EN 15085

RAILWAY APPLICATIONS
WELDING OF RAILWAY VEHICLES
AND COMPONENTS

[Link] HARI
 INTRODUCTION
Why EN 15085?
What is ISO 3834?
 What is the difference between the two?
Why we need all theses certifications, already being
certified with ISO -9001?
 INTRODUCTION
ISO 9001- Quality management system for the
organization
ISO 3834-Quality requirements for Fusion welding of
metallic materials( Quality management system for
Welding and it is a process standard)
EN 15085- Railway applications, Welding of Railway
vehicles and components
 EN 15085 parts
Part-1 : General Requirements
Part-2: Quality requirements and certification for
Manufacturers
Part-3: Design requirements
Part-4: production Requirements
Part-5: inspection testing and documentation
Part-6: Maintenance of Railway vehicles
 SCOPE
This series of Standards applies to welding of metallic
materials in manufacture and maintenance of railway vehicles
and their parts
In railway environment this series of standards defines
certification and quality requirements for the welding
manufacturer
This series also provides
(a) Essential link between performance requirements defined
during design,
(b) Achieves appropriate quality welds during production and
(c) demonstration of required quality by inspection
Helps in
(a) To arrive weld performance(CP) class during
design based on safety and stress category
(b) Assigning the quality levels of imperfections for
weld performance classes (to ensure certain level of
performance intended during design)
( c) Defining certification levels for production(CL)
based on safety relevance,
(d) Defining testing levels for inspection(CT)
(e) Defining testing and qualification levels for
personnel
NORMATIVE REFERENCES
All parts of
EN 15085-welding of railway vehicles and components
EN ISO 3834- Quality requirements of fusion welding
of metallic materials
 EN ISO 14731 – Welding coordination tasks and
responsibilities
What is ISO 3834?
It is a process quality standard
Specifies Quality requirements for fusion welding of
Metallic materials
prepared by ISO/TC 44 (‘Welding and allied processes’ )
in collaboration with Technical Committee CEN/TC 121
‘Welding’.
consists of 6 parts
 ISO 3834
• Criteria for the selection of the appropriate level of
Part-1 quality requirements

• Comprehensive quality requirements

Part 2

• Standard quality requirements

Part 3

• Elementary quality requirements

Part-4
 • Documents necessary to conform to claim
conformity to the quality requirements of ISO 3834-
Part 5 2, ISO 3834-3 or ISO 3834-4.

• Guidelines on implementing ISO 3834

Part 6
 Why ISO 3834?
Welding a special process
ISO 9001 and other QM Systems are Generic
ISO 3834 is a process standard
Can be used across industries
Appropriate level can be selected
Flexible- can be used along other product standards
Created by welding professionals
Easy access to European Markets
 APPLICBLE AREAS
In contracts
By manufacturers
By committees
By quality assessing firms
 USAGE
It is independent of construction
Equally applicable for both works shops and /or sites
Guides for describing manufacturers capability as specified by
(a) A specification
(b) A product standard (c ) A regulatory requirement
 WELDING IS A SPECIAL PROCESS - ?

 As per ISO welding is classified as a special process

The organization shall validate any process 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.
 TERMS AND DEFINITIONS
Terms and definitions given in EN 158085-1 and
Terminological databases maintained by ISO and IEC for
use in standardization will apply
ISO: htpp://[Link]/obp
IEC: : htpp://[Link]/
EN 45020:2006 Standardization and related actives
General vocabulary(ISO/IEC Guide:2004)
CEN/TR 14599:2005 Terms and definitions for welding
purposes
EN ISO 17659:2004 Welding-Multilingual terms for
welded joints with illustrations
Certification level(CL): Level to classify the welded
railway vehicle or the welded component depending on
the weld performance class(CP)
weld performance class(CP): Performance requirements
of the welded joint as defined by stress category and the
safety category of the welded joint
Weld inspection class(CT):Defines the inspection to be
carried out for a given weld performance class
Customer: Organization responsible for defining the
technical requirements, quality requirements and the
acceptance procedures for the welded product
Manufacturer: Organization that uses a welding facility
for manufacture or maintain railway vehicles
(certification levels CL1, CL2, CL3)
or
Designs welded railway vehicles or parts of railway vehicles
or buys welded parts for assembly in to railway vehicles
or sells them to assemble in railway vehicles (CL4)
National Safety Authority(NSA): National govt body
responsible for setting or agreeing the safety
requirements for a railway and ensuring that the
railway complies with laws and statutory requirements
Qualification: Evidence of training, professional
knowledge, skill and experience to enable the
personnel to perform the required tasks
Qualified: person with Evidence of training,
professional knowledge, skill and experience proven
by a test
Subcontracted welding coordinator: Welding
coordinator not employed by the manufacturer
Joint Static dimensioning: the dimension of a welded
joint that is needed to achieve the required static
mechanical characteristics
Acceptance authority: Organization that is responsible
for the acceptance of the product
Effective cross section: cross section of a welded joint
that is considered when performing dimensioning
calculations
Joint fatigue dimensioning: the Dimension of a welded
joint that is needed to achieve required fatigue
characteristics
Stress category: Category decided by stress factor
Stress factor: Ratio of calculated fatigue stress to the
admissible fatigue stress
Admissible fatigue stress: Maximum stress applicable to
materials
Safety category: Defines consequences of failure
Production weld Test: Mock up sample welded joints ,to
prove the manual skill of welder or to demonstrate
acceptable production of welded joint
In General
Customers prescribe performance applicable to finished
products
Don’t prescribe welding methods
If requested, the manufacturer shall demonstrate that they
have control to achieve the required quality level by
a) Company certification
b) Welder and welding operator qualification
c) Welding process and mock up Qualification
REQUIREMENTS FOR
MANUFACTURES
In general Quality requirements for Welding on railway
vehicles are specified in EN ISO 3834(Quality
requirements of fusion welding of metallic materials)
For CL 1 - ISO 3834-2 – Comprehensive
For CL 2 -ISO 3834-3- Standard
For CL 3 - ISO 3834-4 – Elementary are applicable
CL 1 is the highest certification level
The manufacturer shall have sufficient welders and
welding operators as explained and required in EN 15805-
4 (production requirements)
 ACTIVITY TYPES FOR MANUFACTURES
Type of activity indicator Description
Design D Calculation, design and documentation for
production and maintenance of welded
railway vehicles and components
Production P Manufacturing, modification and testing of
welded railway vehicles and
components(including replacement parts)
Maintenance M Repair of welded railway vehicles and
components by welding( including testing)
Purchase and supply S Purchase and supply of welded components
for new fabrication or maintenance without
carrying out welding activities
Manufactures can operate in one or more of these types of activites
 WELDING COORDINATION
It is the responsibility of manufacturer to demonstrate that
welding coordination tasks are fulfilled where welding
activities are carried out
The manufacturer shall have adequate number of suitably
qualified welding coordinators, with relevant technical
knowledge and experience, for the tasks they undertake
according to EN ISO 14731
The manufacturer shall clearly prove and document that the
technical knowledge and experience of welding coordinators is
at the required level
 LEVELS OF WELDING COORDINATORS AS PER
EN ISO 14731
Level A: Personnel with comprehensive technical
knowledge
Level B: Personnel with Specific technical knowledge
Level C: Personnel with basic technical knowledge and
adequate professional experience for the relevant scope of
application
The manufacturer shall have a written procedure, how to
qualify and establish welding coordinators according to
this standard
 WELDING COORDINATION
ORGANIZATION
Welding coordinators shall be involved in the organization in
such a way that they can accept their tasks and responsibility
without reservation
They shall have authority to issue instructions and make
decisions when there are technical problems, independent of
manufacturing pressures
The responsibilities and competencies as well as the mutual
relation ships of all manufacturer’s staff, performing
managerial , design, production or inspection work, which
influence the quality of welding work, shall be documented in
the organization chart of the manufacturer
The following items, in particular shall be, specified
and described
Tasks of welding coordinators
Rules for deputizing for the welding coordinator
Activities which require attendance of RWC
Measures which are required if welding coordinator is
absent
Involvement of welding coordinators in the internal
processes
For CL1 : The firm owners, general managers, production
managers can not be recognized as RWC.
Small manufacturing organization:
For small manufacturing organization they can be
possible, provided, the requirements for welding
coordination staff are met
For CL2: The firm owners, general managers, production
managers as RWC is posssible, provided the requirements
for welding coordination staff are met
 SUBCONTRACTED WELDING COORDINATOR

Subcontracted welding coordinator may be recognized

when the following conditions are fulfilled
1. The manufacturer shall ensure and demonstrate that
the subcontracted welding coordinator is available as
necessary to fulfill his tasks according to Annexe A
2. The work of subcontracted welding coordinator shall
be defined according to clause 5.3.5 of this part of
standard. The activities should be recorded
 IMPORTANCE OF WELDING COORDINATION

Welding coordination is the core issue in application

of this series of standards
The manufacturer should take special care when
1. when a welding coordinator is subcontracted by a
no of companies or
2. the manufacturer subcontracts a no of welding
coordinators
 Inspection personnel
The manufacturer shall have sufficient qualified
inspection personnel like it is explained and demanded in
EN 15085-5
 TECHNICAL REQUIREMENTS
The manufacturer P &M shall have suitable technical
equipment according to En ISO 3834
Additionally the following are required as necessary
-Roofed, dry, well ventilated and sufficiently lit
workshops
-dry store rooms for welding fillers and ancillary supplies
If different materials are welded, separate tools ,machines
and equipment shall be used for each material or prior to
processing these shall be cleaned
-Suitable power supply
-Suitable testing equipment
- lifting gear for transporting and turning parts
-work platforms
-Turning devices or manipulators to facilitate welding
in flat position
-clamping devices for heavy welding assemblies
-Devices for straightening
 WELDING PROCEDURE
SPECIFICATION
The manufacturer shall have qualified WPS like it is as
explained and demanded in EN ISO 15085-4 for
production and EN ISO 15085-6 for Maintenance
In general for every WPS, shall be covered by a WPQR,
except for weld performance class CP D(unless specified
in the contract)
For railway application the following parts of EN ISO
15614-1, EN ISO 15614-2, EN ISO 15614-3, EN ISO
15614-4, EN ISO 15614-7, EN ISO 15614-11, EN ISO
15614-12 and EN ISO 15614-13 are relevant
 Welding procedure qualification Description
standard
ISO 15610 Tested Welding Consumables
ISO 15611 Previous Welding Experience
ISO 15612 Standard Welding Procedure
ISO 15613 Pre-production Welding Test
ISO 15614 Standard test piece
 Manufacturer's evidence of compliance
with the requirements
The manufacturer shall record the following items in a
document
1. Name and address of the manufacturer
2. The location where each activity is under taken
3. The type of welded components covered and the highest
classification level
4. the types of Activity (D,P,M or S)
5. Organization chart with names of responsible welding
coordinators along with his deputies
6. The executed welding processes, metallic materials group
according to CEN ISO/TR 15608 and the range of thickness
of base materials, for which the manufacturer is qualified
The manufacturers shall have documented evidence
to show for which certification level and for which type
of activity they are capable
If a change of one of the above mentioned items
happen, the document shall be duly modified and the
customers of projects in progress are duly informed
 SUBCONTRACTING

The manufacturer who is responsible for delivery of final

product to customer shall ensure-
1. Its subcontractors are able to ensure the requested
quality performances on the the products
2. They are capable of manage the process in accordance
of this series of standards and with the contractual
prescriptions
3. The subcontractors shall comply with the requirements
of EN15085-2 at the relevant classification level and the
compliance shall be clearly assessed and documented
If first article inspection on subcontracted welded product
is planned, an inspection at subcontractors facility shall be
carried out in accordance with EN 15085-5
As a minimum for products with classification level CL1-
Before the beginning of manufacturing activities, the
manufacturer of railway vehicle and /or its components
shall in form the customer about the sub-contracted weld
products and their producing suppliers.
The supply chain for each welded component shall be
made evident at any step of the fabrication process
The necessary evaluation of the sub-contractors facility
shall be done by the manufacturer in order to assess the
capability of the subcontractor to comply with this series of
standards
The manufacturer can also execute inspections at the
suppliers of the subcontractors
The evaluation shall be performed by a WC under the
supervision of RWC
The Manufacturer’s RWC or his nominee will execute the
evaluations at the beginning of the production.(First article
inspection)
Further evaluations are at the discretion of RWC
 CALCULATION OF WELDING
MANUFACTURER SIZE
Parameter Activity Factor
(a)Total no. of welders &welding welding minimum 1
operators
(b)No of activities performed P and/or M 1
P and/or M + D and/or S 1-2

(c )Types of welded materials used Non stainless steels, 1-3

Stainless steels & Non
ferrous materials
(d)No. Of shifts/day Less than or equal to 2 1
More than two shifts 2
(e)No of processes used( two digit welding minimum 1
processes as per ISO: 4063
(f)Classification level CL1 10
CL2 05
CL3 01
WM = a.b.c.d.e.f
If WM is less than or equal to 1500 the manufacturer
should be considered as small manufacturer
 SAFETY RELEVANCE
LOW: failure of welded component does not lead any
direct impairment of the overall function, consequential
events with personnel injuries are unlikely
Medium: failure of welded component leads to an
impairment of the overall function or may lead to
consequential events with personnel injuries
High: failure of welded component leads to consequential
events with personnel injuries and breakdown of the
overall function
 ISO 3834:Part-2
Comprehensive quality requirements

Constructions in which the failure of welds may lead to

Total product failure
With significant financial consequences
Major injury and loss of human life
The product may be subject to dynamic loading and addition to
high static loading.
 ISO 3834:Part-3
Standard quality requirement

Constructions in which failure of welds

Impair the intended use of construction.
Normal safety risk
Financial losses of not extreme in nature
   ISO 3834:Part-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.
 CERTIFICATION LEVELS
Certification levels are based on safety relevance
CL1: for welded railway vehicles and their welded
components with high safety relevance
CL2: for welded railway vehicles and their welded
components with medium safety relevance (Welded
joints with high safety category are not allowed)
CL3 : for welded railway vehicles and their welded
components with low safety relevance (Welded joints
with high or medium safety category are not allowed)
 This level applies to welding manufacturers which manufacture
welded railway vehicles or their welded parts with welded joints
classified in weld performance classes CP A to CP D. Certification
CL1 level CL 2 to CL 4 is included
New build, conversion and repair of rail vehicles and their components Examples for
components

COMPONE bogies (headstocks, sole bars, cross bearers, bogie frames)

NTS &
SUB- underframes (extensions, sole bars, cross bearers, assembly)
COMPONE vehicle body (front walls, side walls, roof);  draw and buffing gear
NTS
MADE BY supporting frames for external equipment parts (e. g. tanks, electrical, air-
MANUFA conditioning and compressed air containers);  wheelset mountings, axle
CTURERS boxes, spring supports, shock absorbers, vibration dampers
WITH
CERTIFIC brake equipment (magnetic track brake, brake rods, brake triangles, brake
ATION cylinders, brake cross beams)
LEVEL supporting frames for heavy duty vehicles including road/rail vehicles
CL 1
welded components for drag transmission from bogie to vehicle (bolster)
fuel tanks of vehicles
finishing welding of castings within components indicated above
pressure gas tanks, tanks and tank containers of rail vehicles with test
 This level applies to welding manufacturers which manufacture welded parts of railway vehicles with
CL2 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 only included according to welded joints
of certification level CL 2 or CL 3

COMPO  New build, conversion and repair of non-pressurised containers

NENTS without special test pressure, e.g.:
& SUB-  payload container for non-dangerous materials;  other transport
COMPO containers. New build, conversion and repair of structural parts for
NENTS rail vehicles, e.g.:  internal parts of passenger coaches (partitions,
MADE walls, doors, panelling);
BY  supporting frame for internal parts (electrical, air-conditioning and
MANUF compressed air installations);
ACTUR  driving cab equipment;  lavatory parts and water containers with
ERS installations;
WITH  sliding doors in vehicles including runways;  fastenings for brake
CERTIFI pipes;
CATION  non-self-supporting equipment boxes underneath the base frame
LEVEL (without supporting frame);
CL 2  gearboxes and consoles for hand brake operation;
steps, hand rails (including handrails in entry areas) and railings
external to the vehicle
CL3 This level applies to welding manufacturers which
manufacture welded parts of railway vehicles with welded
joints classified in weld performance class CP D
COMPO New build, conversion and repair production of simple attached
NENTS parts for rail vehicles, e.g: cranks and levers for various
& SUB- operations;
COMPO equipment boxes and switch cabinets in rail vehicles (including
NENTS gearboxes and consoles for hand brake operation, without
MADE supporting frame);
BY
MANUF holders for index plates;
ACTUR wheel scotches;
ERS covers for freight wagons (heat protection on tank wagons);
WITH
CERTIFI steps, handrails, railings on rail vehicles. New build, conversion
CATION and repair of parts or trade supply parts for rail vehicles, for
LEVEL instance:
CL 3 seating frames
window frames
ventilation grilles
CL4 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
COMPO This certification level is valid for manufacturers that do not carry out their
NENTS own welding fabrication if welded components and parts are:
& SUB- designed
COMPO
NENTS bought and assembled
MADE
BY
MANUF
ACTUR
ERS
WITH
CERTIFI
CATION
LEVEL
CL 4
 STRESS CATEGORIES AND STRESS
FACTORS

The Stress category is determined by the stress factor

Stress factor is the ratio Calculated fatigue stress/
Admissible fatigue stress , adjusted by appropriate
safety factor
 WELD INSPECTION CLASSES
The inspection class applicable to each welded joint is
defined depending on the weld performance class and
are used to identify the various types and minimum levels
of inspections on the welded joint.
 QUALITY LEVELS FOR
IMPERFECTIONS
Weld imperfections shall be defined in EN ISO 6520-1
(Fusion welding) and EN ISO 6520-2 (pressure welding)
Quality levels for Imperfections related to the weld
performance class shall be as listed below in tables 5&6
and in accordance with EN ISO 5817 and EN ISO 10042
Quality levels for Imperfections ,for laser welding are in
ISO 13919-1
Stud welded joints are permitted to weld performance
class CP C3 and CP D only.
Code Description Definition

100 Crack An imperfection produced by a local rupture in the solid state

which may arise from the effect of cooling or stresses
201 Gas Cavity A cavity formed by entrapped gas

202 Shrinkage A cavity due to shrinkage during solidification

cavity
3031 Linear oxide Metallic oxide entrapped in the weld metal during solidification
inclusion
401 Lack of Lack of union between the weld metal and the parent metal or
fusion between the successive layers of weld metals
501 Under cut A irregular groove at a toe of a run in the parent metal or in
previously deposited weld metal due to welding
5011 Continuous Under cut of significant length without interruption
under cut
1.1 Crack
1.3 Surface pore
1.5 Lack of fusion / Micro lack of fusion

1.13 Overlap
1.20 Insufficient throat thickness
2.3 Gas pore, uniformly distributed porosity

2.5 Linear porosity

3.1 Linear Misalignment
Quality requirements for resistance spot welding,
projection welding and resistance seam welding are
defined in table F.2 and for surface quality table F.3
applies.( Annex “F” EN 15085-3)
Resistance spot welding, projection welding and
resistance seam welding is not permitted for weld
performance classes CP A and CP B
Quality requirements for other welding processes may be
agreed between the manufacturer and customer
PRODUCTION REQUIREMENTS
Welding planning documents
Production weld tests
 Requirements for welds
Welding consumables
Parent metals
Welding processes
 Special requirements for maintenance of railway vehicles
General rules for maintenance welding
Testing and documentation
4.0 PREPARATION BEFORE WELDING
4.1: welding planning documents
4.1.1: General
Welding planning documents shall be prepared by the
manufactures with the assistance of welding coordinators
of Level A for new and converted vehicles and
maintenance of rail vehicles.
Type, scope and time of the submission and inspection
should be agreed between customer and manufacturer.
Welding planning documents may include working plans,
welding sequence plans, test planning documents and
Welding procedure specifications
 4.1.2 WORKING PLANS
For the production of railway vehicles working plans for
the following sub-assemblies is necessary
-Bogie (sub-assemblies, assembly)
-under frame(with sub-assemblies)
-body (side wall, end wall, roof)
-- further sub assemblies with high safety and functional
requirements( Shafts, brake cross members, motor
housing, hollow shaft drive, draw bar coupling, bogie
pivot pin, cross bearer)
4.1.3 OTHER WELDING PLANNING
REQUIREMENTS
For more complicated assemblies welding sequence plans are
necessary
--bogies( bogie bolster, bogie center plate including bogie pivot pin
member, bogie bogie pivot pin cross member)
-- Under frame( sole bar, cross members, head stock)
 standardized welding sequence plans that are applicable for different
types of vehicles are also allowed
Other welding planning documents like, tacking sequence plans,
repairing plans, test plans, documents for jigs and tools, remarks for
protection of labour and health, plans for separating of damaged
parts, special instructions for electrical parts,
These details shall be determined by the RWC and /or the customer
 4.1.4 WELDING PROCEDURE
SPECIFICATION
For welds with welding performance classes CP A,CP B,
CP C1, CP C2 and CP C3 welding procedure
specifications according to EN ISO 15609-1 to EN ISO
15609-5 or EN ISO 14555-1 or to EN ISO 15620 are
necessary
For weld performance class CP D this is only necessary if
the customer demands it.
Depending on the weld performance classes according to
EN 15085-3, the following evidences are necessary for the
welding procedure specification
Weld performance class CP A: evidence according to
any of the following EN ISO 15614 or EN ISO 15620
EN ISO 15613 only if a WPQR according to EN ISO
15614 exists
For materials Reh>500Mpa or fully mechanised welding
process EN ISO 15614
 for the WPQR the acceptance criteria of weld
performance class CP A, EN ISO 15085-3 Tables 5 and 6
shall be fulfilled
welding performance classes CP B, CP C1, CP C2:
Evidence according to any of the following standards EN
ISO 15613,EN ISO 14555, EN ISO 15620
If necessary for a component or material EN ISO 15614
welding performance classes CP C3:
Evidence according to any of the following standards EN
ISO 15610,EN ISO 15611,EN ISO 15612, EN ISO 15613,
EN ISO 14555, EN ISO 15620
If necessary for a component or material EN ISO 15614
welding performance classes CP D:
According to the requirement of the customer
In general for every WPS, shall be covered by a WPQR,
except for weld performance class CP D(unless specified
in the contract)
For railway application the following parts of EN ISO
15614-1, EN ISO 15614-2, EN ISO 15614-3, EN ISO
15614-4, EN ISO 15614-7, EN ISO 15614-11, EN ISO
15614-12 and EN ISO 15614-13 are relevant
 4.2 PRODUCTION WELD TESTS
4.2.1 General
[Link] Aim and objective of production weld tests
-if necessary production weld tests shall be carried out
1. To check and ensure the design is satisfactory as
specified in EN 15083-3
2. To prove the welding conditions
3. To demonstrate the skills of the welders
4. to demonstrate the quality of the weld
One production test can be used for for several tasks
mentioned above
 4.2.5 PRODUCTION WELD TESTS TO
DEMONSTRATE THE QUALITY OF THE WELD

weld quality may be demonstrated by production weld tests to

ensure the weld quality for inspection class CT 2,if neither X-
ray nor ultrasonic inspection is possible.
Kind of production weld test and frequency should be given in
the test plan
Production weld tests shall be taken from the assembly or from
the extension of a work piece or from a similar work piece
Production weld tests should be checked in accordance with
EN ISO 15613 and
The tests shall be documented
 WELD QUALITY
Stray arcing is not allowed and if occurs for CP A,CP B or CP
C1welds surface test shall be carried out .
Permission of spatters depends on the material used and application
and shall be agreed between customer and manufacturer
Permanent backing is allowed only if it is specified in drawing
Temporary attachments are permitted with agreement to design(Refer
EN1101-1 )
When nominal thickness of job gets reduced by more than 5%, a
repair operation is necessary and deviations shall agreed by customer
Notch free grinding if specified in drawings for strength reasons, the
grinding shall be in the direction of loading
For repair welds only qualified procedres,suitable for the weld
performance class shall be used
Before repairing the reason of damage or deviations shall be
determined and agreement of the customer shall be obtained
Welding over cracks is not permissible, complete removal of
cracks before welding and surface testing shall be carried out
before and after welding
Flame straightening if used it shall not reduce the strength of
the material and deviations shall be agreed by customer
Temp measurement and control shall be followed and melting
is not permitted
 INSPECTION ,TESTING AND
DOCUMENTATION
Testing and documentation shall be in accordance with EN
15805-3(minimum) when design is according to EN 15085-3
If the weld performance class is unknown the highest
possible weld performance class related to the safety
category of the weld shall be used
For repair welding of single defects testing shall be 100% for
welding performance class of CP C1 and CP B
For all welds 100% Visual inspection shall be performed
All NDT tests shall be recorded
A welding report has to be prepared by a RWC or his nominee
INSPECTION AND TESTING BEFORE
WELDING:
The RWC is responsible for-
[Link] of back gouging and sealing run
[Link] of additional information related to welding
to incorporate in drawings
As proof of execution of above tasks ,the out come
shall be recorded
In order to carry out above tasks, the RWC may seek
support of other departments.
Details of responsibilities for the tasks have to be
defined
TASK OF WELDING OPERATOR OR WELDER BEFORE STARTING OF
ANY TYPE OF WELDING ACTIVITY IS TO CHECK:
[Link] welding is validated and efficient
[Link] of work instructions
[Link] of edges and correct tacking of items to be welded
4. Identification of items to be welded
[Link] of the welding consumables with the WPS
 INSPECTION AND TEST DURING WELDING:
The welders and welding operators performing the job have to check
and ensure
1. Adequate cleaning and shape of the joints during intermediate passes
2. Compliance with the prescribe values of pre heating and /or inter
pass temperatures
3. Compliance with WPS and/or work instructions
4. Compliance with the sequence of operations if prescribed
5. The process steps and phases of a welding activity, are to be
supervised by RWC or his deputy shall be explained in welding
planning documents
6. If the weld sequence plan or testing plan require a check of a weld
during production ,welding shall be continued only after the weld has
been checked
 INSPECTION AND TESTING AFTER
WELDING
After welding the welder or welding operator has to
check
1. That the weld is complete
2. That the weld is cleaned
3. That the profile and dimensions of the weld
conform to the drawing
 SELF INSPECTION BY THE WELDER
OR WELDING OPERATOR
Personnel entrusted with self inspection shall be suitably trained for
visual inspection as per the requirements of EN 15085-3:2007 clause
“5” by RWC or his nominee or by a person certified to level II (ISO
9712)
The inspections carried out by welder or welding operator shall be
clearly defined (acceptance criteria, dimensioning) and recorded in
accordance with table 1
Recording documents shall be signed by the welder or welding
operator and have to be enclosed with other inspection documents
A copy of personnel signatures with names in clear printed text will
be held for all personnel who sign inspection documents.
Alternatively traceability can be achieved by an electronic system
 QUALIFYING THE INSPECTORS
As per EN 15085- 5: clause 4.4.3 all the weld joints classified
under various performance classes(see annex) are to be inspected in
accordance with relevant testing class vizCT1, CT2, CT3 or CT4.
Volumetric NDT methods like RT/UT, surface tests like MPT/DPT
are to be conducted at the rate of 100% for testing class CT1 and at
the rate of 10% for testing class CT2.
All weld joints irrespective of of testing class (CT) are to be
inspected 100% visually.( 100% means full length of weld or all the
components manufactured) .
To have sufficient qualified man power at the disposal of inspection
department ,to carry out above mentioned tests and document the
test results, training has to be imported accordingly.
All the volumetric, surface NDT methods and Visual
inspection of weld joints falling under the testing
classes CT1 and CT2 ( for CP A,CP B & CP C1
performance classes)shall be performed by personnel
qualified according to the standard ISO 9712
Weld joints falling under the testing classes CT3
(CPC2 performance class) shall be visually inspected
by the personnel, whose competence is ascertained by
the manufactures and the same should be documented.
Weld joints falling under the testing classes CT4 (for
CP C3 and CP D performance classes) shall be visually
inspected by welders/welding operators, who are trained
in visual examination and documentation, is not needed.
Personnel entrusted with self inspection of weld
joints(welders, welding operators or any shop floor
person entrusted with self inspection) shall be
suitably trained in ISO 5817: acceptance criteria for
fusion welding of metallic materials(Ref: EN 15085-
3: Clause).
Hence it is advised to the Quality department, to
identify the inspecting personnel requirement to carry
out inspection activities as mentioned above.
Where ever certification as per ISO 9712 is needed,
it can be planned send to outside institutes and any
assistance in this regard can be taken from AWTI.
For visual inspection personnel engaged in
examining of inspection class CT3 category joints
and personnel involved in self inspection of CT4
category joints AWTI is competent enough to train.
AWTI is conducting visual inspection training to
satisfy the above requirements. Every week one batch
for inspectors and supervisors is planned for training
for a period of 02 days.
Welders are also being trained at AWTI for half a day
for identifying the defects and reasons for the defects
so that they can take care during welding
THANK YOU