Issues_in_Welding_Technology_relating_to_PED_complete.pptx

TÜV SÜD Industrie Service GmbH 1
Issues in
Welding Technology
relating to
PED 97/23/EC
and
CPD 89/106/EEC
Department Material and Welding Technology
Business Unit Plant Engineering
Munich, May 2011 Michael Dey
IS-ATA6MUC/dy

Issues in Welding Technology relating to PED/ CPD
Structure
 Introduction
 Results of the audit performed by ZLS on 29th April, 2011
Qualification of welders and welding procedures acc. to harmonized
standards and to the AD 2000 standard
 Certification of manufacturers acc. to AD 2000 W0/ HP0 and EN ISO 3834
 Certification of welding companies acc. to EN 15085-2 for manufacturing
of railed vehicles and railed vehicle parts
 Information about the recognition of TÜV SÜD Industrie Service GmbH
as Notified Body under CPD within the framework of EN 1090
 Discussion about the qualification of welders and welding procedures
acc. to harmonized standards and the ASME Code
IS-ATA6-MUC/dy

Introduction
Structure
 Introduction
Qualification of welders and welding procedures acc. to harmonized standards
and to the AD 2000 standard
IS-ATA6-MUC/dy

TÜV SÜD Industrie Service GmbH IS-ATA6-MUC/dy 4
ATA6-MUC-M.Dey
Organigram of Notified Body under PED
Organisation

TÜV SÜD Industrie Service GmbH
Department
Material and Welding
Technology
Head: Michael Dey
Material Technology
Technical expert:
Dr. Robert Hackl
Core responsibilities
Certification of manufacturers in accordance with:
- AD-2000-W0, TRD 100, KTA 3201.1,KTA 3211.1,
EN ISO 9001 and PED 97/23/EC
- CPD 89/106/EEC as Notified Body
- DVGW (initial certification and surveillance only)
Issue of particular material appraisals (PMA) and
carrying out approval of material with or without particular
material appraisals
Preparation or testing of material specification
(e.g. VdTÜV material data sheets)
Welding Technology
Technical expert:
Michael Schulz
Core responsibilities
Certification of manufacturers in accordance with:
- AD-2000-HP0, TRD 201, KTA 3201.3 KTA 3211.3,
PED 97/23/EC, EN ISO 3834, EN ISO 9001
Consulting services and approvals falling under the scope of
the ASME Code, conventional and nuclear
Certification of welding and soldering procedures and of
welders and solderes
Certification of manufacturers of welding filler material
Testing, monitoring and certification of welding filler material
as per VdTÜV Code of Practice 1153 and as Notified Body
under CPD 89/106/EEC (basis for subsequent DB approvals)
Certification Body
acc. to EN 15085-2
Head: Georg Lecca
Deputy: Angelika Stangl
5
Organisation
IS-ATA6-MUC/dy
Organisation

Results of ZLS Audit
Structure
 Introduction
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Goal of performing the audit by ZLS was to control, if we fulfill all our duties
and tasks which are necessary for maintaining a recognition as Notified Body
under PED
The Results of the audit performed by ZLS on 29th April, 2011 are especially
with respect to certification of welders and welding procedures as follow:
 The auditor pointed out that we don’t exercise all duties and tasks which we
should exercise as “Notified and Central Certification Body” in Munich.
Our used approach of documentation is suboptimal. The documentation is mainly
managed on a decentralised basis therefore we aren’t able in some cases to have
an overview from Munich, which certificates were issued worldwide by our
colleagues of the subsidiaries.
In some cases the inspectors working within the framework of PED especially
relating to welding issues weren’t designated as auditor by the head of Notified
Body.
ZLS: Accreditation body which is responsible for the designation of Notified Bodies acc. to PED in Germany
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Results

To come through the next audit without major problems especially with
respect to certification of welding companies, welders and welding
procedures we have to take action as follow:
Demonstrate the auditor next time that meanwhile we will exercise all essential
duties and tasks as Notified Body under PED.
Revise of existing work instructions and issue of new ones in some cases also
which describe the uniform approach to certification (e.g. of Welders, Welding
Procedures, HP0, EN ISO 3834)
Try to manage the documentation of certification more on a centralised basis
using new possibilities. E.g. listing of issued welder certificates in a databank
(ITAS) by the new version of the program „worldweld“ and make these available
worldwide.
Designate all auditors working within the framework of PED by the Head of
Notified Body and entry the auditors in the “Qualification Matrix” of the Business
Unit “Steam and Pressure”.
No Certificate shall be issued and no inspection shall be performed by an
auditor who isn’t considered in the “Qualification Matrix”!
IS-ATA6-MUC/dy 8
To Do

Qualification of welders and welding procedures
Structure
 Introduction
Qualification of welders and welding procedures acc. to harmonized
standards and to the AD 2000 standard
IS-ATA6-MUC/dy

 Harmonized standards (e.g. EN 13445, EN ISO 3834) and AD 2000 standard
require that only qualified welders and welding procedures shall be used.
 For the purpose of qualification of welders the requirements of the relevant
harmonized standards EN 287-1 (steel) and EN ISO 9606-Part 2-5 respectively
shall be considered.
 For the purpose of qualification of welding procedures the requirements of
the relevant harmonized standard EN ISO 15614 shall be considered.
 Any additional requirements of AD 2000 standard shall be considered also.
 The welding of the test coupons shall be witnessed by a Notified Body in
both cases.
 The certificates and reports about the test results shall be issued by a Notified
Body in both cases also.
Notice:
In comparison of qualification of welders and welding procedures acc. to ASME
Sec. IX the WPQ and PQR shall be issued by the manufacturer but not by a
Notified Body or by an Authorized ASME Inspector.
IS-ATA6-MUC/dy 10
General/ Summary

To carry out qualifications of welders and welding procedures the following
flowcharts were issued:
Qualification of welders
Qualification of welding procedures
In addition to these flowcharts exist the following work instructions which
give more detailed information about the qualification of welder and welding
procedures:
IS-BSD-P-08 (Qualification of welders and solderes)
IS-BSD-P-04 (Qualification of welding procedures)
The work instructions will be revised as soon as possible to consider the
newest harmonized standards and to comply with the requirements made by
ZLS.
The revised work instructions will be submitted to the subsidiaries and the auditors
by newsletters of the Business Unit “Steam and Pressure” or “Plant Engineering”.
The contents of the work instructions shall be considered within the
framework of carrying out above mentioned qualifications.
IS-ATA6-MUC/dy 11
Uniform approach of qualification by TÜV SÜD

Certification of manufacturers acc. to AD 2000/ ISO 3834
Structure
 Introduction
IS-ATA6-MUC/dy

 Manufacturing under CPD and in accordance with harmonized standards
(e.g. EN 13445) or with AD 2000 standard means that the manufacturer has
to demonstrate his ability to produce products which fulfill all requirements
of the above mentioned standards.
 Harmonized standards and AD 2000 refer with respect of welding issues to EN
ISO 3834 which specifies quality requirements for fusion welding of metallic
materials
 Assessment for welding companies acc. to EN ISO 3834 is only mandatory
if required by the relevant product standards (e.g. EN 1090, EN 12732, EN
12952, EN 13445 or EN 15085) or if required by the client when it was fixed
in the contract documents.
 TÜV SÜD IS carries out approvals acc. to AD 2000 HP0 and EN ISO 3834
(Often combined approvals AD 2000 HP0/ EN ISO 3834 can be offered)
 Besides TÜV SÜD IS carries out approvals acc. to AD 2000 W0 similarly to
the above mentioned approvals.
TÜV SÜD IS: TÜV SÜD Industrie Service GmbH
IS-ATA6-MUC/dy 13
General/ Summary

Requirements:
 Standard quality requirements acc. to EN ISO 3834 (quality measures in
connection with welding) shall be met.
 Suitable equipment for manufacture and testing is available
 Qualified responsible personal for coordination / supervision of
welding work (see HP 3) and non destructive testing (see HP 4) is available
 Qualified and certified personnel (see HP 3) for welding and NDE (see HP 4)
is available
 Welding procedure qualifications for the welding processes used for
pressure equipment are available
 The manufacturer has to demonstrate by an audit (assessment of the
manufacturer and review of the relevant documents) that he fulfills all above
mentioned requirements
IS-ATA6-MUC/dy 14
Approval acc. to AD 2000 HP0

 Application and Questionnaire to be filled in by the manufacturer
 Review of documents submitted by the inspector
 Shop survey at the manufacturer, if necessary including welders
qualification tests and welding procedure qualification tests
 Issue of the inspection report as draft by the inspector
 Review of documents of shop survey and the draft of inspection report by
the department Material and Welding Technology*
 Release of the inspection report by IS-ATA6-MUC and confirming the contents of
the report by the inspector who carried out the survey*
 Issue of the certificate AD 2000-HP 0 in connection with EN ISO 3834*
(A certification acc. to harmonized standard for pressure equipment in connection
with EN ISO 3834 can be done, too.)
For the purpose of an uniform approval the existing work instructions will be
revised as soon as possible to consider the newest harmonized standards
and to comply with the requirements made by ZLS.
IS-ATA6-MUC: Department Material and Welding Technology in Munich
*) If nothing else have been agreed
IS-ATA6-MUC/dy 15
Approval procedure acc. to AD 2000 HP0

Certification of welding companies acc. to EN 15085-2
Structure
 Introduction
IS-ATA6-MUC/dy

TÜV SÜD IS is recognized as Certification Body acc. to EN 15085-2 by EBA
The offered services for welding companies of railway vehicles by
TÜV SÜD IS are as follow:
 Technical consulting and preparation for first audit (if nesessary)
 Assessment and Certification of welding companies acc. to EN 15085-2 for
manufacturing of railed vehicles and railed vehicle parts
 Assessment and Certification (Ability) of welding companies acc. to RID
6.8.2.1.23 in connection with EN 14025 and EN ISO 3834-2 for manufacturing
(removable) boilers of tank and battery wagons
 Assessment and Certification of welding companies acc. to DIN 27201-6
(maintenance of railway vehicles)
EBA: German Railway Authority
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General

To carry out services within the framework of EN 15085-2 the auditors have to
demonstrate their technical knowledge relating welding of railway vehicles in an
interview and have to be personally designated by EBA.
EN 15085 differantiates between four level of certification as follow:
IS-ATA6-MUC/dy 18
Certification process acc. to EN 15085-2
Certification Level Examples
CL 1 - bogies (Drehgestell)
- underframes
- vehicle body
- fuel tanks
CL 2 - sliding doors
- steps
- hand rails
CL 3 - covers for freight wagons
- window frames
- ventilation grilles
CL 4 - design
- bought and assembled

Certification intervals Countries of auditors
Year
1 First Audit
2 Annual Audit
3 Annual Audit
4 1st Renewal Audit
5 Annual Audit
6 Annual Audit
7 2nd Renewal Audit
8 Annual Audit
…… ………
Austria
(Bosnia)
(Bulgaria)
Czech Republic
France
Germany
(Hungary)
(Romania)
(Slovenia)
Switzerland

Information relating to EN 1090
Structure
 Introduction
IS-ATA6-MUC/dy

Information,
Legal Foundations
and
Overall Concept
relating to
EN 1090

Legal foundations
One essential goal of European Union:
 Ensure the free movement of all construction products within the
European Union by harmonising national laws with respect to the
essential requirements applicable to these products in terms of health
and safety 
THE CONSTRUCTION
PRODUCTS DIRECTIVE
(89/106/EEC)
IS-ATA1-MUC/dy
EU
-Directives
Application
standards
e.g. steel construction
Basic standards
Pyramid of laws in Europe

Legal foundations
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Internal European
Market
Mandatory legally
regulated area
Harmonized
area
- EC-Directives
- Harmonized standards

Non-harmonized
area
- National laws and regulations
- European standards
- National standards and directives
Voluntary legally non
regulated area
- Supply agreement
- European standards
- National standards
- Other directives and standards

Timetable for implementation of CPD by EN 1090-1
(in Germany)
Announcement in the Official Journal of the EC: Dezember 2010
(and announcement in the German Federal Gazette: 2011)
Announcement in der Building Regulation for the States: 2011
Announcement in the list of the technical construction regulations: 2011
Coexistence phase until 30th June 2012  CE-marking possible/ optional
Withdrawal of DIN 18800-7: 30th June 2012
 As of 1st July 2012: CE- marking acc. to EN 1090 mandatory
IS-ATA1-MUC/dy

Essential changes by implementation of CPD
 International standards, e.g. DIN 18800-7, Chapter 13
 harmonized European standards, e.g. EN 1090-1
 Building Rules List Part A (Ü-marking)
 Part B (CE-marking)
 General building authority approval (DIBt)
 European technical approval (ETA)
DIBt: German Institute of Civil Engineering
IS-ATA1-MUC/dy

Conzept of the harmonized EN 1090
Execution of steel structures and aluminium structures
Part 1: Requirements for conformity assessment of structural
components (German version EN 1090-1: 2009)
Part 2: Technical requirements for steel structures;
(German version EN 1090-2: 2008)
Part 3: Technical requirements for aluminium structures;
(German version EN 1090-3: 2008)
IS-ATA1-MUC/dy

Recognition of TÜV SÜD IS as Notified Body under CPD
 TÜV SÜD IS submitted a request for recognition as Notified Body
under CPD within the framework of EN 1090 to the DIBt last year
 Status quo: We are still waiting for an audit by DIBt to obtain our
recognition as Notified Body under CPD
Problem: EBA want to fix additional requirements, but at the moment
they don‘t know how they can handle this without causing a conflict
between National and European law
 We hope to obtain our recognition within the next months
DIBt: German Institute of Civil Engineering
EBA: German Railway Authority
IS-ATA1-MUC/dy

Offered Services after recognition
After recognition as Notified Body under CPD within the framework of
EN 1090 TÜV SÜD IS will be entitled to carry out the following services:
 Certification of FPC of manufacturers on the basis of:
• Initial inspection of factory and of FPC
• Continuous surveillance,assessment and approval of FPC
The auditors working within the framework of CPD will be designated
by the Head of Notified Body under CPD
More Information with respect to our recognition and to EN 1090
will be given in a separate experience exchange after recognition
as Notified Body
FPC: Factory Production Control
IS-ATA1-MUC/dy

Open Discussion / ASME
Structure
 Introduction
IS-ATA6-MUC/dy

Question:
Do PQRs and WPQs performed acc. to ASME Sec. IX
fulfill the requirements acc. to PED?
 Requirements according to PED, Annex I, paragraph 3.1.2:
“[…] For pressure equipment in categories II, III and IV, operating procedures
and personnel must be approved by a competent third party which, at
the manufacturer's discretion, may be:
— a notified body,
— a third-party organization recognized by a Member State as provided
for in Article 13.
To carry out these approvals the third party must perform examinations
and tests as set out in the appropriate harmonized standards or equivalent
examinations and tests or must have them performed.”
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Required examinations and tests for qualification of
welding procedures acc. to EN 15614-1
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Required examinations and tests for qualification of
welding procedures acc. to ASME, Sec. IX
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Result:
PQRs and WPQs performed acc. to ASME Sec. IX don’t
fulfill the entire requirements acc. to PED?
 Additional examinations and test have to be perform also to fulfill the entire
requirements of PED
The different scope and validity should be considered also
 If Inspectors of TÜV SÜD IS want to review PQRs and WPQs performed in
accordance with ASME as Notified Body or Third Party Inspector, they have to
clarify if only the requirements acc. to ASME are fulfilled or additionally acc.
to PED
 In the first case they shall use as sign of their review the stamp of their
company
 In the second case they shall use as sign of their review the Notified Body
stamp (No. 0036)
IS-ATA6-MUC/dy

Issues in Welding Technology relating to PED/ CPD
Many thanks
for
your
Attention
IS-ATA1-MUC/dy

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