American: Assurance For Fabricators

STD-AWS WQAG-ENGL 07842b5 0534385 8 4 2
Welding Quality Assurance Guideline for Fabricators
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Abstract
This document provides a basic outline for small to medium fabricators to
develop a new welding quality assurance system or to enhance an existing
system.
American Welding Society

550 N.W. LeJeune Road, Miami, Florida 33126
COPYRIGHT 2003; American Welding Society, Inc. Document provided by IHS Licensee=Aramco HQ/9980755100, User=, 06/08/2003
05:07:11 MDT Questions or comments about this message: please call the Document
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Key Words
STDmAWS WQAG-ENGL 07842b5 05L43Bb 784
Qualityassurance, quality system,

-
qualification document control,
materialcontrol weldhg procedure,
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nonconformance, inspection, NDE
Welding Quality Assurance Guideline for Fabricators
Prepared by
AWS Fabricator RecognitionTask Group
Approved by
AWS Board of Directors
Abstract
This document provides a basic outline for small to medium fabricators to
develop a new welding quality assurance system or to enhance a n existing
system.
American Welding Society

550 N.W. LeJeune Road, Miami, Florida 33126
STDOAWS WQAG-ENGL 07842b5 OS34387 615 W
Foreword:
An appropriate quality system is the foundation of delivering a quality product or service.
When designed for the Fabricator‘s unique products and suitably committed to paper and
practice, the daily practices of the Fabricator are more consistent and traceable when
problems arise. I t is an increasing trend t h a t custumers want t o see t h a t a welding quality
a~surancesystem is documented and demonstrated. They are concerned with the
Fabricator’s, and the Fabricator’s subcontractors’ capability of producing products t h a t
meet specifications. Many customers look for a systematic quality improvement process.
The quality rianual will identify duties and responsibilities of management. supervisors and
craftspersons, and will provide the customer with better information about who is
responsible to ensure t h a t the product me&s specifications. Medium-sized and small
companies with a5 few a5 three employees can use this Guideline t o develop an effective
welding quality assurance system,
The intent of this Guideline i5 t o assist; fabricators in developing their first welding quality
a55urance system or refining an existing system. The Fabricator chooses a level of welding
quality as~urancet h a t i5 appropriate for the size r% the organization and the type ofwelded
products they produce. This Guideline can provide an opportunity to review existing
practices. Each section of this Guideline addresses a specific topic, yet not all the il;erns in
this Guideline will necessarily apply to all Fabricators’ scope of work. Appropriate selections
should be made based on the Fabricator’s size and the nature of the products made or
repaired a t the facility(ies). The guidelines presented here can be modified and applied t o
most any facility size.
The welding quality assurance system and the quality manual must actually reflect how
things are done. When there is a difference between what is written and what is done, one
must change. The Fabricator can discover differences during their own internal audit of the
system. The less favorable alternative may be a defect found by the Customer. The audit is
the checks and balance part of a quality system. The process of reviewing and writing the
Fabricatm’s quality documents can be a valuable opportunity to take a firm look a t the way
the company’s products are produced. Use this opportunity t o improve and eliminate
redundant pra~ücea.
This Guideline is the first step in creating a welding quality assurance system which can be
used t o satisfy some registration requlrernents. More detailed requirements for specific
industries may be found in such documents as: 150 3834,Quality Kequirerilentz for
Welding: C5A 47.1, Certification of Companies for Fusion Welding of Steel 5tmctures-
Welding; and the Ai5C Quality Certification Program.
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STDOAWS WQAG-ENGL 07842b5 0514388 5 5 1
Fabricator Recognition Committee
Chair Ann (Anna) Petroski Valmet lnc., ioneycomb Division

Bill Myers Dresser Rand Turbo Products Oiv.
Phil Grimm Modem Welding
Richard Arn Glunt Machine & Fabricating
Ernest Levert, 5r Lockheed Martin Vought 5ysterns
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a This Guideline is for the use of weldment fabricators to assist them in developing,
improving and maintaining a welding quality assurance system.
This Guideline is for the use of purchasers of weldrnents to aqsess the welding quality
assurance programs of their suppliers.
This Guideline i s limited to describing a recommended welding quality assurance for

small to medium sized weldment Fabricators. The scope does not include guidance on
weldment design, design control or design review. Although some elements of a quality
system are applied to weldment fabrication in this Guideline, it docs not constitute the
description of a full, company wide quality system.
Notes:
In the event that this Guideline is used by the customer to qualify a
Fabricator as a supplier, this Guideline is written in an auditable
format.
O As used here the term Fabricaior refers to the organization supplying
weldments to the Customer.
0 Each element of this Guideline should be addressed in the Fabricator's
Quality Assurance Manual. If the Fabricator is not sufficiently large to
benefit from instituting a particular element of this program, a nor
appficuble statement should address the item in the quality system
manual.
a This Guideline may be used for any material or type weidment not
covered by an existing industry specific certification program, such as
AISC for buildings, or ASME for pressure vessels.
This Guideline references the term Governing Specification. If a
nationally recognized standard or customer specification is designated
in contract documents, then the rules regarding welding quality in
those standards apply. The Fabricator may elect to create a system that
complies with one of those standards or may create an appropriate one
of their own.
3.1 . Responsibility and Organization

3.1. I . Personnel whose work affects the quality of the product will be
adequately qualified.' The duties, interrelationships and limits of
responsibility of welding, and welding quality assurance personnel
will be clearly defined.
3.1.2. it is desirable that persanne1 responsible for weldment quality control

(QC) and weldment quality assurance (QA) have defined roles separate
from the responsibility for fabrication and delivery.
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American Welding Society's Wefding Quality Assurance Guidelinefor Fabrkaiors page 1
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STDmAWS WQAG-ENGL 07842b5 0534390 1iOT W
3.2. A statement in the welding quality assurance will specify to which codefs) or
standard(s) or governing specification the welding will conform.
3.3. A written welding quality a5surance manual’. that describes the Fabricator’s QA
system and includes a written policy describing the Fabricator’s commitment to
(weldment) quality. Also define...
3.3.1. ...who is responsible for the management and implementation of
weldment QNQC.
3.3.2. ...who is responsible for the prepmation and revision of the Quality
Assurance manual.
3.3.3. ...how appropriate welding procedures are selected for fabrication
work, or how customers’ procedures are used and controlled.' ,’
3.3.4. ...how the delegation of authority is carried out when persons listed
within the Quality Assurance manual arc unavailable.
3.4. A statement will indikate that responsible QNQC reprtsentative(s) have full
support of upper management, (an owner or officer of the company), and identify
the person responsible to resolve disputes between QAIQC and other department
heads. This statement should include the statement that Quality Control has the
authority to identify quality problems and initiate, recommend, or provide
solutions. QC may verify implementations of solutions and limit or control
further processing and delivery of nonconforming items, until proper
disposition has occurred. These decisions will involve the fabricator’s
engineering group, or the customer’s engineer when appropriate. It is preferable
that these limits be defined.
3.5. The QA Manual should include an organization chart showing the relationship
between management, purchasing, quality assurance, quality control, receiving.
production welding and shipping. If field work is within the scope of work, then
the addition of field construction, qualification and inspection may need to be
included.
4.1. The Fabricator will maintain a description of their facility(ies) and a list of
esseatial equipment and resourus used for weldment fabrication. This list will
serve to describe the Fabricator’s capabilities to potential customers. Include
information applicable to the Fabricator’s unique product or service-suggested
items could include...
e number and level of qualified welders,
a welding process capability,
facility square footage,
e capacity of largest cranes,
e size of the largest fabrications possible in the workshop,
capacities of rolling, bending, cutting equipment,
O typicai items fabricated or customers previously served.
e number of engineers, designers, draftsmen,
e precision level attainable
4.2. The Fabricator should plan an appropriate equipment maintenance program that
ensures continuing process capability.
5.1, Notification will be given in writing and accepted by the customer before
services are subcontracted.
5.2. The Fabricator must address by written practice how the quality of subcontracted
services is assured. For sewices that the Fabricator would regularly supply, but
American Welding Society‘s Welding Qiuiliîy Assurance Guideline for Fabricators page 2
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STD.AWS WQAG-ENGL m 07842b5 05114393 O46 m
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due to capacity requirements or other reasons must subcontract, the Fabricator

must especially address how the quality will meet or exceed the quality of the
item or service as if it had been supplied by the Fabncalor. This could include in-
process, final or receipt inspections.
5.3. The level of control of subcontracted services must be appropriate for the
criticality and risk of the weldment as assessed by the Fabricator or the
customer.
5.4. The level of personnel qualification requirements for NDE services must be
specified in the contract to the subcontractor and available to the ~ustomer.~
6.I. The Fabricator will establish and demonstrate a system of defining how their
work concerning weldments is performed. These documents will include, but are
not limited to the following:
Fabrication Drawings (supplied by the Fabricator)
Fabrication or Layout Drawings (provided by the customer)
o Specifications that define elements of the Fabricator's welding quality
control or quality assurance system
Work Instructions
WPSs (welding procedure specifications)
O Purchasing procedures for base material and welding consummables
6.2. Written documentation will show how the system assures that the lotest
applicable drawings, specifications and instructions required are used for
welding, inspection and testing. The documents are controlled by revision, and
are located where the work is performed, and accessible to personnel with
responsibility to perform work. The system will identify who is responsible for
issue and review, Obsolete documents will be removed or otherwise prevented
from inadvertent use. Changes are clearly identified.
6.3. Customer Documents include all forms of information (communications,
drawings, etc.) received from the customer. "hmwill be a clear system to track
changes that result from written or oral communication with the customer.
Quality Records should include, but are not limited to:

WPQR (welder performance qualification records)
o Nondestructive examination (NDE)reports
PQR (procedure qualification records)
Manufacturer test reports (if required for traceability)
O Mill test reports (if required for traceability)
O Records from subcontractors.
8. I . The fabricator must define when traceability is required by internal processes.

code comdiance or by the customer. An adequate continuity involving
drawings,-purchase orbers. part marking and work records must be id&tified.
8.2. The purchase of ali base materials, welding materials, and related parts that will
be attached by welding will be controlled by a defined system. This system will
provide procedures assuring that all applicable specifications, (which may
include mill test certification), are used when ordering materials.
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STD.AWS WQAG-ENGL 07842b5 0514392 TB2 H
8.3. The system will include a description of how materials are. received. stored and
issued in purchasing procedures. Also include the title of the individual and their
responsibilities for the purchasing of material.
8.4. Procedures will define how materials or parts are identified and how identity is
maintained throughout fabrication. As appropriate for the Fabricator's product
or service, incoming materials will be checked for conformance with the
purchase order, material specifications andior drawings where applicable.
9.1. The Fabricator will have WPSs for production welding.

9.2. When required by the governing specification, or appropriate to the Fabricator's
product or service, WPSs will be written to include essential and non-essential
variables'. Variations from an accepted industry practice must be justifiable for
the Fabricator's application.
9.3. Although strongly suggested, supporting PQRs are not required by this
Guideline. When the governing specification requires that welding procedures be
qualified by testing, the Fabricator will have supporting PQRs that support all
WPSs, except pre-qualified W p s s as allowed by AWS DI. 1, the governing
specification or the Fabricator's standard.
9.4. All WPSs (and PQRS when required by the Fabricator's welding quality assurance
system), will be reviewed and approved for use by the Welding Coordinator (see
qi 1 . I ) before being used in production welding operations.
9.5. All welding procedures will be available to welders or welding operators during
testing and during production welding?
9.6. Welding procedures should be qualified by an AWS Accredited Test Facility, or
by the Fabricator's Welding Coordinator. Other test facilities may be used
provided they have been reviewed to assure that they can perform the required
testing in accordance with appropriate or governing specifications. The welding
quality assurance system should specify who is responsible for evaluating the
test facility, and test results to assure compliance. Regardless of the choice of
facility used to conduct qualification testing, the results must be certified by the
Fabricator.
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9.7. Welding procedures are most effective when they provide complete information
to the welder." WPSs must be revised when essential variables are changed and
should be revised when nonessential variables are changed and improved. New or
additional PQR(s) may be required.
1O. 1. Controls must be in place to assure that the proper filler material is used. The
welding quality assurance system should specify how welders obtain filler
material and who is responsible to assure that the proper filler material is used.
10.2. The Fabricator will purchase the welding consumable$ to appropriate AWS Filler
Metal Specifications whenever possible. AMs and/or MIL specifications may be
used if there are no equivalent AWS specifications. Proprietary filler material
names may be used in the absence of any applicable specification.
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STD=AWS WQAG-ENGL U 07842b5 053h393 939
10.3. Storage and reconditioning of low hydrogen electrodes will meet the
requirements of the electrode manufacturer" as a minimum. The welding quality
assurance system should document how this precaution is handled. The exposure
of low hydrogen'? filler materials and fluxes to ambient air and humidity must be
controlled. The welding quality assurance system must specify how this
exposure is controlled and limited.
10.4. Contaminated filler materials/flux must be kept from inadvertent use until it is
reconditioned or disposed.
10.5. For gas shielded processes, gases should be supplied in a safe and efficient
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manner to eliminate contamination.
1 1. I . W e l d i w Coo rdinator
1 1 . l . 1. As a minimum, the Fabricator will appoint an employee who,
irrespective of other responsibilities, is charged with understanding
how the Fabricator's welding quality assurance system functions, and
must be available during all phases during which welding is performed.
The Welding Coordinator is responsible for implementation of the
Fabricator's welding quality assurance system. The Welding
Coordinator (or an individual in their department) should be an
ANSIIAWS Certified Welding Inspector" or other international
equivalent.
1 1.1.2. The Welding Coordinator may or may not have direct responsibility
for the design and revision of the welding quality assurance system.
1 1.1.3. The Welding Coordinator is responsible for assuring that only
qualified welders are used. Although this responsibility may be shared
by foremen, welding inspectors or other direct supervisors, the
appropriate for the- Coordinator must maintain responsibility for the system irrespective
of production schedules.
1 1.1.4. The Fabricator must have available an individual who possesses the
basic knowledge required to develop, qualify, and specify the
appropriate welding procedures for the fabrication work performed in
the Fabricator's shop Or under the Fabricator's control. This individual
may be the same individual who functions as the Welding Coordinator,
or may be contracted for the function.
1 1.2. Welding Inspecto rs The Fabricator should have at least one employee who
is an AWS Senior Certified Welding Inspector (SCWI), or AWS Certified
Welding Inspector (CWI), The welding inspector should be familiar with the
codes or specifications which apply to the fabrication work performed.
Alternatively, the Fabricator must designate a welding inspector who can
demonstrate their ability to inspect weldments to the requirements of the
applicable codes or specifications. This individual may be the Welding
Coordinator.
1 i .2. I . Inspection may include receipt inspection of raw materiais (plate,
sheet, pipe, etc.) and/or welding consumables. (see 113.3)
i 1.3. Employees who perform non-destructive inspection operations, such as
magnetic particle testing (MT),dye penetrant testing (PT),ultrasonic testing
(UT), radiographic testing (RT), radiographic interpretation (RI), etc. should be
qualified using a program comparable to SNT-TC-1 A level II or A W S NDE
Certification Program or equivalent nationally recognized standard or one
required by the governing specification as a minimum.
Aincrican Welding Society's Welding Quality Assurance Guideline for Fabricators Page 5
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11.4. lydders and Wel-rs Welderr; and welding operators will be

qualified to verify their ability to make sound welds when following an
appropriate WPS".
1 1.5. Welders should have an identifying number, letter or symbol for the purpose of
identification. Responsibility for issuing this identification and how this
identification is used on uie weldment should be defined.
12.1. The Fabricator must qualify all welders that will perform work on weldments for
which the Fabricator is responsible. The welding quality assurance system
should specify to what extent welders should be qualified and who is responsible
for signing certification documents.
12.2. The welding quality assurance system will detail how welders' activities are
monitored and documented and who is responsible. Performance Testing will be
supervised by the Welding Coordinator or their designee. Where possible. it is
preferable that the test supervisor is not the welder's supervisor.
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12.3. It is recommended that the Fabricator use AWS QC7 or QC3" certified welders.
The Fabricator may accept qualifications done by subcontractors or other
agencies; however, acceptance does not absolve the Fabricator of the
responsibility to employ qualified welders who can provide acceptable
weldments.
12.4. All welder performancdqualification records, will be reviewed and approved by
the Welding Coordinator before welders begin production welding operations.
12.5. Unless the governing specification requires specific forms, forms provided in
appropriate AWS codes may be used or may be designed by the Fabricator. If
non-standard forms are used, they will include the essential variables identified
in the appropriate code of construction or Fabricator's standard. Samples of the
forms used should be included the welding quality assurance manual.
12.6. The performance qualification of a welder or welding operator will remain valid
unless.. .
12.6.1. the welder has not welded in production with the qualified process
during a period of six months or more, (unless otherwise specified by
the governing specification) or,
12.6.2. there is specific reason to question the welder's ability to make welds
that meet the specifications. The qualifications which support the
welding heishe is doing will be revoked. All other qualifications not
questioned remain in effect.
12.7. The Fabricator should keep a log or roster of qualified welders and devise a
method to maintain their qualifications.
12.8. The welding quality assurance system should specify how certified welders or
welding operators are assigned to a job and who is responsible for assuring that
only qualified welders are used.
12.9. Some codes may require that tack welders be qualified and other codes may not
require qualification if the tack weld is removed prior to final welding. The
welding quality assurance system should specify the extent of tack welders'
qualifications. If unqualified tack welders inadvertently perform tack welds,
controls are in place to assure that the tack weld is removed before final welding.
American Welding Society's Welding Quality Assurance Guiùeline fur Fahricarors page 6
STDmAWS WQAG-ENGL 0784265 0514395 7 9 1
13.1. Weldrnent inspection may be performed by the Fabricator and/or contracted.

13.2. The Fabricator must create a system that clearly defines acceptance criteria. This
criteria may be derived from the Fabricator's customer, codes, standards or if
created by the fabricator, should reference the basis used to derive the criteria.
i 3.3. The Fabricator must define what inspections (what parts, at what frequency, at
what stage of production) are necessary and how the required inspections am
documented.
13.4. Inspection may include receipt inspection of raw materiais (plate, sheet, pipe,
etc.) andíor welding consumables. This inspection may be done by welders and
fitters or by specifically designated quality control personnel.
14.1. When the required weldment quality-as defined by 113.2 is not met, there is a
nonconformance. The Fabricator will have a system to identify nonconformities
to prevent the item's inadvertent use in the final product. A nonconformity could
occur, but IS -ed
. . to the follow k , when _..
O base material identification and inspection before welding is not
performed or,
0 preparation of the base material andor consumable control is not
followed before welding or.
the procedure is not followed during welding or,
final weldment acceptance criteria is not met.
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14.2. Additionally. a nonconformance may be related to a nonconformity in the
normal procedures required for quality assurance and quality control. The
Fabricator's quality system must identify who has the responsibility to approve
the disposition of a nonconformance.
14.3. The Fabricator's quality assurance system will identify nonconformities and
assign a disposition of.,.
14.3. i . deviation-accept the part as is.
14.3.2. rework-correct the nonconformance to bring the part to full
compliance with the original specification.
14.3.3. repair- modify the part ta bring it back to acceptable quality which
may not be in full compliance with the original acceptance criteria.
14.3.4. scrap-discard the nonconforming part and remake.
14.4. The Fabricator's nonconformance. system will include a method to identify,
investigate and address the mot cause of the nonconformance.
15. I , The Fabricator should demonstrate that adequate resources. including equipment
and the assignment of trained personnel to manage, perform and inspect
weldments to the appropriate quality level, are available.
15.2. The Fabricator should demonstrate a suitable system of equipment maintenance
to ensure continuing process capability.
16.1. The Fabricator should identify a method of assurhg that welding procedure
parameters are maintained dunng welding.
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STD-AWS WQAG-ENGL 0784265 05243ïb b28
16.2. A method of calibration for welding machines or for an appropriate calibrated

measurement device must be determined. The Fabricator must select a frequency
to check calibration of identified devices and create a log that identifies the
status of calibration of welding related devices.
Reference D o c u m e n t s
nie elements of uli5 Guideline may satis@ in patt or whole. the welding quality
assurance system requirements of these documents...
e ANSVAWS Di .X
ANSUAWS 02. I
e ANSIIAWS QC 1
e AWS W,QC3
e AWS Qc4
ASME Boiler and Pressure Vessel Code,Section IX
e API 1104
e MIL Specification 248
e Earthmoving Equipment D14.3
e ANSYAWS D14.6 Rotating Equipment
e ANSVAWS D15. i Railroad
e I S 0 97 12
It is suggested that the Fabricator refer to this document for a more detailed
presentation of the qualification and certification of NDE personnel.
e I S 0 14731 Welding Coordination
It is suggested that the Fabricator refer to this document for a more detailed
presentation of the duties of a Welding Coordinator.
e IS0 3834
It is suggested that the Fabricator refer to this document for an alternate
presentation of a welding quality assurance system when a quality system
conforming to IS0 9001 or IS0 9002 is required.
e IS0 9001/9004-1994
It is suggested chat the Fabricator reference these documents for n detailed
description of the elements of document control, quality records and process
control.
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Antericari Welding Society’s Welding Qualify Assurance Guidelinefor Fabricators Page 8

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STD-AWS WQAG-ENGL 07842b5 0534385 8 4 2

Welding Quality Assurance Guideline for Fabricators

American Welding Society

Qualityassurance, quality system,

nonconformance, inspection, NDE

Welding Quality Assurance Guideline for Fabricators

American Welding Society

Fabricator Recognition Committee

Chair Ann (Anna) Petroski Valmet lnc., ioneycomb Division

This Guideline i s limited to describing a recommended welding quality assurance for

3.1 . Responsibility and Organization

3.1.2. it is desirable that persanne1 responsible for weldment quality control

STDmAWS WQAG-ENGL 07842b5 0534390 1iOT W

due to capacity requirements or other reasons must subcontract, the Fabricator

Quality Records should include, but are not limited to:

8. I . The fabricator must define when traceability is required by internal processes.

9.1. The Fabricator will have WPSs for production welding.

American Welding Society's Welding Qualify Assurance Guidelinefor Fabricators Page 4

STD-AWS WQAG-ENGL 07842b5 0534394 855

11.4. lydders and Wel-rs Welderr; and welding operators will be

13.1. Weldrnent inspection may be performed by the Fabricator and/or contracted.

16.2. A method of calibration for welding machines or for an appropriate calibrated

Antericari Welding Society’s Welding Qualify Assurance Guidelinefor Fabricators Page 8

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