has some respite before starting up the next ladder to climb up the next plateau. The first ladder is the rightmost ladder. Each step in the ladder is like an obstacle the organization has to overcome. The first obstacle is in the dont know barrier. People in the Organization use this term to give a reason for not involving themselves in a new concept. If this barrier is overcome the Organization enters the barrier oor ignore. People may learn about a new concept but then they tend to ignore it. If this barrier is over come then the next barrier is it is not true barrier. In other words I know about the new concept, I dont want to ignore it but I do not believe it, it is not true, I am not prepared to accept it. If this barrier is overcome the next barrier is the scapegoat culture. Somebody else is to be blamed for all failures in the Organization and accuse others. If this barrier is overcome and people are planned to accept that they are at fault, they take shelter under the most popular excuse I dont have time. I am too busy. Rationalization of the situation is tne next barrier to overcome. If this barrier is overcome the Organization reaches the first plateau and there is some respite before you start climbing the second ladder.

The second and third ladders are self explanatory.