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Nowadays, controlling welding as a special process is dealt with in ISO 3834,[3] quality requirements for fusion welding (which was first published as ISO 3834, and as EN 729, in 1995). This standard sets specific requirements for the competence of people with welding responsibilities and this includes: welders, NDT personnel, welding inspectors and welding coordinators. In other words, it is clear that anyone and everyone who can have an impact on the final quality of the welds in the product must have the required competence. It is like a chain - a 'welding quality chain' - if only one link is missing or faulty, the chain will break and the kinds of problems highlighted above may occur. This is recognised in ISO 14731,[4] welding coordination - tasks and responsibilities (first published in1994 as EN 719) which is referred to in ISO 3834.
As mentioned above the special importance of competence in welding has been recognised for many years. Since the 1980s a great deal of effort has gone in to the development of an internationally harmonised education, training, qualification and certification system.[5] The system is now maturing, and is implemented and recognised widely throughout the world. Over 140,000 diplomas have been awarded. Some of these harmonised qualifications are also mentioned in ISO 3834 and ISO 14731.
ISO 14731 requires the manufacturing organisation to appoint at least one Responsible Welding Coordinator (RWC). It is useful that the standard makes reference to the International/European qualification system as a way of dealing with the technical knowledge requirements for RWCs; but what about RWCs who do not possess an International/European qualification EWF/IIW have developed guidance on this for certification bodies conducting compliance assessments of manufacturers to ISO 3834, see Appendix 1. Routes (a) and (b) in Appendix 1 are straightforward because of the presence of the international harmonised certification/qualification. Route (c) is more complicated because it deals with RWCs without such certification/qualification. Some experience of implementing route (c) in the UK is given in the section below.
In order to comply with the standard, the manufacturer must be able to show that employees with any of the tasks listed in ISO 14731 must possess appropriate competence. EWF/IIW have developed a wide range of so-called 'guidelines' that describe courses of training designed to underpin different welding related jobs, see Appendix 2. Therefore for many of the activities covered by welding coordination in ISO 14731, a harmonised and recognised International/European course is available. However, these courses are not widely used at present and, again, more must be done to convince industry of their value.
For all the other welding activities and related tasks and responsibilities identified in ISO 3834 and ISO 14731 there is no such culture of competence assessment. In recent years, TWI has been involved in the assessment of a number of companies against the requirements of ISO 3834 and this has led to a number of interesting issues with regard to competence assurance.
One manufacturer challenged the link between ISO 3834 and ISO 14731. The view of EWF/IIW (and TWI) is that, in order to comply with ISO 3834 Part 2 ('comprehensive' quality requirements) or Part 3 ('standard' quality requirements), the manufacturer must also comply with ISO 14731. It is interesting that neither Part 2 nor Part 3 refers to ISO 14731 directly: the issue is covered only by reference to Table 2 of Part 5 (normative references). This table does indicate the need to comply with ISO 14731 but, in the general section of Part 5, in section 2.1 (according to a corrigendum) it is stated that 'other documents' or 'different supporting standards' can be used in certain circumstances. Unfortunately this provides a basis for a manufacture to challenge the need for compliance with ISO 14731.
Once the manufacturer has accepted the need for compliance with ISO 14731, the first issue to deal with is the competence of the appointed RWC. As mentioned above IIW/EWF have issued guidance on this (see Appendix 1) and, in dealing with route (c) people, TWI has also found it beneficial to follow the requirements of document EA-6/02[10] which state:
In TWI's experience there have been several instances where the appointed RWC has fallen short of the requirements in terms of technical knowledge requirements of ISO 14731. In the UK, RWCs are often people who started their careers in practical welding and, over a number of years, have been successively developed their careers away from practical welding, for example into welding inspection, quality assurance, etc, until they become the most senior welding person in the company. These people are often perfectly competent to follow the procedures and systems that have proved successful in the company over a period of time, but often they do not have the underlying knowledge as to why things are done in the way that they are. This can be a serious problem if there are changes, for example to the materials, welding processes or products used by the company, or if something runs outside of the applicable specification. The person could tell you, for example, what the preheat temperatures are for the all the joints to be welded and how those temperatures are achieved, but may be completely ignorant as to why preheat is necessary. In such cases, TWI recommends that the person attend the relevant European/International Diploma modules in order to acquire the important underlying technical knowledge.
ISO 14731 does allow 'acceptable national qualifications', as alternatives to the European/International ones, to confirm technical knowledge. In the UK, we are fortunate to have had a system for assessing and assuring competence in welding for many years. This is called Professional Membership of The Welding Institute and it is directly related to the UK national system for registering engineers and technicians in all fields.[11] Possession of one of these qualifications can be a convenient way of satisfying the route (c) requirements for RWCs.
If it is clear that there is no one in the company with the capability to meet the ISO 14731 requirements regarding the RWC, the company can engage an external consultant to fulfil this role. In such cases, TWI advises that additional control measures are applied:
Anyone with welding responsibilities, no matter how narrow is categorised by ISO 14731 as a welding coordinator and must be able to demonstrate competence in the allocated tasks. TWI recommends that the manufacturer draws up a matrix of all the welding tasks identified in ISO 14731, together with the names of the people who are responsible for each one. As an example, a storekeeper may be responsible for the correct storage of a wide range of equipment, tools, etc, and this may include welding consumables. In such a case, the storekeeper would be expected to know about the importance of correct storage of welding consumables and to ensure that correct procedures are adhered to. If the storekeeper does not possess the competence to fulfil these tasks, there is a weak link in the 'welding quality chain' and, even if the company has the best welders and the best RWC in the world, problems may arise. The storekeeper is a welding coordinator according to ISO 14731 and should be trained and recognised as such by the company.
The competence requirements in ISO 3834 and ISO 14731 are a major step forward in recognising the special importance of welding and in ensuring that welding production is under competent control. What is important now is for standards writing bodies to call up the standards in applications standards and for client organisations to specify the standards in their contracts. Where possible it would also be beneficial to write in the need for some kind of recognised third party assessment of compliance. Certification bodies are free to offer ISO 3834 assessment and certification services, but these are only likely to bring value of they are under national accreditation in accordance with EA-6/02. Even so there is evidence that accredited certification to ISO 3834 is being carried out that is not in compliance with ISO 3834. The accreditation bodies should address this: EA-6/02 is their document and they should be more rigorous in controlling its implementation.
With regard to the standards themselves, the link between ISO 3834 and ISO 14731 should be made more solid. There should be no scope for challenging the applicability of ISO 14731 in the case of compliance with ISO 3834 Part 2 or Part 3.
In the case of welding manufacture, health and safety, and environmental management are especially important but neither of them is mentioned in ISO 3834 or in ISO 14731. It is recommended that this is addressed by the bodies responsible for these standards. The omission has been recognised by EWF and documents have been published about how to take of heath, safety and the environment from the welding point of view.[12] Manufacturers have the option to undergo assessments against these requirements as part of their EWF ISO 3834 assessment. 153554b96e
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