we VS yey ely IU IOV IIUI GIO. FUNDAMENTALS OF WELDING QA & INSPECTION A GUIDE FOR THE SENIOR WELDING INSPECTOR IQC Training and Services Pvt. Ltd. Shivani Block I, First Floor Rear 40, East Coast Road Thiruvanmiyur, Chennai 600 044, INDIA. Revised 02/13SPEEA EEE eee ee ee ec eee Here EctPQWVWIGOSS POC Cee eS oC ee ec es oVv esse FUNDAMENTALS OF WELDING QA AND INSPECTION CONTENTS Module Title No. 4.1 Introduction and Certification 1.2 Welding and Cutting Safety fa 2 Quality Assurance 3.1 Mechanical Testing = 3.2 Metallurgy 44 NDE of Welds - Introduction | a2 Visual Inspection ie 43 Penetrant Testing 4.4 — | Magnetic Particle Testing 45 Eddy Current Testing 46 Radiographic Testing 47 Ultrasonic Testing 48 Leak Testing & Acoustic Emission Testing 5 Welding Procedures and Performance Qualifications iDODVODOIBDIIOy ee HO eet eee MODULE 1.1 INTRODUCTION & CERTIFICATION In today's world, there is increasing emphasis placed on the need for quality due to various factors such as safety, economics, government regulations, global competition and use of less conservative designs. Quality cannot be inspected into a product onca it has been completed. Quality starts with design and specifications, it continues with the selection of qualified vendors, to selection of material, to incoming inspection, and to qualified welders using qualified procedures. It involves manufacturing operations as Per the procedures, Quality is a process of controlling, testing, inspecting and documenting each and every step of fabrication. Quality shall be in-built into the product, The welding inspector plays a major role in ensuring quality, He performs inspections to applicable procedures and processes and ensures that the work performed and the associate records are maintained and conform to the requirements of applicable standards or other contract documents There is a need for to oversee the inspectors, not just the visual process but other NDE methods as well, to validate vendors, to verify procedures, and to develop and maintain records in accordance with a quality assurance program. To meet this need, American Welding Society has developed the program for Senior Certified Welding Inspectors (ScWh), After an individual has been a CWI for a minimum of six years, and his career has evolved into supervisory or managerial responsibilities in the field of quality controV/quality assurance, he will want to apply for the highest level of certification: a Senior Certified Welding Inspector, or SCWI. SCWis are in demand by companies looking to have it all-skilled, seasoned welding managers who can do the job and supervise others. ‘The SCWI is an individual who is in_a supervisory position and has attained a higher level of experience than a CWI. The successful applicant also has professional education which has provided the opportunity to solve problems with a scope and level Of difficulty beyond those experienced as a CWI. The SCWI examination is developed to confirm the capability of the CWI to handle additional responsibilities with the special qualities of a senior level inspector. The five modules listed below are areas from which SCWI examination questions are prepared. Module 1. Introduction, Certification and Safety Module 2. Quality Assurance Module 3. Mechanical Testing and Metallurgy Module 4. Nondestructive Examination of Welds Module 5. Welding Procedures and Performance Qualifications 1-1-1To cover the above topics, this Manual - Fundamentals of Welding QA & Inspection, A Guide For The Senior Welding Inspector has been prepared by IC, India. The SCWI examination consists of two Parts © Part 1: Fundamentals — 138 Questions (2hrs Duration) * Part 2: Specific - 62 Questions (2hrs Duration) Part 1 : Fundamentals - Topic wise Questions - SUBJECT NO. OF QUESTIONS Nondestructive Tests: 59 (PT-8, MT-8, RT-9, UT-10,VT-14, OTHER NDT-10) | Mechanical Tests (B4.0-10, General -2) _ 12 Quality Assurance - Systems 34 Welding Of Stainless Steel (D 10.4) 29 Welding Inspection & Flaws 2 Safety — ANSI 249.1 Hee] Total Questions 138 Part 2 : Specific — Topic wise Questions SUBJECT NO. OF QUESTIONS Welding Procedure & Performance Qualification ~ AWS B2.1 40 Mechanical Testing ~ AWS B4.0 8 AWS QC 1 4 ASNT = SNT-TC-14 10 Total Questions 62 Both examinations are Open Book Examinations . The applicant can bring any reference material he desires. To pass the exam, the applicant has to score minimum Score of 72%.9Average). the applicant shall answer 144 questions correctly from the total 200 questions. 1-1-2Vow D0 Oo Ceeoe ov oscoogossa00o3 QUALITIES OF SCWI The SCWI has very broad responsibilities, which encompass thorough knowledge of the whole quality assurance process, NDE procedures, and the ability to supervise others. The SCWIis the key to a good welding quality assurance program. He is not only involved in the determination of weld quality according to applicable codes, standards and other specifications, but also responsible for ensuring that quality is met throughout the process. The SCWI is to ensure that appropriate procedures are in - place for each step and that all the operations are carried out in accordance with the procedures. This means that the SCWI will often perform the job functions of an overseer-specialist, ‘The SCWI is responsible for general weld quality and conformance to specifications or he may oversee other inspectors who perform these duties. Because of the SCWI's experience and skills, he is commonly called upon to make a ‘ruling’ on a questionable discontinuity or procedure, The most important quality for the SCWI is athe professional attitude. He shall make Gecisions solely on facts so that the inspections are fair, impartial and consistent. Other important requirements for the SCWI are good health and visual aouity (near vision and color perception) to perform inspection activities, He has the responsibility to ensure ‘» that safety procedures are being followed. He should not violate safety precautions and also not allow other inspectors to deviate from safety procedures. In addition to having good safety and health habits, the SCWVI must have developed x strong leadership. As an overseer of others and one who is responsible for quality and Productivity, he must set an example for both peers and subordinates. The habits of good record keeping, developing new procedures, and addressing quality issues are essential in setting those examples. The SCWI must have enough skill and background to have gained experience in all the NDE processes and their applicability to the fabrication.As a Senior Certified Welding Inspector, he must be knowledgeable on all aspects of quality assurance. He must be familiar with ISO 9000 Standards and other such standards, He must be able to assess quality program to determine its adequacy and compliance in the shop floor. WELDING INSPECTOR CERTIFICATION American Welding Society has published Standards governing the Specification and Certification of Welding Inspectors. 1. AWS B5.1:2003 Specification for the Qualification of ‘Welding Inspectors. 2. AWS QC 1: 2007 Standard for AWS Certification of Welding Inspectors An overview of the above Standards is given blow. This is for general information purpose only, For exact requirements, the applicable standard shall be referred. 11-3Details of AWS BS5.1:2003 Specification for the Qualification of Welding inspectors 4. Scope : This Standard establishes the requirements for qualification and defines the body of knowledge for welding inspection personnel. 2. Terms and Definitions : The terms, as defined in AWS A3.0, Standard Welding Terms and Definitions are applicable. For some special terms, definition is furnished in this Section. Fi 3. Levels of Qualification : There are three levels of qualification for welding inspection personnel — Associate Welding Inspector, Welding Inspector and Senior Welding Inspector 4. Functions : The duties of all levels of inspectors are given in this Section 5. Education and Experience Requirements : This section defines the education and experience requirements for all three levels of inspectors. These requirements are applicable for certification purpose also and referred in QC 1 Standard, Inspector Level Education Requirement Experience Requirement High School Two years Associate Welding | 8" Grade level | Four years Inspector 8™ Grade level and one year vocational | Three years education / Training Less than 8” Grade ‘Six years. 2 years (minimum) of post high schooi | Six months education in engineering or physical science High Schoo! Five years 8"Gradelevel Nine years Welding Inspector | Less than 8" Grade Twelve years 2 years (minimum) of post high school | Three years education in engineering or physical science Senior High School Fifteen years Welding inspector : cnn been |2 years (minimum) of post high school | Thirteen years qualified as WI) _| education in engineering or physical science 14-4 ta eH a ae6. Examination Requirements 6.1 Visual requirements : @. The inspector shall pass an eye examination, with or without corrective lenses, to Prove near vision acuity on Jaeger J2 at not less than 12 inches. b. The inspector must also take a color perception test. Near vision aculty Is considered essential 10 the proper performance of welding examination. Failure to meet the above level of acuity shall be a failure to meet this Standard. Color perception is desirable in some specific applications, butis not considered essential for all examinations. It shall be the employer's responsibilty to establish and enforce visual requirements for the inspectors in his employment. 6.2 : Written Test Requirements : Details are given in general terms. 7. Examination Structure : This section gives the percentage of questions on various topics for various levels of Inspector examination, 8. Maintenance of Qualification : as per this section, inspectors shall demonstrate continuing ability to perform the inspection function and maintenenance of qualification isno more than three years, Details of AWS QC 1: 2007 Standard for AWS Certification of Welding Inspectors 1, Scope : This Standard establishes the requirements for AWS certification of welding inspection personnel.|t describes how personnel are certified, and the principles of conduct and practice by which certification can be maintained. 2. Levels of Certification and Endorsements : There are three levels of qualification for welding inspection personnel: 2.1 Senior Certified Welding Inspector (SCW) 2.2 Certified Welding Inspector (CWI) 2.3 Cerified Associate Welding Inspector (CAW) 2.4 Endorsements 3, Terms and Definitions : The terms, as defined in AWS A3.0, Standard Welding Terms and Definitions are applicable. For some special terms, definition is furnished in this Section, 1-1-5~ bey i ee boy Fay. 4. Functions of Certified Personnel: 4.1 Functions of SCWI ‘+ perform inspections supervise one or more CWis, CAWIs and / or NDE personnel prepare inspection procedures : Teview and interpret joining procedures conduct audits of vendors and / or organisations providing materials or services ensure that the work performed and the records maintained conform to the requirements of the applicable standards and other contract documents * perform all SWI duties listed in 85.1 4,2 : Functions of SCWI and CWI * perform inspections or verify that the work inspected and the records maintained conform to the requirements ‘of applicable standards or other contract documents * certify the qualification of welders to various codesand specifications * perform all SWI duties listed in B5.1 4.3; Functions of CAW! + perform inspections, under the direct supervision of a SCWI or CWI within visible and audible range. 5. Education and Experience Requirements 5.1 Applicants for SCWI, CWI or CAWI certification shall meet the requirements specified in AWS BS.1 5.2 In addition to the requirements of AWS 85.1, applicants for SCWI shall have been certified as a CWI for a minimum of six years. 5.3 More details are given in this section regarding the documentation to meet the requirements for experience and education. 6, 7. Examination Requirements for SCWI, CWI and CAWI: Examination Parts of Exam Minimum No. of | Minimum percentage Se | _Questions | of correct answers. Scwi Parts A&B 200 72% (144 correct answers) Part A - Fundamentals 150 72% cwl Part B - Practical 46 2% Part C= Code Book 46 72% Part A - Fundamentals 150 60% cAWI Part B Practical 46 60% Part C — Code Book 46 60% 1-1-6Sevooloesg SOoOBOOS2SDyVOS90 eee te For cade book exam, an option is available in QC1 to select any one of the following codes. ‘| AWS D1.1 Structural Steel Code API 1104 Pipelines AWS D1.2 Structural Aluminum Code AWS D1.5 Bridge Welding AWS D15.1'Railroad ASME SECTIONS Vill (DIV. 1) & IX ASME Section IX, B31.1, 831.3 . The candidates are to verify with AWS which codes are available and which editions of these codes are applicable to the examination. Upgradation + Candidates (CAWI & failed candidates) can upgrade their status by appearing in the re-examination ‘+ For CWI certification, if the average score is more than 72%, the candidate can appear only in the part where he has not got the required score. if the average score is less than 72%, the candidate has to appear in all three parts of the CWI exam + For SCWI certification, the failed candidate has to appear in both parts of ‘SCWI exam. Re-Examination for CWI Certification Candidates can take re-exam within one year, without additional training After one year, the candidate has to undergo 40 hrs: of training, before re-exam For each additional re-exam also, the candidate has to undergo additional 40 hrs, of training * maximum number of re-exam permitted in a three year period : 3 Re-Examination for SCWI Certification ‘* Candidates can take re-exam within one year, * maximum number of re-exam permitted in the one year period : 2 8. Visual Acuity Requirements 8.1 The visual acuity requirements for applicants for SCWI, CWI or CAWI certification are same and shall meet the requirements specified in AWS B5.1 8.2 Eye examination can be administered by an ophthalmologist, optometrist, medical doctor, Registered nurse, Certified Physician's Assistant or by other ophthalmic medical personnel and shall include the license number. Eye examination shall be performed not more than 7 months prior to the date of AWS exam, 11-78.3 The completed eye examination record shall be received by AWS within 30 days after the AWS exam date. 9. Reciprocity 9.1 The reciprocity arrangements with certification programs in other countries are explained in this section. 10. Certification 10.1 The procedure for documentation of SCWI, CWI and CAWI ertificates, verification of the certification status etc are discussed in this section. 11. Code of Ethics, Rules of conduct and Practice 14.1 the following points, as applicable to SCWI, CWI and CAWI, are discussed in this section. Integrity Responsibility to the Public Public Statements Conflict of Interest Solicitation of Employment Unauthorised Practice 12, Revocation 12.1 AWS committee has the power to suspend, refuse renewal, or revoke the Certification. Details are given in this section. 13. Reinstatement 13.1 The process of reinstatement of revoked certification is explained in this section, 14, Upgrading of Certification 14.1 The procedure for upgrading of CAWI certificate candidates (who have scored pass marks, but did not meet the experience requirements) is discussed in this section. 15. Renewals 15.1 SCWI, CWI and CAWI certificates are valid for three years. At the end of three years, SCWI and CWI certificates can be renewed but CAWI certificates can not be renewed. Renewal at the end of 3 years + submitting renewal application including visual acuity record + No period of inactivity greater than 2 years in welding related activities in this 3 year period Renewal at the end of 6 years : same as above 141-816. Nine Year Recertification for SCWI and CWI 16.1 SCWi & CWI certification renewals are limited to two consecutive three year periods. Before the end of the third three year period, SCWIs and CWls are required to recertify. VOOR 16.2 Receriification at the end of 9 years : re submitting 9 year Recertification application including visual acuity record vy no period of inactivity greater than 2 yéars in welding related activities in this 0° third 3 year period and + passing Parts B exam for CWis and Parts A & B exams for SCWIs or * passing Committee approved endorsement exam or min. 80 Professional Development Hours (PDHs) earned during the 9 year ~~ cettification period, with 20 of these PDHs eared during the last 3 years 16.3 Complete details regarding the procedure for renewal and recertification of SCWI ‘and CWI certification are given in these sections 15 and 16. NONDESTRUCTIVE EXAMINATION CERTIFICATION In addition to Welding Inspector certification programs, SCWI shall be familiar with the certification programs for NDE personnel. The most widely recognized scheme is issued by American Society for Nondestructive Testing (ASNT). The guidelines for certification of NDE personnel are outlined in their Recommended Practice No. SNT- zi TC-1A. This document describes the recommended procedures for a company to oO certify inspectors performing nondestructive testing. It is not ASNT which qualifies or oO Certifies personnel to SNT-TC-1A, itis the employer. The principal procedure ASNT uses to assure that NDE Personnel possess the Q required qualification consists of * Training to impart the necessary knowledge ) «Experience supervised by knowledgeable people O * Qualification examinationto demonstrate that the individual has acquired ) sufficient knowledge and capabilities * Certification to document successful instruction of competence Overview of SNT-TC-1A ; 2006 The first thing to understand is that SNT-TC-1A is not a standard/specification, It is a set of guidelines or recommendations to employers about how to establish and conduct an NDE personnel qualification and certification program, Certification, in accordance with SNT-TC-1A means certification of an individual by the employer. Because only the employer can give it, certification terminates if the individual leaves the employer. 1-1-9 eeeSNT-TC-1A guidelines have two requirements that must be met for a company to certify personnel. First, the company must prepare a written practice or procedure for qualifying and certifying company NDE personnel. The second requirement is that the employer shall modify the recommendations of SNT-TC-1A as necessary to make the qualification and certification requirements appropriate for the company’s needs. Details of SNT-TC-1A : 2006 * 4, Scope 1.1 This section covers the scope of the document. It indicates the requirement of a written practice by a company and the employer shall review and modify the recommendations to suit his company needs. 2. Definitions 2.1 Section 2 defines the terms used in SNT-TC-1A, as used ‘in this document. Because SNT-TC-1A is only a recommendation, the definition of ‘should’ and ‘shall’ are different. In this document, ‘should’ means recommended and ‘shall’ means strongly recommended. aL 2.2 Two other words having a different meaning are Comparable — being at an equivalent or similar level of NDT responsibility and difficulty as determined by the employer's Level Ill Experience — Work activities accomplished in a specific NDT method under the direction of qualified supervision including the performance of the NDT method and related activities but not including time spent inorganised training programs. 3. Nondestructive Testing Methods 3.1 This section listd the NDT methods applicable to this guide. They are Acoustic Emission Testing Elctromagnetic Testing Laser Testing Methods Leak Testing Liquid Penetrant Testing Magnetic Flux Leakage Magnetic Particle Testing Neutron Radiographic Testing ). Radiographic Testing 10. Thermal/Infrared Testing 11. Ultrasonic Testing 12. Vibration Analysis 13. Visual Testing PENOPaeNa 1-41-10 ) Reece4, Levels of Qualification a 4.1 This section defines the three basic levels of qualification. The employer may subdivide these levels to meet specific needs. While an individual is training and gaining experience, he is considered as ‘Trainee’. LEVEL! * performs specific calibration, specific ndt and specific evaluation, according to written__instructions © receives necessary instruction / supervision from a certified level iii | LEVEL I J © qualified to calibrate & set up equipment © to interpret and evaluate results as per code / standards / specifications © organize and report the results of NDT tests LEVEL Il establishing and approving techniques and procedures interpreting codes standards and specifications and procedures designating ndt methods and procedures. should have general familiarity with other appropriate ndt methods, applicable materials and processes establishing acceptance criteria when not available training and examining level | & I! personnel TRAINEE © in the process of being qualified shall work with a cettified individual * shall not independently conduct, interpret, evaluate or report results 5. Written Practice 5.1 This section explains the procedure and contents for the written practice, to be established by the employer. 6. Education, Training , and Experience Requirements for Initial Qualification 6.1 This section defines education, training , and experience requirements for initial qualification for all Levels. The requirements for Levels | and || are furnished in Tables 6.3.1A, B, and C 141-11» < 6.2 The requirements for Level# are given in this section * 4year degree in science / engineering and tyear experience equivalent to Level It ‘ or ae 2yearr degree in science / engineering and 2years experience equivalent to Level II or © 4years experience beyond Level II 7. Training Program 7.1 This section describes the required training programs for all levels of certification. It is mentioned that the training shall be formal and organized. 8, Examinations 8.4 Administration and Grading An NDT Level Ill shall be responsible for the administration and grading of examinations. The administration and grading of examinations may be delegated to a qualified representative of the NDT Level III and so recorded. A qualified representative of the employer may perform the actual administration and grading of examinations for Level Ill, There are three parts examination * General,specific & practical for Levels | & I! * Basic, method & specific for Level II * To pass - composite grade of 80% with minimum 70% in individual exam Additional details are given in this section regarding number of questions for Levels | and I for written and practical examinations. 8.2 Vision Examination Near Vision Acuity : ‘+ Jaeger j2 or equivalent at least in one eye with or without correction © Ortho-Rater minimum 8or similar test pattem + To be done annually Colour Contrast Differentiation © Capability of distinguishing and differentiating contrast among colours or shades of gray. * To be done upon initial certification and every five years 1-1-12BOUIVI SIs 8.3 The requirements and criteria are given in detail, for the following examinations General Test (Written - for NDT Levels | and ||) and full details are given. Specific Test (Written — for NDT Levels | and Il) and full details are given. Practical Test (Written ~ for NDT Levels | and |!) and full details are given. Level III examination Sample questions for each method can be obtained from ASNT and full details are given. 8.9 Reexamination : The candidates failing to attain the required grades shalll wait at least 30 days or receive additional training as determined by the NDT Level Ill before y examination. : de peatiicaion pe « Employer is responsible for all levels. * Option is available to use outside agency for NDT Level Ill services, but the responsibility stil lies with the employer * Certification records (details are given in this section) shall be maintained by the employer. 10. Technical Performance Evaluation 10.1 NDT personnel may be reexamined any time at the discretion of the employer and 10.2 The technical performance of Level | and Il personnel sould be evaluated and documented by Level Ill, periodically, as defined in the written practice. 41. Interruped Service 11.1 This section states that the written practice should include the requirements for Teexamination/recertification for the interrupted service. 12. Recertification 12.1 All levels of NDT personnel shall be recertified periodically by * Evidence of continued satisfactory performance OR * Reexamination in parts selected by Level II! 12.2 The recommended maximum interval for recertification for all levels is 5 years 11-4343. Termination 13.1 As this scheme is employer based certification, the certification is revoked when employment is terminated, 13.2 New employer can certify to the former level, based on: examination within six months of termination. 44, Reinstatement 14,1 NDT personnel whose certification has been terminated may be reinstated to the former level, without a new examination, if * complete records of certification maintained * certification did not expire during termination * employee reinstated within 6 months of termination SUMMARY SCWI must have enough knowledge of quality related processes and procedures to ensure that qualified people are performing work which conforms to procedures. Hence familiarity and understanding of the AWS-QC1 and ASNT SNT-TC-1A will be important to SCWI.MODULE 1.2 WELDING AND CUTTING SAFETY au 3 9 o y 9 9 INTRODUCTION . The purpose of this section is to give the ‘Senior Certified Welding Inspector insight into ywelding health and safety issues more relevant to management and supervision. This section is based on the American National Standard 49.1, Safety in Welding, Cutting and Allied Processes. For a detailed review of Z49.1, it is suggested that the CD-ROM, Welding and Cutting Safety, available from the American Welding Society, be used. For further safety and health information, it is suggested that the AWS Safety and Health Fact Sheets be consulted. The United States Department of Labor also has rules on the subject of welding safety. hese are found in the code of Federal ~ Regulations in the section called 29 CFR 1910, General Industry Standards (Figure 1.2.1) Most of the welding rules are found in 29 CFR 1910 subpart Q. Information on labeling and Material Safety Data Sheets is found in 29 CER 1910.1200 ARo4 There is a set of three signal words, common to all safety issues. These words are found in ANSI 2535, Standard for Product Safety Signs and Labels. Danger indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. The use of this signal word is to be limited to the most extreme situafons, Warning indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. Caution indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It may also be used {to alert against unsafe practices, For welding safety there are some additional definitions which are important. These are: * ‘SHALL means that the rule is mandatory. SHOULD indicates that the practice is recommended. _ APPROVED and APPROVAL as ised in this section mean acceptable to the authority having jurisdiction, AUTHORITY HAVING JURISDICTION refers to the organization, office, or individual responsible for “approving” equipment, an installation, or procedure, such as the Occupational Safety and Health Administration of the Deparment of Labor, The National Institute for Occupational Safety and Health, state and local fire marshals, and others having jurisdictionsModule 1 - Welding and Cutting Safety LISTED means that the equipment or material is included in a list published by a nationally recognized testing laboratory such as Underwriters Laboratories and the Factory ‘Mutual Engineering Corporation or items that meet nationally recognized standards or that have been tested and found safe for use in a specific manner. WELDER from a saféty standpoint designates any operator of electric or oxyfuel gas welding or cutting equipment. CONFINED SPACE is a relatively small or restricted space such as a tank, boiler, ditch, pressure vessel, or small compartment. Confinement implies poor ventilation as a result of construction, size or shape rather than restriction of egress of personnel. CYLINDERS IN USE refers to cylinders of compressed gas connected for use, a single cylinder in the use location ready to be connected, or a one-day supply of cylinders in the use location ready to be connected. CYLINDER STORAGE refers to cylinders of compressed gas standing by on the site and not those connected for use. GENERAL RESPONSIBILITIES -_ ANSI 249.1 is applicable to operators, managers, and supervisors of arc and gas welding operations. Everyone involved with welding and cutting shall comply with the requirements for set-up, installation and operation of welding and cutting equipment. This means that all applicable codes shall also be followed. Manufacturers’ recommendations shall also be followed if consistent with Z49.1. Both operators and management shall recognize their mutual responsibilities for safety in welding and cutting. Management and 4-2-2 supervision, besides welders, have specific des regerding safety in welding and MANAGEMENT Management is responsible for providing training to both welders and their supervisors regarding the safe operation of their equipment, the safe uses of the processes, and emergency procedures, Management shall assure that workers are trained regarding hazards and safety precautions before the start of work. Management shall designate approved areas and establish procedures for safe welding and cutting. A designated management representative shall be responsible for authorizing welding and cutting operations in areas not specifically designated for such processes. Management shall assure that the individual is aware of the hazards involved and is familiar with the provisions of Z49.1. Management shall also assure that only approved apparatus, such as torches, manifolds, regulators, pressure reducing valves, acetylene generators, welding machines, electrode holders and personal protective devices are used. Management shall also select contractors to do welding who have suitably trained and qualified personnel, and who have an awareness of the #isks involved. Management shall advise contractors about flammable materials oF hazardous conditions of which they are not aware. SUPERVISORS Supervisors shall guarantee the safe handling of equipment and the safe use of all welding processes. They shall determine what flammable and combustible materials are present or likely to be present in the work location. Supervisors shall have the work moved to 2 location free from combustibles anda away from the hazardous areas. They shali have the combustibles moved a safe distance from the work or properly shielded against ignition if the work cannot be readily moved. Supervisors shall schedule welding and cutting so that combustible materials are not exposed during welding and cutting operations. Supervisors shall also confirm that welders have approval, and that conditions are safe, before starting welding and cutting operations. They shall also assure that the proper personal protective equipment is used. They shall assure ) that fire protection and fire extinguishing equipment are properly located... Supervisors shall assure that fire watchers are assigned as required, Supervisors shall assure that “HOT ” authorization procedures are followed where required. Final inspection of fire watches hall be by the Supervisor one-half hour after > completion of the welding operations to detect » and extinguish possible smoldering fires. OVISY evo. ° WELDER The welder is a vital part of welding safety and has specific responsibilities, Welders shall understand the hazards of the operation to be done and the procedures to be used to control , the hazardous conditions. They'shall handle the equipment safely and use it so as not to endanger lives and property. Welders: shall = ) have permission of management before starting ) to weld or cut. They shall continue to weld or | cut only while conditions are unchanged from those under which permission was granted ) Welders shall mark as “HOT” any work ) remaining hot from welding if others may ) unknowingly contact the hot material. ) GENERAL RULES Rules serve to protect personnel and the > general area where welding is performed. This ) Means that welding equipment, machines, Module 1 -Welding and Cutting Safety — eee cables, and other apparatus shall not present a hazard to personnel. Good housekeeping is important for your own safety. Appropriate warning signs shall be posted designating welding areas and stating that eye protection shall be wom. Protection shall be provided to others in the welding area by protective screens. This is for protection from both the radiant energy and the spatter of welding and cutting. Other workers shall be required to wear eye and face protection and protective clothing. Where arc welding is regularly carried out, adjacent walls and other surfaces shall have low reflectivity to ultraviolet radiation. Ultraviolet (UV) is the brilliant part of the aro; it’s what causes “arc flash” to the eyes and skin burns. Be especially careful when welding on metals of high reflectivity such as stainless steel and aluminum. EYE AND FACE PROTECTION Safety spectacles with side shields, goggles or other suitable eye protection shall also be worn. This is in addition to the helmet or hand shields with filtet lenses and cover plates used by welders and nearby personnel when viewing the arc, Goggles (Figure 1.2.2) or other approved eye protection shall be worn during all oxyfuel gas welding and cutting, and submerged ure welding operations. acnad epaeeeaea All filter lenses shall be in accordance with ANSI Z87.1 and the shade shall be in Figure 1.2.2- Goggles, ) 4-2-3 + , )Module 1- Welding and Cutting Safety accordance with ANSVAWS F2.2, Lens Shade Selector (see Table 1.1). Persons with special eye conditions shall consult their physician for ‘fic information on protective equipment. AWS Fact Sheet Number 12 on contact lens wear states that since 1967, AWS has received reports of problems with contact lenses worn by ‘welders, but none have been verified. Safety bulletins issued by OSHA, FDA, and National Safety Council have all refuted that such incidents could possibly have occurred. Refer to the Fact Sheet 12 for a set of seven guidelines ‘on the use of contact lenses in welding situations. Table 1 of Z49.1 lists various welding processes and general amperages used for each process as the basis for specific filter lenses (see page 1-2-18). LIFT FRONT-HELMETS ‘When lift-front helmets are used, there shall be an impact resistant safety lens or plate on the inside of the frame next to the eyes to protect the welders eyes when the front is lifted. The lift-front provides excellent protection when properly used, but of course is of no protection when the helmet is removed. FILTER LENSES All fillerlenses shall meet the requirements of ANSI Z87.1 for ultraviolet, luminous and infrared transmittance. Filter lenses shall have markings for manufacturer, shade number, and 787.1. GENERAL CLOTHING RULES Helmets, hand shields, and goggles shall be well maintained and should not be transferred from one employee to another without cleaning Other clothing shall be selected to reduce the potential for ignition, burning, trapping hot se ys" Figure 1.23 - Melied Polyester Cloting sparks or electric shock. The protective clothing to use for a specific welding situation may vary. The protective clothing needed will depend on the size, nature and location of the welding work to be done. Be especially careful not to wear materials that can melt and cause severe burns (Figure 1.2.3). Remember also that sparks may lodge in rolled-up sleeves, pockets of clothing, or cuffs of overalls and trousers. Therefore it is recommended that sleeves and collars be kept _ buttoned and that pockets be eli tiie front of cluthing-~f packet: they should be kept empty of combustible materials and have flaps that will keep sparks from entering. Trousers should not have cuffs and should overlap shoe tops. High-top shoes without laces or boots are also preferred as they reduce the chance of sparks or molten-slag from entering the shoe. Generally steel-toe safety shoes are required. Frayed clothing is especially easy to start on fire and should not be worn while welding. Above all, be sure that all outer clothing provides sufficient coverage to reduce burns 4-24v 9 oy d Module 4 «Welding and Cutting Safety cee erom sparks, spatter or radiation. This clothing Vshould also be reasonably free from grease and Qpil to reduce the tendency for burning, 9, GLOVES vy All welders shall wear protestive flame yesistant gloves. Leather gloves are generally Lecommended and insulated linings are also helpful when high levels of radiant energy are jnvolved. 'NOISE CONTROL Noise does exist in welding and cutting operations, Welding and cutting processes that Jare especially noisy and generally require ear Iprotection are air-carbon arc cutting and plasma sarc cutting. Power sources are sometimes ‘noisy, but engine driven generators are often ‘quite noisy. ) Noise is any unwanted or unpleasant sound. {The control of noise should be at the source of the noise when feasible, but welders working in noisy areas can wear ear protection to prevent ‘both bums and hearing loss. Excessive noise is va known health hazard; it can reduce the ability to hear normal sounds. The result may be a Jong-term effect resulting in loss of ability to hear or a short-term effect preventing one from ficating safety directions. Noise may create stréss that car atiect both ‘one’s physical and mental well-being. The loss Jor reduction in hearing ability can cause yaccidents, If a person is exposed to a high noise Jevel for a long enough time, the loss of hearing may become permanent, The time required to ause permanent hearing loss depends on the Jindividual, the noise level, and the time exposed fo the noise. Evidence shows that excessive noise affects other bodily functions and havior. J Use engineering methods such as room jpeoustics to control the noise. OSHA a J d ) ) regulations require a hearing conservation program if noise levels exceed 85 decibels on an 8-hour time weighted average basis. If the noise level is questionable, have a certified safety specialist or industrial hygienist take measurements and make recommendations RESPIRATORY EQUIPMENT It must be recognized that there are situations when ventilation alone is not sufficient, and respiratory equipment is required. Details for this type of equipment are found in ANSI 288.2, Practices for Respiratory Protection. Airline respirators or face masks that give protection against all contaminants are generally preferred. Filter type respirators are generally not recommended for welding applications. The mask must be selected which will provide the necessary protection Figure 1.2.4). The person shall be physically capable of wearing the mask, and the mask shall be fitted to the individual to ensure protection. VENTILATION The first sentence of paragraph 5 in'Z49.1 Ventilation, says, “Adequate ventilation shall be Provided for all welding, cutting, brazing, and Figure 124- Respatas 1:25Module 1- Welding and Cutting Safety —_—_————$S———— related operations.” That brings up the question of what is adequate ventilation. ANSI Z49.1 states, “Adequate ventilation shall be enough ventilation such that personnel exposures to hazardous concentrations of airborne contaminants are maintained below the allowable limits specified by the authority having jurisdiction.” ‘The next statement is, “Respiratory protective equipment as specified in 4.5 shall be used when adequate ventilation is not practical.” The factors for determining adequate ventilation include the following: 1. The first factor listed is the volume and form of the space in which operations occur. This means that welding in a 10-foot square room with a low ceiling has different ventilation requirements than welding in a large high bay facility common to some heavy industries. 2. The second factor for determination of ventilation requirements is the number and type of operations, or welders. Consider the difference in fume generation if only one person is Gas Tungsten Arc Welding clean carbon steel as compared with ten people welding with large diameter flux cored wires. 3. The-third factor for d ion_of ventilation requirements is the possible evolution of hazardous fumes, gases, or dust according to the metal involved. Welding on galvanized steel or stainless steel will produce specific contaminants that may be cause for special ventilation. The authority having jurisdiction sets the limits for the actual contaminants. If the values for allowable exposure limits vary among recognized authorities, the lower values should be used to affect the maximum personnel protection. 4, The at factor for determination of er air flow, Including the rate and ger atmospheric conditions where the work is done. 1 5. The fifth factor for determination of ventilation requirements Is the location of the welder’s and other person’s breathing zones in relation to the. contaminants or sources. FUMES AND GASES The fumes and gases generated during welding and cutting are complex in many ways. The composition and quantity of fumes and gases are dependent upon: 4, The metal or material being worked 2. The process and consumables being used 3. Coatings on the work such as paint, galvanizing or plating 4, Contaminants in the atmosphere such as halogenated hydrocarbon vapors from cleaning and degreasing activities The factors itemized for determination of adequate ventilation. 5. The gaseous products generated by welding . -and cutting generally. include carbon monoxide, 1-2-6 carbon dioxide, fluoride, nitrogen oxides and ozone. The recommended way to determine adequate ventilation is to sample for the composition and quantity of fumes and gases to which personnel are exposed. The Occupational Safety and Health Administration (OSHA) may be the authority having jurisdiction OSHA uses publications of many organizations, and for fumes and gases, has often adopted the recommendations of the American Conference of Governmental Industrial Hygienists. If the concentration ofModule 1 - Welding and Cutting Safety RS airbome fume contaminants is to be determined by sampling the atmosphere, sampling shall follow ANSIAWS F1.1, Method for Sampling Airborne Particulates Generated by Welding and Allied Processes. AVOID THE FUME ‘Welders and cutters shall take precautions to avoid breathing the fume directly. That is probably the most important single sentenice in this standard from the welder’s health standpoint. Welding fumes are not what people normally breathe. Avoiding the fumes can be done by positioning of the work, the head, or by ventilation which captures or directs the fume away from the face (Figure 1.2.5), The fume is a clearly visible plume that rises directly from the spot of welding or cutting. The plume should be drawn away from the welder’s face and not toward the face. If sampling shows that the natural ventilation does not keep the contaminants below the allowable limits of the authority having jurisdiction, mechanical ventilation or respirators shall be provided. Special ventilation can be a local exhaust, or respirators that reduce the contaminant level to or below the allowable limits. Special ventilation applies to all persons in the immediate vicinity of the operations. Please note that special ventilation is: needed uniess"~ breathing zone sampling has shown that the evels are below the allowable limits when welding, cutting or brazing operations involve the following: antimony + arsenic barium beryllium cadmium chromium @ cobalt ‘+ copper @ manganese mercury @ nickel ozone @ selenium silver vanadium @ lead Special ventilation rules apply to confined spaces when fluxes, coatings, or other materials contain fluorine compounds. Fumes and gases from fluorine compounds can be dangerous to health and can bum eyes and skin on contact. ‘When fluorine compounds are involved in open space, the need for local exhaust or respirators ‘will depend upon the individual circumstances. However, experience has shown that such protection is desirable for fixed location production welding and for all production welding on stainless steels. ‘When welding or cutting operations involve consumables, base metals, or coatings containing zinc or copper, the situation also requires local exhaust or respirators. When cleaning compounds are used before welding, the manufacturers’ instructions shall be followed. Because the welding arc can cause chlorinated hydrocarbons to form phosgene, 2 deadly gas, special precautions are necessary. Vapors from the cleaning compounds shall not reach the atmosphere surrounding molten metal or the arc. Also, the vapors shall not be reached by the ultraviolet radiation of the arc. When thermally cutting by oxyfuel, gas shielded arc, or plasma arc, local mechanical ventilation or other suitable means shall remove the fumes generated. Asbestos is Figure 1.25 - Welding Fumes,Module 1- Welding and Cutting Safety _—_—_— still with us in older buildings and products. Where welding or cutting is to be done op surfaces covered by asbestos insulation, the regulations of authority having jurisdiction shall be consulted before beginning the work CONFINED SPACES ‘Because of hazards to both the inspector and the welder, special rules apply when working in confined places, These rules are found in ANSI 2117.1, Safety Requirements for Working in Tanks and Other Confined Spaces. Before entering confined spaces, special training is usually mandated. The Senior Certified Welding Inspector must be aware of such requirements to protect all personnel, A confined space is not always a small space, but rather one where ventilation is poor Figure 1.2.6), The confined space situation can apply in many situations; such as tank bottoms, pits, ditches, and near ceilings. The adequate ventilation requirements for confined space apply to personnel who may be present in the area, The ventilation in confined spaces shall be sufficient to assure adequate oxygen for life support, to prevent accumulation of flammable or explosive mixtures, to prevent oxygen-enriched atmospheres, and to keep airbome contaminants in breathing atmospheres below allowable limits... =F es Confined spaces shall not be entered unless they are well ventilated and tested to assure that they are safe for entry. The exception to this is ifthe space is not ventilated, it is entered if: | @ The space has been tested and determined not to present an oxygen deficient or oxygen atmosphere, a fire or explosion hazard, or an atmosphere hazardous to life, A trained second person equipped for a rescue is present outside the confined space. ° enriched. Before entry and during occupancy the atmosphere in confined spaces shall be tested for toxic or flammable gases, dusts, and ‘vapors. Testing shall also be done to determine adequate or excess oxygen. The quality and quantity of air supplied to a confined space shall be such that personnel exposures to hazardous contaminants are below the allowable limits. Breathing air supplied by cylinders or compressors shall meet the Grade D requirements of ANSICGA G-71. Oxygen or any other gas or mixture of gases shall not be used for ventilation. The supply air line for respirators shall be a dedicated line that cannot be valved to a-line containing a hazardous substance. When welding or cutting or related Processes are performed in areas immediately dangerous to life or health, positive pressure, self-contained breathing apparatus (SCBA) or combination airline respirators with auxiliary air supply shall be used, Gas cylinders must be outside the confined space. Welding power sources should be outside the confined space. If heavy equipment is brought into the confined space on wheels, the equipment ‘shall be secured to prevent accidental movement before starting operations in the confined space. Any ventilation ducts used to ventilate a confined space shal! be " comistriéfed of noncombustible materials, befree of internal combustible materials, and be fully functional. Personnel doing welding or cutting operations next to a confined space shall be made aware of the hazards of the confined space and not enter without proper precautions. When a person enters a confined space through a manhole or other small opening, means shall be provided for signaling outside personnel for help. Standby personnel shall be stationed outside the confined space when atmospheres immediately dangerous to life or health may be present or may develop. The standby stationed outside a confined space shall have a ") preplanned rescue procedure for quick removal ) OF protection for those working inside in case of | an emergency. Positive pressure self contained breathing apparatus shall be available for each attendant, ) Tequired to enter as a rescuer or first responder. If body belts or harness systems are used for emergency rescue purposes, they must be attached and arranged so that they do not ) become obstructed in passing through the exit path (Figure 1.2.7). © The welding of containers, especially those that have held dangerous substances, present ) special hazards. Do not allow welding on containers without knowing all the facts of the situation, 29 CFR 1910.252 (3) notes not to weld on used containers until they have beeri s0 ) thoroughly cleaned as to make absolutely , Sertain that there are no flammable materials or toxic materials present. Details on the welding or cutting of such containers are found in AWS. ) F4.1, Recommended Safe Practices for the » Preparation for Welding and Cutting Containers and Piping that have held Hazardous Substances. ) LABELS > Paragraph 9 of 249.1 states. “Exposed ) Personnel shall be informed of the potential J ) d 1-2-8 Module 4-Welding and Gutting Satety hazards from fumes, gases, electric shock, heat, radiation and noise.” A series of precautionary information labels shall be placed on equipment and containers of welding materials (Figure 1.2.8). Additional information and labeling may be required by other authorities. Where noise has been determined to be a hazard, the statement of the hazard, “Noise can damage hearing” shall be placed after the statement of the hazard, “Electric Shock can Kill.” First aid information shall follow the last Precautionary measure. This is generally found only on products that present immediate and ‘major health hazards. When the fume from a product contains a by-product whose allowable limits will be exceeded before the general welding fume allowable limits, the by-product ‘component shall be identified on the Material Safety Data Sheet. The suppliers of welding materials shall provide a Material Safety Data Sheet, or equivalent, which identifies the hazardous materials, if any, used in their welding and cutting products. Employers’ management shall assure that the information described in this section is communicated to end-users of the products, If brazing materials contain cadmium, a special label is attached. If the brazing and ges welding fluxes contain fluoride, a special label is attachedModule 1- Welding and Cutting Safety Protect yourself and others ¢ FUMES AND GASES can be hazardous to your health. ARC RAYS can injure eyes and burn skin, ELECTRIC SHOCK can KILL Before use, read and understand the manufacturer's Instructions, Material ‘Safety Data Sheets, and your employer's safety practices. Keep your head out of the fumes, ‘Use enough ventilation, exhaust at the arc, or both, to keep fumes and gases from your breathing zone and the general area. 4 Wear correct eye, ear and body protection. 4 Do not touch live electrical parts, o eS Figure 1 Tabel COMPRESSED GAS SAFETY There are some terms that shall always be used, Oxygen shall be called by its proper name, oxygen, and not by the word “air”. It is felt that use of this proper name will decrease -the chanecs of misuse, Fuels, fuel gases and liquid fuels shall be called by their proper names, such as acetylene, propane, natural gas and not by the word “gas. Proper identification is needed to to determine the correct hazards, All portable cylinders used for the storage and shipment of compressed gases shall follow 49 CFR 173 regulations of the U.S. Department © of Transportation. No device or attachment facilitating or permitting mixtures of air or oxygen with flammable gases before consumption, except at a bumer or in a torch, 4-240 shall be allowed unless approved for the purpose, This is to prevent the accumulation of explosive mixtures. Acetylene shall not be used at a pressure ; greater then 15 psig (103 kPascals) because it is subject to explosive dissociation at higher pressures. This is because gaseous acetylene at pressures more than 15 psig may suddenly explode. ‘Compressed gas cylinders used in welding and cutting contain gases at pressures of approximately 2,500 psi (17,238 kPa) or higher. Gases at these pressures are dangerous if not properly handled, Because gases expand when heated, it is important that cylinder contents shall not exceed 125° F (52°'C). ‘The procedures or rules stated in Z49.1 are intended to prevent damage or abuse to gas cylinders that might cause them to leak or - explode with the consequences of serious damage, injury or death. Users of cylinders are not authorized to fill cylinders; only the gas supplier shall mix gases ina cylinder or transfer gases from one cylinder to another. The identification of the gas cylinder contents shall be.clear. Either the chemical or trade name shall be legibly marked on the cylinder. If the label is missing or illegible, the cylinder shall not be used. Such cylinders shall be retumed to the supplier. The numbers and markings-stampedinto cylinders shall be according to 49 CFR 173 regulations of the U.S. Department of Transportation All cylinders with a water weight capacity over 30 pounds (13.6 kg) shall be equipped with ‘a means of connecting a valve protection cap or with a collar or recess to protect the valve. The valve protection cap shall be in place and be hand tight unless cylinders are in use or connected for use. It is suggested that the valve protection cap be kept with the cylinders so they can be reassembled when the regulator is removed.Seer e Soe SsVeovVIooloS , lead to explosions and fire Module 1 - Welding and Cutting Safety — Aceylene and liquefied gas cyliners shall be kept vertical, with the valve end up, This is to prevent liquid from flowing into regulators and hoses. CYLINDER STORAGE The. National Fire Protection Code sets limits for how much fuel gas may be stored in a given area. Consult the code for specific applications. Cylinders shall be stored where they will not be exposed to physical damage or tampering, or subjected to excess temperatures. REGULATORS Always use a suitable and approved regulator to reduce the pressure from a high pressure gas cylinder. Pressure-reducing regulators shall be used only for the gas and pressures for which they are labeled. Regulators shall not be interchanged among designated gas services. Contamination can The inlet connections shall comply with ANSV/CGA. Standard V-1, Compressed Gas Cylinder Valve Outlet and Inlet Connections. The threaded connections on regulators shall be inspected before use to detect faulty seats that may cause leakage when the regulators are attached to cylinder valves or hoses. Damaged ) Ruts or connections shall bé replaced.” Gauges used for oxygen service shall be marked “Use No Oil”, Regulators shall be drained of gas before they are attached to a cylinder or manifold or before the cylinder valve is opened. The regulator is drained of gas by momentarily opening and then closing the downstream line to the atmosphere with the regulator adjusting screw engaged. The cylinder valve is then closed, Before connecting a regulator to a cylinder valve, the valve outlet shall be wiped clean with V2ett aclean cloth free of oi! and lint. The valve shall be opened momentarily or “cracked” to clear the valve of dust or dirt that otherwise might enter the regulator. Stand to one side away from the valve outlet when “cracking” the cylinder. Fuel gas cylinders shall not be “cracked” near other welding work or possible sources of ignition Z49.1 provides the following special procedure for oxygen cylinders after the tegulator is attached to the oxygen cylinder: 1. Engage the adjusting screw and open the downstream line to drain the regulator of gas. 2. Disengage the adjusting screw and open the cylinder valve slightly so that the regulator cylinder-pressure gauge pointer moves up ‘slowly before opening the valve all the way. 3. Stand to one side of the gauge face ‘when opening the cylinder valve. Whenever regulators or any parts of regulators need repair, the work shall be done only by qualified mechanics. HOSES AND TORCHES The hoses for oxyfuel gas service shall comply with the Rubber Manufacturers Association, IP-7, Specification for Rubber + Weldisig Hose; ‘The generally recognized colors in the United States are red for fuel gas hose, green for oxygen hose, and black for inert-gas and air hose. Other countries sometimes use different colors such as blue for oxygen and yellow for fuel gases. Only approved torches, meaning those approved by the authority having jurisdiction, shall be used. This means that “home made” or “shop made” torches shall not be used unless they have been specifically approved by the responsible authority; in the U.S,, it is often Underwriters LaboratoriesModule { - Welding and Cutling Safety So Torch connections shall be checked for leaks after assembly and before lighting the torch, OPERATION Before lighting the torch for the first time each day, hoses shall’be purged individually. This purging, shall not-be done into confined spaces or near sources of ignition. Hoses shall be purged after a cylinder change. This is to prevent the contamination of oxygen with the fuel gas in either hose. Allowing each gas to flow through its respective hose separately allows any flammable mixture in either hose to be purged or removed. Purging the hoses before lighting the torch is important. A friction lighter, stationary pilot light or other suitable source of ignition shall be used to light the torch. Matches, cigarette lighters or welding arcs shall not be used for lighting torches. The purpose of this rule is to reduce burns to the hands and fingers. Sometimes there is disagreement on the sequence of operations followed in lighting, adjusting and extinguishing'torch flames. The tule is to follow the torch manufacturers’ procedures. The sequence depends upon the type of torch, so there is no one answer. Follow the manufacturers’ recommendations! There-are also rulés-regarding the operation vf iorches in confined spaces to minimize the Possibility of gas accumulation in a confined space due to leaks or improperly closed valves. The fuel gas and oxygen supply to the torch shall be positively shut off at a point outside the confined area whenever the torch is not to be used. Unattended torches and hoses shall be Temoved from the confined space whenever the torch will not be used for an extended time such as lunch breaks and overnight. If special devices such as check valves or flashback arrestors are used, they shall be used 4-242 ‘Double Seating Valves. aintained following the manufacturers instructions, If a cylinder is designed to be operated with a special wrench rather than a handwheel, the special wrench or key shall be in place during operation. This is to allow one to quickly shut off the valve if an emergency occurs. During operation, a high pressure or non- liquidfied gas cylinder shall be opened fully to prevent leakage around the valve stem This type of valve (double seating valve - see Figure 1.2.9) seats both open and closed to prevent leakage. AC 3, Bi preferably not more than 3/4 turn, Keep all items away from the top of a cylinder that would in any way interfere with closing the valve or cause damage to the valve, Cylinder valves shall be closed whenever the equipment is unattended. Before a regulator is removed from a cylinder, the cylinder valve shall be closed and the gas released from the regulator. Again this is to prevent regulator fires and explosions. The withdrawal rate from gas cylinders shall not exceed the manufacturer's recommendation, shall not be Be :The usual withdrawal rate is 1/7 the cylinder capacity per hour. An example follows: A torch with a tip that-uses 18 cubic feet per hour (cfh) is attached to a cylinder of 102 cubic feet. The maximum withdrawal rate for such a cylinder is 102 1 7 or 14.8 cfh. The torch must be attached to a cylinder of 126 cubic foot or more, (7x 18 126) ) ARC SAFETY 2° ) wUIVODIQV Sd ee Ate welding and cutting equipment shall ) meet National Electrical Manufacturers ) Association (NEMA) and American National Standards Institute (ANSI) standards. The nstallation of arc welding and cutting ) equipment shall follow the requirements of the ) current American National Standard Institute - , National Fire Protection’ Association's ” ANSUNFPA 70, National Electrical Code, and ) all local codes, There may be some special Purpose machines that do not conform to ANST ) of NEMA standards, but they shall conform to the standards set forth in Z49.1. This installation includes grounding, necessary ) disconnects, fuses and type of incoming power lines, Any gas equipment used with arc welding ~ and cutting equipment shall be governed by the yinfounation previously covered for gas well yand cutting equipment. ” “The personnel in charge of are welding and cutting equipment, or designated to operate arc < ywelding and cutting equipment, shall have been Properly instructed and qualified to maintain or operate such equipment and approved as competent for their work responsibilities, Rules and instructions covering the operation and . maintenance of the arc welding and cutting equipment shall be readily available. These last < }wo statements mean that both the operators Jperating the equipment and the technicians peaintaining the equipment shall have been 3 ) ) higher, than those ‘specified int Module ‘Welding and Cutting Safety i Seely properly trained, qualified, and approved. It also means that operator’s manuals will be available to operators and maintenance people, The welding environment is especially Prone to electrical shock hazards when alternating current or transformer-rectifier arc welding machines are used, and the operators shall take special care to prevent electrical shock, When unusually hazardous service conditions are encountered, consulting with the manufacturer may be necessary. Please note that water or perspiration may cause electrically hazardous conditions in welding. Use non-conductive gloves, clothing and shoes to prevent electrical shock. Avoid accidental contact with live electrical parts. Working in cramped, kneeling, sitting or lying positions may cause the operator to contact conductive parts. In such cases reduce the hazard by insulating conductive parts near the operator. This can often be done by insulating blankets. The use of reduced voltage controls may also be desirable. This limits the exposure to a ‘maximum of 50 volts direct current. There are other conditions which impact the electrical hazards of arc welding and cutting equipment use. When special welding and cutting processes require open circuit voltages adequaté insilation shall be provided to prevent the operator from making accidental contact with the high voltage. Terminals for welding leads shall be protected from accidental contact by personnel or by metal objects. This means the terminals will be insulated and/or covered to prevent accidental contacts, Portable controls which are carried by the ‘operator shall not be connected to an AC circuit of higher than 120 volts, Exposed metal parts of portable control devices operating on circuits of more than 50 volts shall be grounded by a grounding conductor in the control cable. Auto 4-243 MA'EW,Module 1- Welding and Cutting Safety transformers or AC reactors shall be limited to 80 volts. The actual electrical loading of are welding equipment shall comply with the manufacturer's ampere and duty cycle ratings to prevent overheating and deterioration of insulation which increases electrical shock hazards. Welding cables shall be-of a size adequate for expected current and duty cycle The true grounding of the workpiece which the welder welds shall be at earth potential or Srounded independent of the welding leads unless a qualified person assures it is safe to work on the piece ungrounded. The grounding of the workpiece shall be accomplished by locating the work on a grounded metal floor or Platen or by connection to a grounded building frame or other satisfactory ground. The work lead and work lead clamp are sometimes incorrectly called the ground lead and the ground clamp. The work(piece) Jead Connects the work to the arc welding equipment Ggure 1.2.10). If the work is not specifically Brounded by a separate grounding conductor, the work lead does not ground the work. Grounding of electrical systems and circuit conductors is done to limit voltages due to lightning, line voltage surges, or inintentional contact with higher voltage lines, and to ,_ Stabilize voltage to. ground during normal 1 operations: Limitiig the voltage by grounding lgure 1.210 - Work Leads 4244 helps to prevent accidental shocks when ‘equipment is mis-connected or insulation fails Special radio frequency grounding may be necessary for equipment using high-frequency are stabilizers, Welding current shall be Tetumed to the welding machine by cable with sufficient current capacity. Connection of a cable from the welding machine to a common conductor or properly bonded structure on which the work rests, or to which the work is connected, shall be a Permissible alternate procedure. This means that connecting the work lead from the welding machine to the structural steel of a building is Permissible when welding on piping connected or attached to that structural steel. Conduits containing electrical conductors shall not be used for completing a work lead circuit, Pipelines shall not be used as a permanent part of a welding circuit, but may construction, extension, or repair i is not carried through threaded joints, flanged bolted joints, or caulked joints. Avoid sparking at the connection of the Work lead cable. Chains, wire ropes, cranes, hoists and elevators shall not be used to carry welding current. When a building or fabricated metal structure is used for a welding current retum circuit, it shall be checked to determine if Proper electrical contact exists at all joints: If ~~ there-is:any sparking ‘or heating a any joint, find another circuit, Tf welders are working on one structure and sufficiently close so that the exposed parts of more than one electrode can be touched simultaneously, the following precautions are necessary 1. All de machines shall be connected with the same polarity. 2 Alll single phase ac machines shall be Connected to the same phase of the Supply circuit, and have the same instantaneous polarity, ait ays GreOS 3. When these two precautions cannot be met, the operator and other area personnel shall be instructed on the importance of avoiding ‘simultaneous contact with the exposed metal parts of more than one electrode. This means that if a welder is using electrode negative for @ gas tungsten arc root weld and another wolder is using electrode positive for the fill and cover passes with E7018, don’t touch the tungsten with electrode negative to the electrode with electrode positive because the voltage received will be doubled. ) OPERATING ARC WELDING ‘) AND CUTTING EQUIPMENT oO ©) Workers assigned to operate or maintain are welding equipment shall be familiar with those parts of 249.1 applicable to their work assignments. The frame of the welding machine is to be grounded following the electrical code. Coils of electrical conductors act as transformers and generate heat, Coiled welding cable should be kept to a minimum length and any excess is to be spread out to avoid overheating and insulation damage. A good > practice is to have cables of various lengths or cables with connectors, allowing the welder to ft the length of the cables to the job rather than always using long cables. SoOoCIsVOeosaao engine fuel can be a hazard to the welder’s safety and are not permitted. This is because water can carry electric current increasing the chance of electric shock; shielding gases can ) cause asphyxiation; and fuels can cause _y explosions or fires. Written rules and instructions covering the } safe operation of equipment shall be made ) available to the welder and the welder shall strictly follow these rules, Whenever the welder leaves the work or stops for an Cee coed Leaks of cooling water, shielding gadox ast Module 1 - Welding and Cutting Safety _—----——_————— appreciable time, the equipment shall be tumed off. Whenever the machine is to be moved, the input power supply to the equipment shall be electrically disconnected. When arc welding or cutting equipment is not in use, there are several safe practices intended to prevent injury to those working near or around the equipment. Electrodes, both metal and carbon, shall be removed from the-holder to eliminate danger of electrical contact. When electrode holders are not in use, they shall be so placed that they cannot make electrical contact with persons, conducting objects, flammable liquids, or compressed gas cylinders. When guns of the semiautomatic, or wire feed, processes are idle, they shall be placed so that the gun switch cannot be operated -accidentally. The welder shall never permit the clectrically-live metal parts of an electrode or holder to touch bare skin or any wet covering on the body. The welder shall use dry insulating material for protection from electrical contact with the work or ground. The insulation is especially important when the welder is sitting or in a prone position because of the large body contact area. Other factors of electric shock prevention include: + * Wear dry shoes or boots in good condition. Wear rubber sold "shées‘or beots in damp. areas. Wear protective boots when working in standing water or other wet areas. Dry gloves in good condition shall be used. Damp or wet gloves may lead to electric shock. If moisture or perspiration is a Problem, rubberized gloves or other ‘special insulating means should be used. Electrode holders shall be well insulated and kept in good repair. Generally, new insulators are available for holders at a very small cost. + 4-245Module 1- Welding and Cutting Safety a Some arc processes, especially at higher amperages, do require water cooling, but these water cooled holders and guns shall not be used if any water leak or condensation exists which could adversely affect the welder’s safety. Shielded metal arc electrodes are changed while the machine is energized, but for all other arc welding or cutting process the welding machine shall be electrically de-energized when electrodes or contact tips are changed. Also, to prevent électric shocks, the welder shall not coil or loop welding electrode cable around parts of the body. The cable shall not be spliced within ten feet of the holder. Falls are a hazard whenever one is working off the floor and precautions shall be taken to prevent shock-induced falls, This means to be especially thorough in preventing the possibility of an electric shock because electric shock causes involuntary muscle contractions. Use adequate insulation when welding above the ground and be especially careful to use non- conductive ladders. Another safety factor which welders and welding supervisors shall be aware of is the possible hazard for wearers of electronic life support items, such as heart “Pacemakers.” MAINTENANCE ‘The maintenance of arc: welding and cutting _ equipment is vital to safety. 249.1 provides rules for the safe maintenance of this equipment. All arc welding equipment shall be maintained in safe working order always. Both the welder and maintenance personnel are responsible for reporting any equipment defect or safety hazard to the supervisor. It is strongly recommended in Z49.1 that periodic inspections be made to assure safe equipment conditions. 41-246 The use of reported unsafe equipment shall be discontinued until its safety has been assured, Repairs to arc welding and cutting equipment shall be made by qualified personnel only. Rectifier welders shall be inspected frequently to detect accumulations of dust or lint that could interfere with ventilation or insulation. Any electrical ventilation ducts shall be similarly inspected and cleaned. It is a good Practice to blow out the entire welding machine with dry compressed air using adequate safety precautions, Fuel systems on engine-driven machines shall be inspected for leaks and accumulations of water that might cause nisting. Rotating and moving items shall be kept properly shielded and lubricated. Welding equipment used in the ‘open shall be protected from inclement weather. If welding machines do become wet, they shall be thoroughly dried and properly tested before being used. Equipment not in use shall be adequately protected or better, stored in a clean, dry area. If modifications are made which reduce the noise level of the machine, it must be determined that electrical or mechanical ratings have not been exceeded. Do mufflers or sound baffles interfere? The maintenance of welding cables is especially important because of their role... - Inspect. cables for. wear and. daitiagé. Damaged ~ insulation or connectors shall be replaced or repaired to achieve the mechanical strength, insulating quality, electrical conductivity and ‘water tightness of the original cable, Splices in cables shall be done by methods specifically intended for that purpose. The connection methods shall have insulation adequate for the service conditions. The maintenance of compressed gases for shieldingSoOGsooyvescvn79o QWDWOL , ) > d 3 ) ) d ) ed ) J J ) J Biodule 1 - Welding and Cutting Eavety in arc welding operations shall follow the applicable provisions of section 10 of ANSI 249.1. Be aware that some’ states and some companies may have safety rules which exceed those stated in this section, The rules stated here are minimums. Other rules shall net conflict with these rules. SUMMARY It is imperative that safe practices are followed in all welding and cutting operations. Injuries to workers not only cause pain and suffering but also increase medical costs and medical insurance retes, and cause additional financial losses due to the worker's absence as well as the cost of training his or her replacement. Remember, ALL. ACCIDENTS. (CAN BE PREVENTED! 4-217ANSIZ«91:2005 ’ Tablet Fi : Guide for Shade Numbers. * ) (Geom AWS F2.2, Lew Shade Selector) ; Shade numbers are given asa gulde only cd may bo atte to sult individual ness, ‘Minions ‘Suggesod® + Blstode Ste ‘re Curent Pracatve Shade No, Process ‘nam (Gnperes) ‘Sindo (Comtex) Shielded Meal Are Welding Less than 332(24) Lee han 60 7 GMAW) 1¥32-5732(24-40) o-10 8 S321 (40-64) 190-250 0 Mocethan 14 (68) 250-880 a (Gas Metal Are Welding (GMAW) Less than 69 7 - snd Flax Cored Aro Welding 0-160 10 u caw) 160-250 10 2 ) 250-500 0 « Gas Tungsten Ate Welding Less than $0, 8 0 F «cTaw) 50-150 3 2 3 150-500 0 “ Hit ‘Al Carbon Are Ligh) ess than 500 » 2 ‘Cutting (CAC-A) (Geavy) 500-1000 a oy eo tasma Aro Welding PAW) Ts than 20 ‘ 6008 ) 29-100 3 0 100-400 10 ra ce ; 400-310 rr Fr ) Phases Ae Cuting PAC) ess than 20, ‘ ‘ ‘| E 20-40 s 5 i oo 6 6 } | on 8 8 30-200 8 9 : 300-400 9 2 f 400-300 10 a“ , 5 | “Torch Beating IB) - _ set } i Torch Sol ding (1S) a a 2 o / ‘Carbon Arc Welding (CAW) 7 - 1“ ’ : Sone ) Shade No, Confer) oO ‘Cuyficl Gas Welding (OFW) qi Tighe Under 18 Under 3 sos o> Mediom to 72 30013 Ses Hoary ‘Over V2 Ore 13 bat a Oxygen Cutting (00) a i Vader 1 Under 25 Boca ‘Medium 1106 25 t0 150 AoS ) Beary Ones ‘Over 50 Sec6 ; ‘Ase rsof thumb, sar wi «ads dari oo dak a0 the wold zoo. Then goo «lighter so which sis afin vw of wo zn ‘wiicat gong blow hm iam Inca gar weidag cating. orang wine he toch endl fix podacvshigh yellow ihe dbtetble ) {Susoa Sores ta ectbe it yellow ot soon line of ha val gsc : ae] ) , ) ) ,OU oe POOI3IS2 Soocuooo5 MODULE 2 QUALITY ASSURANCE INTRODUCTION In Module 2, the rationale and mechanics of Quality Assurance (QA) and Quality ‘Management Systems (QMS) are reviewed. QA is a business philosophy. QA and QMSs are aimed at eliminating the opportunities for error that arise in-all business environments. Poor communications between one level and another, working from obsolete drawings, using an incorrect material; all these are common ‘occurrences in industry. They result in rework, delayed deliveries, and added costs. They strain relations between purchaser and supplier. an effective QMS, most of these problems can be avoided, This means reduced production time, better deliveries, improvement in the bottom line, In well- managed establishments, it also means better pay and conditions for personnel, and a congenial working environment. Internal political squabbles can be reduced and morale enhanced. If a problem develops, there is a mechanism in place for its solution. ‘Of course, this obviously desirable situation does not develop overnight, it takes time. Change is involved, and many people at all levels iesist change on principle. This means that when a QMS system is to be introduced to ‘an organizatis ¢ ‘selling’. It requires involvement at the very top level. A QMS cannot be introduced somewhere in the middle with any hope of success. WHY DO WE NEED A QA SYSTEM? There are a variety of reasons for an organization to introduce a QA system. The worst possible reasons are: takes time and it. takes .. ~. dindustrit 24 @ Jeanne! keep my best customer without a QA, system, & My competition has It 80 | better fait in + tne, Rather, the reason should be based on a desire to produce a better product, with on-time deliveries. Of course, if you have the perfect product, with no rework ever required and no delayed deliveries, and you pay personnel top-dollar down the Tine, then you do not need a quality system. Otherwise, you do. ‘A question that may reasonably be asked is, why now? Why didn’t industrial businesses of the last century need a quality system. The answer is, they had one - as do all businesses. It is just that it had not been recognized or accepted as a formal system. Until the modem cra, industry was owned and controlled by entrepreneurs. Most were on-the-shop floor managers, with the right to hire and fire on the spot if a mistake was made, The ‘quality system’ was whatever this person thought it should be. ‘Common sense and unions did away with the industrial tyrant, the ‘iron masters’. relitions'often-become sirained-yet today, but in most Cases accommod reached. A new job function for people was established, the ‘inspectors’. Inspectors initially gave themselves credit for everything that was right, and blamed others when things went wrong. They tended in many cases to inhabit air conditioned chambers and emerged in their ‘own good time, Many were good people, some were not. : Over time, it became apparent that ‘quality’ whatever it means, is not inspected into the job. It must be built into the job. As we in thewelding industry have known for years, certainly anyone involved with products made to ASME, Section VIII (or II), there is a relatively simple way to go about things. We check the design, use only certified materials, weld to qualified procedures, and use only qualified welders. We check weld preps, joint fit-up and back-gouging and we expect the finished job to be satisfactory and it usually is. It may be contended that a pressure vessel or boiler are special cases. That is true, especially from the point of view of insurance companies who motivated the boiler and pressure vessel codes in the early 1900's. However, to a building’ owner, the safety and integrity of a structure is just as important, Likewise, a fan in a mine shaft or the cage carrying the product to the surface for processing can be just as critical. Everything needs some level of quality to adequately serve it’s purpose. Even the farm gate, because if the ptize bull gets out, there could be real trouble. ORIGINS OF QA SYSTEMS Since early in the 20th century, industry has ‘been conscious that while automation can ‘produce things faster, it can also produce scrap equally fast. Systems were developed, based on the requirements of industries producing large numbers of identical products. Over time, what we now knoiw. 28 ‘Statistical Process Control” (SPC) methods were introduced. Names such as Shewart were instrumental in the development of the mechanics, Tables showing sample numbers (of items for testing) for a given production ‘lot’ have been developed and are regularly used. The principles employed are based on well known statistical techniques. There is always variation in the output of a machine. If these variations in a ‘sample of a lot” are within certain limits, fixed beforehand and based on statistical theory, the process is said to be ‘in 22 control’. However, when a sample exhibits dimensions or attributes outside these limits, the process is said to be ‘out of control” and corrective action is required. In the case of small lots, involving multiple functions, a different approach was developed to obtain similar benefits. Over the last fifty years the method has become known as Quality “Assurance and the methodology as Quality Management Systems. INTRODUCTION OF QUALITY MANAGEMENT SYSTEMS IN THE USA While in one sense, the origin of formal QMSs was in the United States, adoption as a formal ‘system’ here has been somewhat later than in other countries. The story is told of Edward Deming; he was involved in the development of the QA methodology during World War II and saw the great benefits to be derived from its wide application. He spoke to many industry leaders here in the U.S. and while most expressed interest, they were put off by the time frame of 2 to 5 years for completion. As a result, no significant action took place. Just before the Korean War, Deming was invited to Japan by General McArthur and he spoke to industrialists there, They: too expressed interest. When asked how long would take to implement, the ever-cautious Deming suggested 10 to 15 years, The response was somewhat different from that of their U.S. counterparts. “When can we get started?” was the Japanese answer. It is interesting to note that the first Hondas came to the USA in 1967. This was about 15 years after QA was first introduced in Japan. The effect of this on the American economy and on U.S. industry in particular, has been both revolutionary and in many areas, traumatic.Geog oor svc Vo sao oSCoj8. Module 2 - Quality Assurance On the other side of the Atlantic, late in the 1950's, the British Navy created a task force to explore ways of better assuring the quality of their purchases. Other European countries followed suit and a range of systems was developed. This has culminated in the ninety- odd countries of the International Standards Organization (ISO) pooling their resources in what we know today as the ISO 9000 quality ‘management specifications. ISO 9000 SERIES STANDARD SPECIFICATIONS There are many QA systems used in companies which perform welding. The most universally-accepted systems being used comply wiht the ISO 9000 Series standards. The ISO 9000 Series standards are international standards published by the International Organization for Standardization (ISO). ISO is also the symbol for equal in all directions, indicating that these standards are the same or equal for all. Many of the ISO 9000 series standards have been adopted as American National Standards. These may contain some editorial changes to incorporate American language usage and spelling, but they are equivalent to the corresponding ISO Standards. ‘The numerical designation of the American National Standards is the same numerical designation: as thé-""" corresponding International Standard, with a prefix such as “Q”. The ANSI/ISO/ASQC documents are publised by the American Society for Quality (ASQC or ASQ). This organization is located at 611 East Wisconsin Ave., P.O, Box 3005, Milwaukee, WI 53202. These standards have been adopted by the American National Standards Institute (ANSI). ANSTis the US. member body of ISO. 23 The ANSI/ISO/ASQC Q9000 series of dociments consists of three models plus several guidelines (the information in this module Pertaining to ISO 9000 was taken from Q9001- 1994), The three models are: 1. ANSIISO/ASQC Q9001 Quality Systems - Model for Quality Assurance in Design, Development, Production, Installation and Servicing 2. ANSIISO/ASQC 9002 Quality Systems - Model for Quality Assurance in Production, Installation and Servicing 3. ANSVISO/ASQC 09003. Quality Systems - . Model for Quality Assurance In Final Inspection and Test These three models represent three distinct forms of quality system requirements suitable for a supplier to demonstrate its capability, They also provide for the assessment of that capability by external parties. 1S0/Q9001 is “for use when conformance to specified requirements is to be assured by the supplier during design, development, production, installation and servicing”: It is for ‘manufacturers who design and build their own equipment, either as a cataloged item, or as a cataloged item modified to a purchaser's requirements. General Electric. would be an example; GE designs: and: builds railroad locomotives, aircraft engines, power generation equipment, along with other products, and they also install and service these products. The performance of their products is fully monitored with feedback to design, when appropriate. 1S0/Q9002 is “for use when conformance to specified requirements is to be assured by the supplier during production, installation and servicing”. It is applicable to a wide range of fabricators of welded products. Many welding shops might use this modelModule 2 - Quality Assurance 1S0/Q9003 is “for use when conformance to specified requirements is to be assured by the supplier solely at final inspection and test”. ‘This would be for mass producers, who buy raw materials, process these materials in appropriate machinery and sell the output. By and large, the only effective ‘inspections’ are those carried out ‘on the raw materials and the finished product. Makers of bolts and nuts, paint, welding wire, electrodes, gases, all fall within this category. In the fabrication field, some makers of standard products such as gates, fences, ‘windows, and so forth may also find this model suitable. ‘The requirements in the three models are intended to complement any technical or product specifications or requirements, such as codes or standards, These are quality system requirements which are not a replacement nor alternative to those codes and standards. These models provide the requirements which determine what elements a suppliers’ quality ‘system should encompass. However, ANSI and ISO do not enforce uniformity of quality systems. ‘The varying needs of the supplier, such as the products, services and processes, will determine the actual design and implementation of its’ quality system, It is intended that the ISO/Q 9000 models will be adopted by the supplier, but may need to be tailored by adding. or deletitig tértaini requirements ‘for the” suppliers’ needs (or for a specific contract). The I80/Q 9000 series standards also include two main guidelines. These provide guidance on how to select the appropriate quality assurance model (whether it should be Q9001, Q9002 or Q9003), what quality system elements to use, how to tailor the quality system requirements to specific company needs, etc. The guidelines are: 1, ANSIISO/ASQC Q9000 Quality Management and Quality Assurance Standards Part 1 - Guidelines for Selection and Use Part 2 -Generlc Guidelines for the Application of ISO 9001, ISO 9002 and 180 9003 Part 3 - Guidelines for the Application of 180 9001 to the Development, Supply Software and Maintenance of Part 4 - Guide to Dependability Program Management 2 ANSVISO/ASQC 9004-1 Quality Management and Quality System Elements Part 1 - Guidelines Part 2 - Guidelines for Services Part 3 - Guidelines for Processed Materials Part 4 - Guidelines for Managing Quality Improvement The Quality System models from ISO 9001, 9002 and 9003 were, in large part, adopted from the British Standard BS 5750, which was originally used for two-party contractual situations. As such, they were used as conformance standards, The supplier was required to meet the provisions of the applicable specification. More lately, this has changed where working in conformance to a given model can be regarded as a ‘qualification’. “GERTIFYING BODIES FOR’ QUALITY MANAGEMENT SYSTEMS In the past several years a number of bodies, both from the public sector and the private sector, have set themselves up as certifying bodies for Quality Management Systems. Before this development, each purchaser would descend on prospective suppliers and conduct an audit, which sometimes became very combative, Gilbert and Associates in the U.S.A. and Lloyds in the ws vse2535 34. 5905 PEOOBVoosIIas Module 2- Quality Assurance —_—_— UK. took the lead, and based on experience and training, designated qualified persons as Lead ‘Auditors and others as Auditors. This greatly reduced tensions and led to a more professional approach to quality system conformance: In due time, the certifying bodies set up registers of organizations that had been found to satisfy the requirements of a particular Quality System model. These registers ar administered by a ‘Registr i used in a broader sense to indicate the cert body - be it Bureau Veritas or the American Bureau of Shipping (ABS). Choice of a Registrar is a very important decision. It should be based on what potential Registrar purchasers are most likely to hold in the necessary esteem, Quality professionals are usually equipped to offer suitable advice. For firms seeking registration, it is advisable to engage an outside quality professional. A QUALITY MANAGEMENT SYSTEM Basic requirements for quality management systems include the requirement of being fully documented, generally in the following format: 1. Quality Manual - which sets out the manner in which an organization addresses each element of the QMS model 2, System Procedures - embodying all the procedures on how each element of the quality system Is to be implemented in practice 3, Work Instructions and Quality Plans - detailing the manner in which specific activities are to be carried out . Quality Records - in which are filed all the documents supporting and/or pertaining tothe quality system. This typically includes audit reports, system non-conformance 25 reports, corrective action disposition and similar documents showing the current ‘status of the system. QUALITY MANAGEMENT SYSTEMS ARE DYNAMIC Quality Management Systems, especially in respect to Procedures and Work Instructions, are subject to continual revision and upgrading. ‘There are two basic reasons why a system clement, and its documentation, may have to be changed: + Deficiency revealed by an Internal or external audit, Deficiency tevealed by ongoing non- conformance. - Internal audits of system elements are on- going, as is typically detailed in the QA Manual. External audits are carried out either by ‘an appointed agency, the registering body or a prospective client, An external agency may be called upon to conduct annual audits by the organization. As an auditor cannot effectively carry out an official audit on his own department, smaller organizations usually need to retain an external auditor. The quality system may be likened to the financial system with. respect to audit rationale: - The dynamic nature of quality system elements is recognized by, and implemented under, “Document Change and Control”. Any non-conformance can be traced back to some quality system deficiency. It is from this basis that the need to determine the ‘real’ cause of every non-conformance arises. In one sense, when its implications are local, and readily contained and corrected, this may seem to be making a big fuss about potentially insignificant occurrences, Yet it is the sum of smallModule 2 Quality Assurance —_————— non-conformances that often lead to major problems down the road. MEASUREMENTS In determining and verifying the conformance of product ‘measurements’, Quality Management. Systems (QMS) typically stress the importance on the state of ‘calibration’ of the measuring and testing equipment used. While in general, ‘accuracy’ and ‘tolerances’ are well understood, this is not always the case with the concepts applicable to quality control methods. In this context, ‘measurements’ applies to ‘characteristics’ which may be ‘attributes’ or ‘variables’. In the control of quality, what is known as the ‘Method of Attributes’ is defined as a method that notes the presence (or, if appropriate, the absence) of one or more characteristics of a product. The ‘Method of Variables’ is the measuring, to some defined scale, of one or more characteristics of a product. It goes without saying that measurements made using an instrument or item of test equipment with doubtful accuracy is of little value. While a machinist’s rule (scale) with finely divided graduations is unlikely to vary with use, most other instruments and gages may develop inaccuracies in service... Needless to-sdy, cone & Periodic ‘calibration’ is the process of verifying the state of accuracy of the application item of measuring or test equipment. Logically, the interval between successive calibrations of a given item of measuring or test equipment will be influenced by its vulnerability. Many instruments are supplied with appropriate items of calibration equipment. Micrometers, particularly those with interchangeable anvils, are a case in point. Reference blocks used in association with hardness testers are normal. ‘These and other nerable-than-others. ~~ ‘calibration blocks’ are generally defined as having a given order of accuracy, based on an appropriate standard. In the United States, the National Institute for Standards and Testing (NIST) is considered and accepted as the ultimate authority. In other countries, corresponding organizations serve a similar Purpose. ‘The general approach used in a QMS is to. have a library of reference standards, from which may be verified the accuracy of each item of measuring and test equipment. This activity is typically under the direct control of the Quality Assurance Manager. In larger organizations, the mechanics of calibration are delegated to appropriately: skilled and trained personnel. The reference standards are directly traceable to a NIST standard, ‘These standards are appropriately housed, maintained, and periodically ‘recalibrated” by a NIST-certified test laboratory. i : Records of each item of measuring and test equipment are to be maintained. These records will show the recalibration, and the results. In service, should there be a valid reason to question the accuracy of either measuring or test equipment, immediate recalibration is customarily required. Needless to say, 2 “Procedure is required to cover the mechanics of both internal or external recalibration. Tnstraments and test equipnient; activity. This covers the range. from incoming product inspection, through in-process inspection to final and/or acceptance inspections. With multiple product or large project orders, inspection using one or more statistical techniques may be employed. The use of such methods is usually agreed upon between buyer and seller, except were it is customary practice in the industry concerned. Mainly by virtue of a lack of understanding, wn 26 a oo ego ah nt th:cusrent “calibration; aie required for any qilality control ~ See ta ereSoo e UU LUE S209900a 2o057 Pia ew retool et i on Module 2 - Guatty Assurance as statistical techniques are frequently overlooked in the verification of welded product quality. In the present context, only a brief overview can be given. As a basic principle, ‘variability’ (of supposedly identical product) has been recognized from the beginning, It was noted by the builders of the pyramids and by the clock makers of the Middle Ages. The 19th century USS. rifle and pistol makers began to quantify variability but it was Dr. Shewart and others at the Bell Laboratories in the 1920's and 30’s who gave a finite dimension to'it as an industrial problem. The general method used control charts to differentiate between normal variations resulting from(Chance and variations resulting from@assignable causes) When these latter became excessive for the activity involved, it was said to be ‘out of control’. Such a condition signals'that a corrective action is necessary to restore the requisite degree of control. Control charts may be of various types but tend to be directed to determining either averages or deviations therefrom. Control charts, of whatever type, are developed from data provided by ‘sampling’. A ‘sample’ is a finite part of a statistical ‘population’ whose properties are being studied to gaithinformation about the population as a whole. A ‘population’ is all the individual characteristics of a singie ~~ design available during the period of interest and from which one or more samples may be taken. \ Other terms that may be encountered include the following: A ‘lot’ is a group bf individual items that are produced or sold as a unit, ‘Random sampling’ is the taking of a sample from a ‘lot’ or ‘population’ in which each unit has the same chance of being included in the sample. A ‘range’ is the alte between the largest and smallest value i given set of observations. uals Sampling to determine conformance of a product or group of products as a whole is a well proven technique. Tables such as the Dodge-Romig and MIL-STD-105 have been around for more than 50 years, -Certain unique terminology is used with such tables. It cannot be over emphasized that any inspection and subsequent conformance based on statistical techniques only be implemented with the buyers’ approval. + THE QA AUDIT ob? 201"? ‘While there are several types of and reasons for conducting audits of Quality Management Systems, the mechanics and the objectives are essentially the same, The aim is to establish the on-going integrity of the system in terms of ability to produce goods (or services) of the specified ‘quality’. Audits may be comprehensive, where the whole ofa system, and its several parts, are reviewed in detail. ‘Alternatively, a lesser ‘sample’ may be audited. This is frequently the form adopted for internal audits and some external audits. Welding-related audits may include a check- list for such items as: 1. Use of approved and qualified welding procedures 2. Documentation of ead qualification and ~-eertification a = 3. Welder identification on jialas 4, Certification of welding consumables 5, Use of approved and up-to-date drawings and ‘specifications 6. Inspection status of product 7. Records of nonconformance , oe Quality system audits provide a check that the supplier is giving the appropriate attention to the details. The results of an audit will benefit the supplier in taking corrective and ner ote we!Module 2 - Quality Assurance preventive action. Audits should not be viewed as bad, but rather as a positive means for the supplier's activities to improve. SUMMARY After the above overview of QA & QMS principles, we will now review an ISO model and portions of an ISO guideline to see what elements are required for a particular model. ao. yo ow ye a ) of a oA or 28 BR eb See fae eetVV ILD S 200 SUS oe Module 2 Quality Assurance OVERVIEW OF ANSI/ISO/ASQC Q9001 & Q9004-1 The introductions to the Q9000 series standards state that they are complementary, not alternatives, to the technical or product specified rules, These standards are for quality systems, The technical standards, such as the AWS D1.1 or ASME Section VII, still apply. It must be recognized that this Manual is a training and reference source as preparation for the AWS Senior Certified Welding Inspector examination, As such, it should not be used to develop a quality system for a company. One must always refer to -the actual ANSV/ISO/ASQC standards for that purpose. Also, recognize that these standards are revised at regular intervals, so make sure you are using the latest versions of these standards. ANSIISOASQC Q9004-1 9004-1, Quality Management and Quality System Elements-Guidelines provides guidance on quality management and quality-system elements. It is one of the guidelines to help understand and implement the Q9001 through 29003 models, This guideline charts the relationships of the various organizations in the supply, chain for the - Q9001 through Q9003 standards. A “supplier” is the company or organization which is Preparing the Quality System and providing the Product. The organization which purchases or Teceives the final product is the "customer". Any organization from which the supplier Purchases raw materials or parts is a "subcontractor". The Q9004-1 standard discusses certain “elements” or requirements of the quality system and describes or provides guidance on them. These help describe or augment the 7. 29 requirements in the models, in this case Q9001. For example, Q9001 states that “the supplier's management with executive responsibility” is responsible for the supplier’s quality. Q9004-1, Section 4.1 states that "the responsibility for and commitment to a quality policy belongs to the highest level of management’, not just any level of management The Q9004-1 is a guide that helps explain and support Q9001. It provides details on what information might be used in each element to assure that all pertinent areas are addressed. Thus, certain information from Q9004-1 will be used to explain some of the requirements in 0001. However, the majority of information which the SCWI should know comes from the 9001 standard, with backup from Q9004-1: 9004-1 defines various "Quality system Elements", the appropriate ones of which can be selected by an organization. The extent to which these elements are adopted and applied by an organization depends upon factors such as the market being served, nature of the product, production processes, and customer and consumer needs. ‘The major topics or "elements" listed in the ‘Table of Contents’ oF “Q9004-1 “are: 71. Scope ~ oe Normative References Definitions Management Responsibility Quality-System Elements Financial Consideration of Quality Systems Quality in Marketing Quality in Specification and Design . Quality in Purchasing 10. Quality of Processes 11, Control of Processes 12, Product Verification 3. 4, pena