Factory Production Control System

FACTORY PRODUCTION CONTROL SYSTEM
WELDING QUALITY MANAGEMENT SYSTEM

FACTORY PRODUCTION CONTROL
(QUALITY REQUIREMENTS FOR

FUSION WELDING OF METALLIC MATERIALS)
For
based on
EN ISO 3834-3:2005
BS EN 1090-1:2009 +A1:2011
Manual No. Issue: 01
21st January 2017
Issued to
Michael Roulston
Date Issued 23rd Jan 2017
Controlled / Uncontrolled
Page: 1 of 29 Doc 01_Factory Production Control System

Printed 23/01/17 Uncontrolled when printed
Issue: 1
Dated: 23/01/2017
Page 2 of 29
Contents
1. Scope
2. Normative references
3. Terms and definitions
4. Compliance with ISO 3834
5. Review of requirements and technical review
6. Subcontracting
7. Welding personnel
8. Inspection and testing personnel
9. Equipment
10 Welding and related activities

.
Welding consumables
11
. Storage of parent materials
12 Post-weld heat treatment

.
Inspection and testing
13
. Non-conformance and corrective actions
14 Calibration and validation of measuring, inspection

. and testing equipment
15 Identification and traceability

.
Quality records
16
. Appendix A Associated Forms

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Scope, Normative References, Dated: 23/01/2017
SECTIONS: 1 to Terms and Definitions & Page 3 of 29
4 Use of this part of ISO 3834
Section 1 – Scope
This Manual defines compliance with standard quality requirements within BS EN 1090-
1:2009 +A1:2011 Execution of steel structures and aluminium structures and BS EN 3834:3
for fusion welding of metallic materials both in workshops and on installation sites; to achieve
Execution Class 2 in accordance with BS EN 1090-2:2008+A1:2011.
2. Normative References
Section 2 – Normative References
The following referenced documents are obligatory for the application of this manual. For
dated references, only the edition cited applies. For undated references, the latest edition of the
referenced document (including any amendments) applies.
ISO 3834-1, Quality requirements for fusion welding of metallic materials – Part 1: Criteria
for the selection of the appropriate level of quality requirements.
ISO 3834-5:2005, Quality requirements for fusion welding of metallic materials – Part 5:
Documents with which it is necessary to conform to claim conformity to the quality
requirements of ISO 3834-2, ISO 3834-3 or ISO 3834-4.
3. Terms and Definitions
Section 3 – Terms & Conditions
For the purposes of this document, the terms and definitions given in ISO 3834-1 apply.
4. Use of this part of ISO 3834
Section 4 – Use of this Manual
For general information on the use of this Manual the relevant parts of ISO 1090:1 & ISO
3834-1 shall be used. In order to fulfil the quality requirements given in ISO 3834, the
conformity to relevant documents given in ISO 3834-5 shall be verified.
This manual relates to the comprehensive requirements of ISO 3834-3. In certain situations
e.g. where manufacturing is more suited to ISO 3834-4, or where particular operations, such
as heat treatment, are not undertaken, the requirements detailed in this part of ISO 3834 may
be selectively amended or deleted.
Otherwise, the requirements contained within this Manual and ISO 3834:3 shall be adopted in
full.

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SECTION: 5 Review of Requirements
Page 4 of 29
and
5. Review of Requirements and Technical Review
Section 5.1 – General
The contractual and technical requirements of the project must be fully understood by all
departments to allow compliance with the specification & standards and enable an Inspection
Test Plan to be prepared.
Section 5.2 – Review of Requirements
A review of the project requirements
a) Product & supplementary standards
b) Statutory & regulatory requirements
c) Any additional requirement
d) Our capability to meet the prescribed standards
Section 5.3 – Technical Review
A review of the technical requirements
a) Parent material specification and welded joint properties

b) Quality & acceptance requirements for welds
c) Location accessibility and sequence of welds including inspection
d) Specification of procedures, NDT & heat treatment
e) Qualification of welding procedures
f) The qualification of personnel
g) Selection, identification and/or traceability (eg for materials & welds)
h) Quality control requirements including independent body involvement
i) Inspection & testing
j) Sub-contracting
k) Post weld heat treatment
l) Other welding requirements ie ferrite, ageing, hydrogen, backing, finish, profile
m) Special methods (full pen without backing etc)
n) Dimensions and details of prepeartion and completed weld
o) Welds in workshop or site etc
p) Environmental conditions (low temp, ambient, protection, weather)
q) Handling of non-conformancies

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Review of Requirements
SECTION: 5 Page 5 of 29
and
On receipt every order is given a unique reference number. The number sequence and list of
every order is recorded in our bespoke system.
A full review of all the documents and drawings forming the basis of the contract is carried
out.
The allocation of the project number verifies that the initial contract review has taken place.
The next stage is for the Drawing Office Manager designate to assess the job content in detail
and to control and monitor all stages of progress.
The basis of the controls applied are to verify the design of the product in order to ensure that
the specified requirements and obligations under Fabriclad regulations are met. The contractual
arrangements determine the type of design work involved which can include:-
a) Design input.
The design input requirements be identified, documented and reviewed by the relevant
nominated Engineer in accordance with the design checklist for the project including
significant health and safety hazards and risks of the design. Any incomplete, ambiguous or
conflicting requirements shall be resolved.
b) Design output.
The design output shall be documented and expressed in terms of requirements, calculations
and analyses, and shall:-
i. meet the design input requirements;
ii. contain a reference of acceptance criteria;
iii. conform to appropriate regulatory requirements whether or not these

have been stated in the input information;
c) Design Control
Identify those characteristics of the design that are crucial to the safe and proper functioning
of the product;
Provide adequate information on health and safety and risk assessment.

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Review of Requirements
SECTION: 5 Page 6 of 29
and
Design Stages
i. Read specification and associated relevant documentation.

ii. Identify British Standards applicable. Identify client specification to be used.
iii. Carry out risk assessments in compliance with Fabriclad regulations. Update check list to
record review carried out. Advise planning supervisor of risk assessment review.
iv. Formulate loading references;
v. Special loading to be advised by client
vi. Normal loading in accordance with:BS 6399 pt 1 & 3 BS 5939 CP3 cpt V pt 2
vii. iii) Abnormal loading: Earthquake, Wind, Snow, Other.
viii. Identify shortfalls in information. Advise client and indicate when information is
required by.
The documented design calculations are produced both manually using controlled calculation
sheets and relevant reference standards and specifications. Also, design analysis program. The
computer program contains all the various engineering formulae, is furnished with the
relevant specification details, carries out the design calculations and produces detailed
printouts thereof.
d) Design Verification
Design verification shall be planned to take place (as per the design checklist) and shall be
documented and carried out by competent persons. The design verification shall establish that
the design output meets the design input requirements by such means as:-
I. holding and recording design reviews;

II. carrying out risk assessments in relation to:
a. materials, substances, plant and equipment
b. construction work
c. maintenance of completed structure
III. undertaking qualification tests and demonstrations;
IV. carrying out alternative calculations;
V. comparing the new design with a similar proven design.
The design checklists include the verifications that are to be carried out. This is usually done
by a nominated authorised competent person independent of the engineer responsible for
preparing the design calculations.The correct functional operation of the integrated design
analysis program is verified prior to use as included on the design checklist.
e) Design Changes
All changes to design details (data, criteria, specification, etc.) shall be identified,
documented and subject to the appropriate review and approval. This is usually carried out in
the same manner as per original calculations.

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SECTION: 5 Review of Requirements
Page 7 of 29
and
In satisfying all requirements and whilst maintaining full control of all design and
development aspects the following stages are followed. The Drawing Office Manager
maintains the “design checklist” with the current up-to-date process stage of the design, this is
held with the project details in the technical file.

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Subcontractin Page 8 of 29
SECTION: 6
6. Subcontracting
Section 6 –
6.1 In the event that subcontracting is necessary, all subcontractors shall return the Vendor
Self Assessment Subcontractor Questionnaire. The Works Manager will ensure
correct subcontractors are used on the contract.
6.2 Sub-contractors required to perform NDT shall submit their procedures and
qualifications to the RWC for review and approval prior to use on the contract.
6.3 Sub-contractors required to perform post weld heat treatment shall submit their
procedures and qualifications to the RWC for review and approval prior to use on the
contract.
6.4 All NDT certificates, dimensional reports, test reports, weld documents etc.
originating from the sub-contractor shall be filed with the contract file.
6.5 The sub-contractor cannot change their procedures etc without written confirmation
from the RWC.
6.6 The sub-contract shall be issued with all the relevant data for the contract including
the information from the Review and Technical review meetings.
6.7 The sub-contractor shall provide such records and documentation of his work (i.e.
Certificate of Conformity) as stated in the Purchase order/Request

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Welding Page 9 of 29
SECTION: 7
7. Welding Personnel
All welding procedures and welders shall be qualified in accordance with EN ISO 15614-1 (weld
procedures) and BS EN 287-1/BS EN 9606-1 (welder approval) or the latest prevailing ISO
standards.
The Works Manager holds production meetings with the works supervisor/ WC.
All manufacturing/testing/inspection requirements and lot scheduling are planned and recorded.
For production welding the RWC shall issue a set of code qualified ‘standard’ WPS’s that are
permanently displayed in the fabrication shops. The WC shall review each new contract/drawing
requirements to determine if there is a need to qualify and issue new/additional WPS’s.
Section 7.2 – Welders & Welding Operators
Welders shall be re-qualified when any one of the following occur:
When they have not welded with a process during a six month period or more, their qualifications for
that process will expire.
When there is reason to question their ability to make welds that meet the specifications such as
regular non-conformances, the qualifications which support the welding they are doing will be
revoked. All other qualifications not questioned remain in effect.
The welder shall mark his identification adjacent to each weld he makes, marking of drawings is also
acceptable.
Tack welds whether left in place or removed, shall be made by platers/welders following a qualified
WPS.
Tack welds may be removed or be suitably prepared so that their starting and stopping ends can be
satisfactorily incorporated in the final weld.
Tack welds shall be examined by the welder prior to being incorporated in the weld and if defective
will be completely removed.
Tack welds shall not be less than the throat thickness or leg length of the root run to be used in the
joint and shall be subject to the same welding conditions as those specified in the WPS.
The edges and surfaces to be joined by fillet welds shall be in as close contact as possible since any
gap increases the risk of cracking, but in no case shall the gap exceed 3mm.

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SECTION: 7
Alignment of butt joints at the root edges or root faces shall not be out of alignment by more than
25% of the thickness of the thinner material up to and including 12mm thick, or by more than 3mm
for material thicker than 12mm.
Welds for temporary attachments shall be made in accordance with the same requirements as the
specified WPS. When attachments are to be removed this should be done carefully as to leave the
parent material surfaces smooth by grinding and if necessary followed by crack detection.
Precautions shall be taken to avoid stray arcing on parent materials. Careful placement of earth return
clamps and cables shall be made. Should stray arc marks be evident they shall be ground and crack
detected prior to weld repair and ground flush to reinstate the surface condition.
Surfaces shall be protected from the weather. Whenever there is evidence of condensation taking
place on metal surfaces warming shall be carried out to remove such condensation. In any case no
welding shall be carried out on parent material below 0°c. When rain or snow is falling or during
periods of high wind, necessary precautions shall be taken to protect outdoor welding areas. Draughts
shall be prevented from blowing along the bores of hollow sections when the bore will be penetrated
during welding. Where gas shielded welding processes are being used sufficient screening shall be
used to keep winds and draughts away from the welding area.
Parts to be welded shall be assembled such that the joints to be welded are easily accessible and
visible to the welder/operator. All of the above paragraphs are the responsibility of the welder/plater
to ensure the integrity of the weld joint to the required standard/specification.
Section 7.3 – Welding Coordination Personnel
The RWC is responsible for the generation of welding procedure specifications and qualification of
procedure qualification records (PQR). He is also responsible for the qualification of welders and the
generation of the welder performance qualification record (WPQ).
The RWC or a suitably qualified deligate shall supervise the welding of the test pieces for
qualification, recording the actual variables applicable to the process used during welding. The
preparation and testing of the specimens is performed by a testing laboratory in accordance with the
qualifying standard. The test/laboratory report shall be reviewed and if acceptable, prepare the
procedure qualification record (PQR) or (WPQ) as applicable.
The RWC shall the review the PQR or WPQ for compliance with the standard and if satisfactory will
certify the PQR or WPQ.
The RWC shall revise or write a new WPS whenever there is a change in one or more of the standard
essential variables, when applicable will require a new qualification.
The RWC may call for the re-qualification of a qualified WPS or welder if he has cause to question
the ability of either to produce sound welds. Additionally the RWC has the authority to stop
production works if he has serious concerns regarding weld quality or circumstance affecting weld
integrity.

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SECTION: 7
The WC shall maintain a file of welder performance qualifications and shall check welding
inspection reports to verify and ensure qualifications are kept current.
The RWC shall maintain welder approval qualifications by signing at six monthly intervals, the date
following the preceding satisfactory performance to a maximum of three years upon which the
certificate is renewed or recertified.
An updated copy of the register of welder capability shall be retained on file by the WC.

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Inspection and Test Personnel Page 12 of 29
SECTION: 8
8. Inspection and Test Personnel
8.1.1 Welders shall perform first line inspection of completed welded joints.
8.1.2 Inspections are validated by the WC as necessary.
8.1.3 The Works Manager shall be notified of any inspection/manufacturing standard requirements
of the project specifications including inspection methods by issue of an Inspection Test Plan
(ITP)
Section 8.2 – Non Destructive Testing Personnel
8.2.1 The drawings shall specify dimensional tolerances/limits, weld sizing/spacing. Post welding
requirements ie: peening, heat treatment, grinding, flush, etc.
8.2.2 The drawing office shall specify on drawings the weld types/joint connections intended to be
used. The use of standard weld symbols and or notations shall be used.
8.2.3 The Works Manager and Works Supervisor shall have the responsibility of planning
scheduling of inspection stages considering the production sequences to allow access
requirements for NDT/rework/repair welding.
8.2.4 The WC shall provide welders / operators with the measuring the devices for checking weld
sizes ie: fillet weld gauges, adequate lighting etc.
8.2.5 The Works Supervisor shall supervise the welders / operators to ensure they are carrying out
visual inspections properly to contract requirements.
8.2.6 Non destructive testing personnel are engaged on a sub-contracted basis when required by the
contract specifications.
8.2.7 The NDT sub-contractor shall submit NDT operator qualifications to the RWC for inspection
and approval prior to commencing work.
8.2.8 The NDT sub-contractor shall make the RWC aware of any changes / additions of personnel
process qualification expiry dates.
8.2.9 NDT sub-contractor qualifications shall be recognised by ISO standards.
8.2.10 The RWC where necessary shall audit the NDT sub-contractors registered premises to ensure
the capabilities the company has to carry out reporting, maintenance of testing equipment,
record retention library standards etc.

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Equipment Page 13 of 29
SECTION: 9
9. Equipment
Section 9.1 – Production & Testing Equipment
I. Bandsaws
II. MIG welding plants
III. Gas burning set
IV. Various Grinders, pistol drills & magnetic drills
Section 9.2 – Description of Equipment
 One fork lift truck with capacities of 2.5 Tonne
Section 9.3 – Suitability of Equipment
All new equipment will be assessed by the Works Manager prior to final ordering
Section 9.4 – New Equipment
Installation will be by qualified and suitably experienced person
Completion certification will be provided by installer prior to handover.

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Equipment Page 14 of 29
SECTION: 9
Section 9.5 – Equipment Maintenance
All electrical wiring will be inspected at 4 yearly intervals
All small tools will be PAT tested at 12 monthly intervals
All office & IT equipment will be tested at 12 monthly intervals
Plant & Machinery will be inspected annually or repaired on diagnosis of fault
Tools will be repaired as required
Defective Equipment shall not be used and tagged as “out of service”.

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Welding and Related Page 15 of 29
SECTION: 10
10. Welding and Related Activities
Section 10.1 – Production Planning
The Works Manager holds production meetings on a daily basis with the Works
Supervisor/WC, these meetings are not formally recorded/minuted.
Section 10.2 – Welding Procedure Specifications
For contract production welding the RWC shall issue a set code qualified “standard” WPS’s
that are permanently displayed in the fabrication shops.
The WC shall review each new contract to determine if there is a need to qualify and issue
new or additional WPS’s.
Section 10.3 – Qualification of Welding Procedures
Weld procedures shall be qualified inaccordance with BS EN ISO 15614.
Section 10.4 – Work Instructions
Tack welds shall be examined by the welder prior to being incorporated in the weld and if
defective will be completely removed.
Tack welds shall not be less than the throat thickness of leg length of the root run to be used
in the joint and shall be subject to the same welding conditions as those specified in the WPS.
The length of tack weld shall not be less than four times the thickness of the thicker part or
50mm whichever is the smaller.
The edges and surfaces to be joined by fillet welds shall be in as close contact as possible
since any gap increases the risk of cracking, but in no case shall the gap exceed 3mm.
Alignment of butt joints at the root edges or root faces shall not be out of alignment by more
than 25% of the thickness of the thinner material up to and including 12mm thick, or by more
than 3mm for material than 12mm.
Welds for temporary attachments shall be made in accordance with the same requirements as
the specified WPS. When attachments are to be removed this should be done carefully as to
leave the parent material surfaces smooth by grinding and if necessary followed by crack
detection.

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Welding and Related Page 16 of 29
SECTION: 10
Precautions shall be taken to avoid stray arcing on parent materials. Careful placement of
earth return clamps and cables shall be made. Should stray arc marks be evident they shall be
ground and crack detected prior to weld repair and repair and ground flush to reinstate the
surface condition.
Surfaces shall be protected from the weather. Whenever there is any evidence of
condensation taking place on metal surfaces warming shall be carried out to remove such
condensation. In any case no welding shall be carried out parent material below 0˚C. When
rain or snow is falling or during periods of high wind, necessary precautions shall be taken to
protect outdoor welding areas. Draughts shall be prevented from blowing along the bores of
hollow sections when the bore will be penetrated during welding. Where gas shielded
welding processes are being used sufficient screening will be used to keep winds and draughts
away from the welding area.
Parts to be welded shall be assembled such that the joints to be welded are easily accessible
and visible to the welder.
Section 10.5 – Procedures for Preparation & Control of Documents
All of the above paragraphs are the responsibility of the welder/plater to ensure the integrity
of the weld joint to the required standard/specification.
The Welder is responsible for recording all inspection findings.
The WC is responsible for monitoring all weld inspections and preparing weld defect reports
and, where applicable, Non Conformance Reports.

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Welding Consumables Page 17 of 29
SECTION: 11
11. Welding Consumables
All welding consumables will be controlled by the Works Supervisor.
Section 11.2 – Batch Testing
Batch testing of welding consumables shall be carried out only if specified by the Client or
individual project specification.
This will be identified in the Tender review and noted on the Inspection Test Plan.
Section 11.3 – Storage & Handling
All welding consumables follow the same principles applied in ‘STEEL DELIVERIES’.
Welding Wire -: Test Certificates are taken off driver/office and handed to the supply
chain/goods inward department.
Delivered wire is then checked against purchase order.
Test Certificates are checked and stamped with a unique number and documented by the
RWC.
Documentation follows similar rule as ‘STEEL DELIVERIES’.

Delivered wire will have the unique test certificate number manually marked on the box.
Delivered wire is stored in heated welding stores in date order (this enables older dated wire
to be used first).
When a welder/plater requires a new reel of wire the unique test certificate number on the box
must be recorded stating which contract the wire is to be used for (manual documentation is
acceptable as an addition)
All welding wire test certificates follow same procedure as for material test certificates.
All Stainless Steel Consumable deliveries must be stored in designated STAINLESS ONLY

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Storage of Parent Page 18 of 29
SECTION: 12
12. Storage of Parent Materials
Section 12 – Storage of Parent Metals
12.1 Parent materials are delivered to the Workshops by steel suppliers transport
12.1.1 The receiving personnel receive all incoming parent materials checking the order
details for quantity , size, grade and condition and issues delivery notes and test
certificates to the Works Supervisor/WC.
12.1.2 The receiving personnel also check the material identification numbers match the
material test reports supplied with the delivery. If there are any discrepancies material
is rejected immediately or admitted into the return area.
12.1.3 The receiving personnel shall check the material specification grade for compliance.
12.1.4 Parent materials bought for stock will be inspected as previous but marked as stock
12.2 Parent materials shall be stored by means off the ground and arranged so that water
cannot accumulate preventing corrosion damage.
12.2.1 Parent materials shall be adequately supported to prevent permanent distortion.

Timbers shall be strategically placed to distribute the material weight evenly. Visual
periodic checks shall be done by the receiving personnel for materials in long term
storage ensuring no deterioration/damage of supports has taken place.
12.2.2 Parent material shall not be stacked in a potentially dangerous manner to avoid
personnel injury and surface abrasion/damage to parent materials and property.
12.3 Parent materials shall be stored in an arrangement allowing further safe movement.
12.4 Protection shall be given to corners and edges when lifting/moving parent materials to
prevent crushing/mechanical damage.
12.5 Site storage of parent materials shall be treated the same as above

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Post-Weld Heat Treatment Page 19 of 29
SECTION: 13
13. Post-Weld Heat Treatment
Section 13 – Post Weld Heat Treatments
The Technical Review meeting will determine the requirement for post weld heat treatment
and this will subsequently be recorded on the Inspection & Test Plan.
A UKAS accredited test laboratory with suitability calibrated heat treatment facilities and
documented procedures outlining their method for control of the complete PWHT process
(ie. Control of temperature, heating and cooling rates), would be used.
The RWC shall then arrange a meeting with the heat treatment company to discuss the
specific requirements and establish that it is capable/competent to carry out the work on-site,
has appropriate documented procedures, suitably calibrated equipment and can provide the
necessary documentation to demonstrate control of the complete rocess.
The RWC is responsible for review/authorisation of the heat treatment procedure and
ensuring it satisfies the technical requirements of the project.
Prior to commencement of the heat treatment process, the RWC shall ensure that the
equipment being used is appropriate for the task, in calibrated condition and that the
equipment operator is fully aware of the requirements of the procedure.
The procedure and the supporting temperature/time record charts shall be kept in the job file
for review by the client or his representative, as required.

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Inspection and Page 20 of 29
SECTION: 14
14. Inspection and Test
14.1.1 The Works Manager and Works Supervisor shall ensure welders/tradesman are given
the necessary contract information including weld procedure specifications prior to
work commencement.
14.1.2 The WC shall provide adequate facilities to enable testing. Full inspection of welds ie:
adequate lighting conditions, fillet weld size gauges/weld inspection devices.
Section 14.2 – Inspection & Testing before Welding
14.2.1 The welder/fabricator is responsible for checking weld assembly ‘fits up’ are as
specifications on contract drawings and weld procedure specification prior to final
welding.
14.2.1 The welder is responsible for checking the surface condition of the parent materials
ensuring absence of contaminants ie: paint, rust, scale, grease, lacquers etc prior to
welding.
14.2.3 The welder is responsible for checking that tack welds are adequate for their purpose
and that they are suitable to be incorporated into the final weld.
14.2.4 The welder is responsible for checking the working condition of the welding machine
along with calibration status at the start of each shift.
Section 14.3 – Inspection & Testing During Welding
14.3.1 In process inspections shall be carried out by the works supervisor and WC during
production of contract welding. Monitoring checks for compliance with the WPS
parameters shall be carried out to maintain weld quality requirements.
14.3.2 The welder shall check during making welds for sizing, special requirements for stitch
weld dimensions etc and visually inspect for the absence of defects and
discontinuities.
14.3.4 In instances of the welder or his supervision being unsure of the acceptability of welds
then the RWC shall be notified for the final deposition.

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Inspection and 7
SECTION: 14
Section 14.4 – Inspection & Testing After Welding
14.4.1 Significant visual defects/discontinuities shall be reported by the welder to his

supervisor who will in turn report them to the WC. The WC will record on a non-
conformance report (NCR) and will issue work instruction for the repair work.
14.4.2 The WC shall ensure that all welding repair are carried out to his satisfaction. Upon
completion of the repair the RWC shall sign off the NCR and file with the contract
documentation.
14.4.3 Final visual and dimensional inspections shall be carried out by the Works Supervisor
on a random basis as inspections are conducted by the fabricator in process.
14.4.4 The fabricator shall mark the steelwork/component as passed stage/final inspection
only if required by the contract specification. Records of inspection are retained on
production drawings or separate inspection sheets.
14.4.5 The policy for ‘process’ NDT is a partially sub-contracted activity.
14.4.6 When the contract specification requires ‘process’ NDT the Works Manager shall
raise a purchase order on the sub-contracted NDT company.
14.4.7 The RWC shall provide the NDT company with all the pertaining contract
information including specific acceptance/rejection criteria.
14.4.8 The RWC shall notify the NDT company of planned inspection/schedule
14.4.9 The sub-contracted NDT company shall notify the RWC of all defects found to be
outside the applicable specification limits.

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Inspection and Page 22 of 29
SECTION: 14
Section 14.5 – Inspection & Testing Status
14.5.1 All significant defects that are detected and reported shall be recorded on an NCR
form.
14.5.2 The sub-contracted NDT company shall provide reports upon completion of testing.
All NDT reports shall be reviewed by the RWC and filed along with the contract file.
14.5.3 The Works Supervisor shall enter the final inspection on the production drawing as
necessary.

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Non-Conformance
Page 23 of 29
SECTION: 15 and
15. Non-Conformance and Corrective Actions
Section 15 – Non Conformance & Corrective Actions
15.1 A nonconformity is any condition which does not comply with the applicable contract
document specifications this manual or other specified requirements.
15.2 It is the duty of all employees to report any condition they believe to be nonconformity
to the Works Supervisor, who shall then notify the Works Manager immediately. The
Works Manager shall verify the condition and if found to be nonconforming they will
quarantine the material and initiate a non-conformance report (NCR)
15.3 Material or items rejected during receipt at the stores/receiving bays shall be
segregated from compliant material.
15.4 The NCR will be completed, detailing the nonconformity and will be forwarded to the
Works Supervisor/RWC for the recommended rework. This will then be recorded on
an NCR if appropriate and consultation held with the Works Manager to decide the
course of action.
15.5 In the event that rework is inappropriate then a concession shall be applied for and the
item may only be used when agreed with by the Client.
15.6 In such instances the Works Manager shall consult the Client and obtain his
agreement prior to further work. This agreement will be indicated by the Works
Manger signing/dating the NCR with the concessionay wording.
15.7 Items requiring repair work or rework may be made using standard approved weld
procedures or special procedures approved by the RWC prior to carrying out the work.
15.8 For defects in material that are to be repaired, the Works Supervisor shall raise an
NCR and consult the Works Manager for the method and extent of repair.
15.9 If the deposition of the NCR is scrap or return to vendor the Works Supervisor will
ensure that the nonconforming item has been removed from the work area.
15.10 The shop supervisor shall re-inspect the nonconforming item once the repair work has
been completed. When he is satisfied that the item meets the requirements he shall
sign the NCR, remove any quarantine marking and verbally convey to the tradesmen
that the item can be incorporated back into production.

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Non-Conformance
SECTION: 15 and Page 24 of 29
15.11 The Works Manager shall review all NCR’s on a annual basis to determine if any
adverse trend patterns exists. If trends are detected the Works Manager shall call for a
meeting with the Supervisor/RWC to establish more effective process control
measures to be implemented.
15.12 Closed out NCR’s will be returned to the Works Supervisor for filing.

Issue: 1
Calibration and Validation of Dated: 23/01/2017
SECTION: 16 Measuring, Inspection and Testing Page 25 of 29
Equipment
16. Calibration and Validation of Measuring, Inspection and Testing Equipment
Section 16 – Calibration & Validation
16.1 Measuring equipment used for inspection purposes with the exception of rulers, spirit
levels and squares shall be calibrated in accordance with this manual.
16.2 The Works Supervisor shall maintain a calibration register of equipment showing the
equipment serial number and the calibration frequency.
16.3 The frequency of calibration and acceptance criteria are determined by the Works
Supervisor based on experience with each type of instrument, manufacturers
recommendations.
16.4 Each piece of measuring equipment which requires calibration is identified with a
calibration label /sticker attached to the item or its container. It is the responsibility of
the users of calibrated equipment to ensure the item is within current calibration
period.
16.5 Calibration may be performed by company personnel or be sub-contracted to a

calibration test laboratory who will provide records of calibration showing traceability
to national standards. Calibration of all new welding machines shall be done after
final location installation.
16.6 Each instrument shall be recorded in the Equipment Calibration Register and will
record, or reference the results of calibration, calibrator, serial number where
appropriate, description, measurement range, tolerance and next due date.
16.7 Any equipment found to be outside tolerance will be tagged by the Works Supervisor
‘DO NOT USE UNTIL CALIBRATED’ and will be kept from the work area until
replaced or adjusted.
16.8 All calibration records including those for sub-contractors equipment shall be made
available on request.

Issue: 1
Dated: 23/01/2017
SECTION: 17 Identification and Page 26 of 29
17. Identification and Traceability
Section 17 – Identification & Traceability
17.1.1 ‘Parent materials’ traceability is established at the designated receiving area.
17.1.2 Deliveries are verified against the purchase order requirements. The signed delivery
notes and pertaining material test certificates together are forwarded to the Works
Supervisor/WC, subsequently the delivery notes are then forwarded to the accounting
department and the (EN 10204-3.1) material test certificates retained by the WC for
checking and filing in the relevant correct files.
17.1.3 Materials will be identified with the contract number.
17.1.4 When materials are ‘job’selected for cutting, cut pieces will be marked by the machine
operator with the contract number.
17.1.5 Large piece parts fabricated by machine/hand shall be marked by the tradesman with
the contract number or item/part number.
17.1.6 Small piece parts relating to a drawing/job number shall be placed onto job pallets by
the tradesmen/operator producing the part. Applicable lot number & job number shall
be clearly marked on the outside of the pallet prior to movement to applicable
fabricators work station
17.2 Welding consumables issue/returns/technical details are recorded in the welding

consumables stores log book.
17.3 Drawings shall contain sufficient information to enable all component pieces to be
identified and linked to drawings by unique reference numbers.
17.4 Weld information requirements shall be specified on drawings using standard symbols
and notations using metric size requirements, detailing leg or throat for sizing fillet
welds. Special requirements ie: stitch/intermittent fillet welds or partial penetration
butt welds shall be clearly identified/sized.

Issue: 1
Dated: 23/01/2017
Identification and Page 27 of 29
SECTION: 17
17.5 Weld procedure specifications shall be marked if required with the contract number by
the RWC when issued. If required by the contract, copies of the WPS’s shall be filed
with the contract records. All WPS’s shall display unique alphanumerical references.
17.6 NDT procedures and personnel qualifications shall be reviewed for suitability again
contract requirements by the RWC and kept on file.

Issue: 1
Dated: 23/01/2017
Quality Page 28 of 29
SECTION: 18
18. Quality Records
Section 18 – Quality Records
18.1.1 All records described in the preceding procedural sections are collected during the
duration of the contract and reviewed for completeness by the Works Supervisor/WC.
18.1.2 Parent material certificates shall be filed in contract specific files.
18.1.3 Welding consumable certificates are kept on file by the WC.
18.2 The Works Supervisor shall maintain a register of welding/plant maintenance records.
18.2.1 The WC shall keep on file welding plant calibration certificates.
18.3 The WC shall keep on file all welding qualifications documents ref: (PQR) procedure
qualifications records, (WPS) weld procedure specifications, (WPQR) welder
personnel qualifications in separate files.
18.4 NDT procedures and operator qualifications shall be kept on file by the RWC.
18.4.1 Post weld heat treatment procedures/calibration certificates/reports will be kept on file
by the RWC.
18.5 Copies of NCR (non conformance reports) shall be kept on file by the Works
Manager.
18.6 Surface treatment reports ie: painting, galvanizing, shotblasting etc shall be filed with
the contract file.
18.7 Quality and documentary records are available for inspection and shall be retained for
a minimum period of TEN years in controlled storage. Retention time may be extended
if required by the project.
18.7.1 NDT reports subject to deteriation ie: radiographs shall be stored in accordance with
the film manufacturers recommendations to maintain usefulness.

Issue: 1
Dated: 23/01/2017
SECTION: 19 Appendix A - Associated Forms Page 29 of 29
Appendix A Associated Forms


Factory Production Control System - Welding Quality Manual 23-01-17 - Issue 1

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WELDING QUALITY MANAGEMENT SYSTEM

(QUALITY REQUIREMENTS FOR

Date Issued 23rd Jan 2017

Page: 1 of 29 Doc 01_Factory Production Control System

3. Terms and definitions

4. Compliance with ISO 3834

5. Review of requirements and technical review

8. Inspection and testing personnel

10 Welding and related activities

12 Post-weld heat treatment

14 Calibration and validation of measuring, inspection

15 Identification and traceability

Page: 2 of 29 Doc 01_Factory Production Control System

Section 2 – Normative References

3. Terms and Definitions

Section 3 – Terms & Conditions

4. Use of this part of ISO 3834

Section 4 – Use of this Manual

Page: 3 of 29 Doc 01_Factory Production Control System

5. Review of Requirements and Technical Review

Section 5.1 – General

Section 5.2 – Review of Requirements

A review of the project requirements

a) Product & supplementary standards

b) Statutory & regulatory requirements

c) Any additional requirement

d) Our capability to meet the prescribed standards

Section 5.3 – Technical Review

A review of the technical requirements

a) Parent material specification and welded joint properties

Page: 4 of 29 Doc 01_Factory Production Control System

i. meet the design input requirements;

ii. contain a reference of acceptance criteria;

iii. conform to appropriate regulatory requirements whether or not these

Provide adequate information on health and safety and risk assessment.

Page: 5 of 29 Doc 01_Factory Production Control System

i. Read specification and associated relevant documentation.

I. holding and recording design reviews;

Page: 6 of 29 Doc 01_Factory Production Control System

Page: 7 of 29 Doc 01_Factory Production Control System

Page: 8 of 29 Doc 01_Factory Production Control System

Section 7.2 – Welders & Welding Operators

Welders shall be re-qualified when any one of the following occur:

Page: 9 of 29 Doc 01_Factory Production Control System

Section 7.3 – Welding Coordination Personnel

Page: 10 of 29 Doc 01_Factory Production Control System

Page: 11 of 29 Doc 01_Factory Production Control System

8. Inspection and Test Personnel

Section 8.1 – General

8.1.2 Inspections are validated by the WC as necessary.

Section 8.2 – Non Destructive Testing Personnel

8.2.9 NDT sub-contractor qualifications shall be recognised by ISO standards.

Page: 12 of 29 Doc 01_Factory Production Control System

II. MIG welding plants

III. Gas burning set

IV. Various Grinders, pistol drills & magnetic drills

Section 9.2 – Description of Equipment

 One fork lift truck with capacities of 2.5 Tonne

Section 9.3 – Suitability of Equipment

Section 9.4 – New Equipment

Installation will be by qualified and suitably experienced person

Completion certification will be provided by installer prior to handover.