焊接質(zhì)量手冊(cè)

{品質(zhì)管理質(zhì)量手冊(cè)}焊接質(zhì)量手冊(cè)章節(jié)號(hào)標(biāo)題頁(yè)碼ChapterSubjectPage頒布令/Statement3前言/Forward41應(yīng)用范圍/Scope62參考標(biāo)準(zhǔn)/Normativereference63術(shù)語及定義/Termsanddefinitions84縮寫詞介紹/Abbreviation95要求評(píng)審和技術(shù)評(píng)審/Reviewofrequirementsandtechnicalreview106分承包/Sub-contracting147焊接人員/Weldingpersonnel158實(shí)驗(yàn)及檢驗(yàn)人員/Inspectionandtestingpersonnel199設(shè)備/Equipment2010焊接及相關(guān)活動(dòng)/Weldingandrelatedactivities2511焊接材料/Weldingconsumables3012母材的貯存/Storageofparentmaterials3213焊后熱處理/Post-weldheattreatment3314實(shí)驗(yàn)及檢驗(yàn)/Inspectionandtesting3415不符合項(xiàng)及糾正措施/Nonconformanceandcorrectiveactions4316測(cè)量、檢驗(yàn)及實(shí)驗(yàn)設(shè)備的校準(zhǔn)46/Calibrationandvalidationofmeasuring,inspectionandtestingequipment17標(biāo)識(shí)及可追溯性/Identificationandtraceability4718質(zhì)量報(bào)告/Qualityrecords48附錄AAnnexA附錄BAnnexB附錄CAnnexC附錄DAnnexD附錄EAnnexE任命書/Appointment50焊接組織結(jié)構(gòu)圖51/Structurechartofweldingcoordinationorganization焊接職責(zé)分工/Responsibilitiesofweldingcoordinators52部門職責(zé)/Responsibilitiesofallthedepartments59修改控制/Modificationcontrol63頒布令Statement足顧客及有關(guān)法律法規(guī)的要求，本手冊(cè)現(xiàn)進(jìn)行換版并正式頒布，于2012年4月1日起實(shí)施。Thismanualisguidelinetoweldingqualityofourpany,isthehighestruleforweldingactivities,allstaffmuststrictlyplywithitinordertoensurethatweldingqualitymanagementsystemgettoberuneffectivelyandthatweldingqualityofproductscontinuouslymeetwithrequirementsofcustomersandrelevantlawsorspecifications.Nowthismanualisrevisionandissuedofficiallyandtobeimplementedon1.2012.總經(jīng)理：Generalmanager前言ForwardXXXXXXX有限公司（以下簡(jiǎn)稱為公司）成立于20XX年，位于中國(guó)XXX城——河北省XXXXXXXXXXXX和XXXXXXXXXXXX供應(yīng)軌道車輛的鋁制品部件，大量的為焊接件。XXXXCo.,Ltd(followingwillcallit“thepany”)wasbuilt-upin20XXX.Itisinthe“XXXX”——XXXXXcity,Hebeiprovince.ThepanyisjointedventurebyXXXXXXGroup(followingwillcallitXXXXl”)andXXXXXCo.,Ltd(followingwillcallit“XXXXX”).Thepany’smajorbusinessistosupplyaluminumalloypartsofrailwayvehicletoXXXXXXincludingalotofweldments.根據(jù)公司生產(chǎn)產(chǎn)品的特點(diǎn)，決定按照“ISO3834-2:2005完整質(zhì)量要求做焊接質(zhì)量控制體系管理。本手冊(cè)編制于公司成立初期，主要為申請(qǐng)EN15085-2CL1級(jí)資質(zhì)認(rèn)證，所以此手冊(cè)在編制過程中將EN15085-2EN15085的第3至5部分的要求。另外，公司做ISO9001或者其他質(zhì)量體系認(rèn)證時(shí)，此手冊(cè)可作為其ISO3834系列標(biāo)準(zhǔn)和ISO9001理體系可作為ISO9001質(zhì)量管理體系的子體系。Thepanydecidestoperformweldingqualitycontrolsystemmanagementaccordingto“ISO3834-2:2005Comprehensivequalityrequirements”consideringthecharacteristicofproductsofourpany.Thismanualispreparedatthebeginningperiodaftersettingupthepany,itsmajorobjectiveistoapply“EN15085-2CL1”certification.Allthespecificrequirementsofthisstandardandthethirdtothefifthpartoftheseriesstandard“EN15085”willbeconsidered.Furthermore,ifthepanydeterminestoapplyISO9001orotherqualitymanagementsystem,thismanualcanbetreatedasasubmanualofqualitymanualaccordingtoISO9001orotherqualitysystem.Corresponding,weldingqualitymanagementsystemcanbetreatedassubsystemofqualitysystemaccordingtoISO9001basedontherelationbetweenISO3834andISO9001.ISO3834-2是完全按照ISO3834-2具體內(nèi)容以ISO3834-2EN15085的相應(yīng)部分的相關(guān)條款的要關(guān)人員的協(xié)商并得到最高管理者的批準(zhǔn)才能生效。Intheprocessofpreparingthismanual,thepilingsequencewasinccordancewithISO3834-2:2005inordertobeconvenientforcheckingandauditing.AllthetitlesofcorrespondingclauseareinaccordancewithISO3834-2:2005besidesclause3.ThecontentofthismanualisbasedontherequirementsofISO3834-2:2005,prehensivelyconsidertherequirementsofallthepartsofEN15085andtheactualstatusandoperability.However,becauseofsomereasons,thismanualwillbefoundthatsomerequirementsareunreasonableandneedtobemodified.Anymodificationmustgetapprovalofthegeneralmanager.1應(yīng)用范圍/Scope2本手冊(cè)規(guī)定了影響到產(chǎn)品焊接質(zhì)量的所有因素，適用于公司所有涉及到焊接的產(chǎn)品，涉及到多個(gè)業(yè)務(wù)部門，因此作為本公司的焊接質(zhì)量控制的綱領(lǐng)性文件。3Thismanualspecifiesallrequirementsforallfactorsthatcaninfluenceweldingqualityofproducts.It’ssuitableforalltheproductsinvolvedinweldingprocessing.Manydepartmentsofthepanywillbeinvolved.Thismanualshallberegardedasguidelineofthepanyintheaspectofweldingqualitymanagement.4參考標(biāo)準(zhǔn)/Normativereference5引用標(biāo)準(zhǔn)中凡注明年號(hào)的，應(yīng)該按此版本，未注明的使用其最新版本。6Fordatedreferences,onlytheeditioncitedapplies.Forundatedreferences,thelatesteditionofthereferenceddocument(includinganyamendments)applies.7ISO3834-1:2005金屬材料熔化焊的質(zhì)量要求-第一部分相應(yīng)質(zhì)量要求等級(jí)的選擇準(zhǔn)則8ISO3834-1:2005Qualityrequirementsforfusionweldingofmetallicmaterials-Part1Criteriafortheselectionoftheappropriatelevelofqualityrequirements9ISO3834-2:2005金屬材料熔化焊的質(zhì)量要求-第二部分完整質(zhì)量要求10ISO3834-2:2005Qualityrequirementsforfusionweldingofmetallicmaterials-Part2Comprehensivequalityrequirements11ISO3834-5:2005金屬材料熔化焊的質(zhì)量要求-第五部分確認(rèn)符合質(zhì)量要求所需的文件12ISO3834-5:2005Qualityrequirementsforfusionweldingofmetallic13EN15085系列標(biāo)準(zhǔn)（1-5部分）14EN15085:2008seriesstandard（part1-5）15EN287-1焊工考試-熔化焊-第一部分鋼EN287-1Qualificationtestofwelders-Fusionwelding-Part1SteelsISO9606-2焊工考試-熔化焊-第二部分鋁及鋁合金ISO9606-2Qualificationtestofwelders-Fusionwelding-Part2Aluminiumandaluminiumalloys.EN473無損檢測(cè)-人員的資格認(rèn)證EN473Non-destructivetesting-QualificationandCertificationofpersonnelISO13916焊接-預(yù)熱溫度、道間溫度及預(yù)熱維持溫度的測(cè)定ISO13916Guidanceonthemeasurementofpreheatingtemperature,interpasstemperatureandpreheatmaintenancetemperatureforweldingISO14731焊接管理-任務(wù)及職責(zé)ISO14731:2008Weldingcoordination-TasksandResponsibilitiesISO15607金屬材料焊接工藝規(guī)程及評(píng)定-一般規(guī)則ISO15607:2003Specificationandqualificationofweldingproceduresformetallicmaterials-GeneralrulesISO15609系列標(biāo)準(zhǔn)ISO15609seriesstandardISO15610~15614系列標(biāo)準(zhǔn)ISO15610~15614seriesstandardISO17635~17640系列標(biāo)準(zhǔn)ISO17635~17640seriesstandardISO/TR17663焊接-與焊接及相關(guān)工藝有關(guān)的熱處理質(zhì)量要求指南ISO/TR17663Welding-Guidelinesforqualityrequirementsforheattreatmentinconnectionwithweldingandalliedprocesses.ISO5817:2003鋼、鎳、鈦及其合金的弧焊（電子束焊除外）接頭-缺陷質(zhì)量等級(jí)ISO5817:2003Welding-Fusionweldedjointsinsteels,nickel,titaniumandtheiralloys(beamweldingexcluded)-QualitylevelsforimperfectionsISO10042:2006鋁及其合金的弧焊接頭-缺陷質(zhì)量等級(jí)ISO10042:2006Arc-weldedjointsinaluminiumanditsalloys-Qualitylevelsforimperferctions16術(shù)語及定義/Termsanddefinitions17見ISO3834-1：2005,EN15085系列標(biāo)準(zhǔn)。鑒于這兩個(gè)標(biāo)準(zhǔn)都是英文版的，為了不至于被混亂的稱呼，在此統(tǒng)一一下一些定義的標(biāo)準(zhǔn)中文名稱。18SeeISO3834-1:2005andEN15085:2008seriesstandard.BecausethesetwostandardsareallEnglishrevision,herebylisttheEnglishtermsandChinesetermscorrespondingly.19Weldingcoordinators：焊接管理者20Responsibleweldingcoordinator:焊接主管21Deputyoftheresponsibleweldingcoordinator:焊接主管代表22Deputyoftheweldingcoordinator:焊接管理者代表23Weldingcoordinationorganization:焊接管理機(jī)構(gòu)24在我公司，焊接管理機(jī)構(gòu)就是焊接中心。根據(jù)EN15085-2的5.3條規(guī)定，焊接主管決定才能無保留地承擔(dān)起符合ISO14731的任務(wù)和職責(zé)。所以，公司必須設(shè)立焊接管理機(jī)構(gòu)，即焊接中心。25Inourpany,weldingcoordinationorganizationis“WeldingCenter”.AccordingtoEN15085-2:2008clause5.3,responsibleweldingcoordinatorcanonlyberecognizediftheyareinvolvedintheorganizationofthepanyinsuchawaythattheycanaccepttheirtasksandresponsibilitywithoutreservationaccordingtoISO14731.Forthispurposetheyshallhavetheauthoritytoissueinstructionsandmakedecisionswhentherearetechnicalproblemsindependentofmanufacturingpressures.Sothepanymustsetup“WeldingCenter”.根據(jù)企業(yè)實(shí)際運(yùn)行情況，增加關(guān)于“主管焊接工程師”的定義。所謂“主管焊接工程師”是指：主要負(fù)責(zé)某個(gè)（些）訂單項(xiàng)目的所有或部分焊接產(chǎn)品的焊接技術(shù)工作。Asactualmanagementmethodherebyspecifythedefinitionof“responsibleweldingengineer”.Responsibleweldingengineeristhatinchargeofallweldingtechniquejobofone(some)project(s).26縮寫詞介紹/Abbreviations27IWE國(guó)際焊接工程師/InternationalWeldingEngineer28IWT國(guó)際焊接技術(shù)員/InternationalWeldingTechnologist29IWS國(guó)際焊接技師/InternationalWeldingSpecialist30IWP國(guó)際焊接技士/InternationalWeldingPractitioner31IWIP國(guó)際焊接質(zhì)檢人員/InternationalWeldingInspectionPersonnel32NDT無損檢測(cè)/Non-destructiveTesting33VT外觀檢驗(yàn)/VisualInspection34pWPS焊接工藝預(yù)規(guī)程/preliminaryWeldingProcedureSpecification35WPS焊接工藝規(guī)程/WeldingProcedureSpecification36WPQR焊接工藝評(píng)定報(bào)告/WeldingProcedureQualificationRecord37WI作業(yè)指導(dǎo)書/WorkInstruction38NCR不符合報(bào)告/Non-conformanceRecord39QC質(zhì)量檢查/QualityCheck40要求評(píng)審和技術(shù)評(píng)審/Reviewofrequirementsandtechnicalreview40.1總則/General公司應(yīng)針對(duì)顧客提出的招標(biāo)書、詢價(jià)書、合同、技術(shù)草案等要求，在承諾前組織相的控制、成本、進(jìn)度的所有變化。Thepanyshallorganizerelevantpersonneltoreviewrequirementsofcustomerbeforepromise(signformalcontract),suchrequirementsmaybeshowninbiddingdocuments,inquirydocuments,contract,techniquedraftetc.,toensurethatthepanyhasadequateresource(e.g.equipment,staff),thepanycandeliveryonthetimeandalltherequirementshavebeenclarified,conflictinghavebeenagreedbeforeacceptingorderorcontract.Ifthereisdeferenceorvariationbetweenformalcontractandpreviousbiddingdocuments,quotation,contract(nonformal)andtechniquedraft,thepanymustensurethatthedifferenceorvariationeasytobedistinguished,atthesametimethepanyshallletcustomerknowallthevariationintheaspectofcontrol,cost,progressetc.在焊接結(jié)構(gòu)件的生產(chǎn)制造前，應(yīng)對(duì)結(jié)構(gòu)件的焊接技術(shù)、質(zhì)量要求開展技術(shù)評(píng)審，確劃地開展后序的焊接工作。Thepanyshallorganizetechnicalreviewbeforemanufacturingweldmentsaboutweldingtechnique,qualityrequirementandconfirmpletenessandsuitabilityofalltheinformationrelatedweldingtoensurethatthepanycancarryoutweldingactivityorderlyaccordingtodrawings,standards,contractandtechnicalagreement.40.2要求評(píng)審/Reviewofrequirements包括：Projectdepartmentshallorganizereviewofrequirementbeforeprovidingpromisetocustomer.Thecontentsofreviewshallincludethefollowing:a）將采用的產(chǎn)品標(biāo)準(zhǔn)及所有附加要求；theproductstandardtobeused,togetherwithanysupplementaryrequirements;b）法定（法規(guī)）及常規(guī)要求；statutoryandregulatoryrequirements;c）制造商確定的所有附加要求；anyadditionalrequirementdeterminedbythepany;d）制造商滿足描述要求的能力。thecapabilityofthepanytomeettheprescribedrequirements.為滿足顧客產(chǎn)品所涉及的焊接質(zhì)量要求，項(xiàng)目部在評(píng)審前必須通知主管焊接工程師保留要求評(píng)審的相關(guān)記錄。Forsatisfyingtheweldingqualityrequirementsofproductsofcustomer,projectdepartmentmustnotifyresponsibleweldingengineertoattendreviewmeeting.Reviewrecordmusthavesignatureofresponsibleweldingengineer.Whenrelevantweldingqualityrequirementsincontracthavebeenchanged,projectdepartmentshallnotifyresponsibleweldingengineertoreviewchangedcontents.Projectdepartmentisresponsibleforsavingreviewrecord.40.3技術(shù)評(píng)審/Technicalreview在產(chǎn)品的技術(shù)審查階段，技術(shù)工藝部應(yīng)通知主管焊接工程師參加技術(shù)評(píng)審，評(píng)審的內(nèi)容應(yīng)包括：Intheprocessoftechnicalreview,techniquedepartmentshallnotifyresponsibleweldingengineertoattendtechnicalreview.Thecontentsoftechnicalreviewshallincludethefollowing:a）母材技術(shù)條件及焊接接頭性能；parentmaterial(s)specificationandweldedjointproperties;b）焊縫的質(zhì)量及合格要求；qualityandacceptancerequirementsforwelds;c）焊縫的位置，可達(dá)性及次序，包括試驗(yàn)和無損檢測(cè)的可達(dá)性；location,accessibilityandsequenceofwelds,includingaccessibilityforinspectionandfornon-destructivetesting;d）焊接工藝規(guī)程、無損檢驗(yàn)規(guī)程；thespecificationofweldingprocedure,non-destructivetestingprocedures;e）焊接工藝評(píng)定所使用的方法；theapproachtobeusedforthequalificationofweldingprocedure;f）人員的認(rèn)可；thequalificationofpersonnel;gselection,identificationand/ortraceability(e.g.formaterials,welds);h）質(zhì)量控制管理，包括某個(gè)獨(dú)立檢驗(yàn)機(jī)構(gòu)的介入；quality-controlarrangements,includinganyinvolvementofanindependentinspectionbody;I）試驗(yàn)及檢驗(yàn)；inspectionandtesting;j）分承包sub-contracting;k）焊后熱處理；post-weldheattreatment;l永久襯墊、噴丸、表面加工、焊縫外形；otherweldingrequirements,e.g.batchtestingofconsumables,ferritecontentofweldmetal,ageing,hydrogencontent,permanentbacking,useofpeening,surfacefinish,weldprofile;m）特殊方法的使用，如單面焊時(shí)不加襯墊獲得全焊透；useofspecialmethods(e.g.toachievefullpenetrationwithoutbackingwhenweldedfromonesideonly);n）坡口及焊縫的尺寸、細(xì)節(jié)；dimensionsanddetailsofjointpreparationandpletedweld;o）在車間或其它地方施焊的焊縫；weldswhicharetobemadeintheworkshop,orelsewhere;p有害氣候條件；environmentalconditionsrelevanttotheapplicationoftheprocess(e.g.verylow-temperatureambientconditionsoranynecessitytoprovideprotectionagainstadverseweatherconditions);q）不符合項(xiàng)的管理。handlingofnon-conformances;主管焊接工程師應(yīng)根據(jù)上述內(nèi)容對(duì)產(chǎn)品的焊接技術(shù)要求進(jìn)行評(píng)審，并簽字認(rèn)可。對(duì)人員進(jìn)行溝通和確認(rèn)，所有問題在沒有得到有效澄清和解決之前，圖紙不得下發(fā)使用。核后，簽字確認(rèn)。Responsibleweldingengineershallperformtechnicalreviewaccordingtouppercontentsandconfirmbysignature.Forqueriesfoundduringreview,responsibleweldingengineershallfillthemin“technicalreviewrecordtable”andmunicatewithdesigner.Drawingscan’tbeissuedbeforeclarifyingandsolvingallthequeries.Ifthepanyusesdrawingsofcustomers,responsibleweldingengineershallrequireprojectdepartmenttomunicatewithcustomerswhenqueriesarefoundintheprocessofreview.接人員應(yīng)考慮“5.2要求評(píng)審”中的四項(xiàng)條款內(nèi)容。Followweldingactivitiesjustcanbecarriedoutaftergettingagreementandformattingformaldocuments.Responsibleweldingcoordinatorshallstamponthedrawingthatwasreviewedbyhim/her.41分承包/Sub-contracting報(bào)告和文件。Whenthepanyintendstousesub-contractedservicesoractivities(e.g.welding,inspection,non-destructivetesting,heattreatment),informationnecessarytomeetapplicablerequirementsshallbesuppliedbythepany.Thesub-contractorshallprovidesuchrecordsanddocumentationofhisworkasspecifiedbyourpany.分包商的工作應(yīng)以訂單為準(zhǔn)，并對(duì)我公司負(fù)責(zé)，其工作應(yīng)完全符合ISO3834-2的有關(guān)要求。我公司應(yīng)向客戶保證分包商可以滿足規(guī)定的質(zhì)量要求。Asub-contractorshallworkundertheorderandresponsibilityofourpanyandshallfullyplywiththerelevantrequirementsofISO3834-2.Ourpanyshallensurethatthesub-contractorcanplywiththequalityrequirementsasspecified.我公司提供給分包商的信息應(yīng)包括所有從要求評(píng)審（見5．2條）到技術(shù)評(píng)審(見5．3條）的相關(guān)資料。為了保證分包商符合技術(shù)要求，可能需要規(guī)定附加要求。Theinformationtobeprovidedbythepanytothesub-contractorshallincludeallrelevantdatafromthereviewofrequirements(see5.2)andthetechnicalreview(see5.3).Additionalrequirementsmaybespecifiedasnecessarytoassuresub-contractorpliancewithtechnicalrequirements.42焊接人員/Weldingpersonnel42.1總則/General產(chǎn)管理人員和焊接管理人員的管理，焊接管理人員對(duì)焊工、焊接操作工的管理體現(xiàn)在以下方面：Weldingpersonnelincludeweldersandweldingoperatorsandweldingcoordinators.Weldersandweldingoperatorsaresupervisedbyproductionmanagementpersonnelandweldingcoordinatorsmeantime.Theweldingcoordinatorssuperviseweldersandweldingoperatorsbyfollowing:焊接管理人員決定焊工、焊接操作工能否上崗生產(chǎn)，能生產(chǎn)哪些具體的產(chǎn)品；

Weldingcoordinatorsdecidewhetherwelder,weldingoperatorcanattendproductioninshopandwhatkindsofproductscanbemanufacturedbythem;焊接管理人員對(duì)焊工、焊接操作工的焊接行為進(jìn)行監(jiān)督，發(fā)現(xiàn)違規(guī)有權(quán)制止，并保留通過人力資源部進(jìn)行處罰的權(quán)利；Weldingcoordinatorssupervisetheweldingactivitiesperformedbyweldersorweldingoperators,theycanstoptheirweldingactivitieswhentheyfindwelderorweldingoperatordoesn’tplywithweldingprocedurespecificationorotherprocedureruleevenpunishthembyhumanresourcedepartment;焊接管理人員對(duì)焊工、焊接操作工的業(yè)績(jī)進(jìn)行評(píng)估，對(duì)其崗位技能的評(píng)定起到?jīng)Q定作用；Weldingcoordinatorsevaluatetheperformanceofweldersandweldingoperators,theydecidetheirqualificationregardingtotheircareerskill;焊接管理人員對(duì)處于脫產(chǎn)培訓(xùn)期的焊工、焊接操作工負(fù)完全的管理責(zé)任。Weldingcoordinatorsarefullyinchargeofmanagementresponsibilityforthoseweldersandweldingoperatorsduringweldingtraining(separatefromproduction);公司要為焊接制造過程控制配備足夠的、有資質(zhì)的人員，并進(jìn)行有效的管理，以滿足焊接工作的需要。Thepanymustprovideadequate,qualifiedweldingpersonnelandperformavailablemanagementtoassuretherequirementsofweldingwork.42.2焊工及焊接操作工/WeldersandweldingoperatorsISO9606-2合金焊工要按EN287-1要求通過考試，并取得資格證書，焊接操作工應(yīng)按EN1418要求通過考試，才能上崗工作。資格證書由公司焊接中心負(fù)責(zé)保管。AllweldersmustbequalifiedandgetinternationalweldercertificatesaccordingtoEN287-1（steel、nickel、titanicandtheiralloywelder）orISO9606-2(aluminiumwelder).WeldingoperatorsshallbequalifiedaccordingtoEN1418andthencarryoutproduction.Allthecertificatessavedbyweldingtechnologydepartment.字確認(rèn)，并將相關(guān)確認(rèn)記錄保留，作為辦理證書延期手續(xù)時(shí)的證明材料。Weldingcoordinatorsshallcarryoutevaluationofperformanceofwelders,weldingoperators(e.g.byinspectionofallthestepsofwelding,regularlycollect).ResponsibleweldingcoordinatorconfirmsalltheIWcertificatesbysignatureandsaverelevantrecordsasevidenceforprolongingvalidity.針對(duì)具體的產(chǎn)品，焊工施焊的方法、材料類別、尺寸范圍、位置、接頭形式應(yīng)與證工才能上崗操作。Foractualproducts,weldingprocess,materialgroup,dimensionscope,weldingposition,jointtypeetc.mustbeinaccordancewithallowablerangeofIWcertificate.However,therearesomebigdifferencebetweenactualproductsandstandardtestpiecesaccordingtoqualificationstandard,especiallyforsomeplexproductsorspecialstructures(e.g.thinplate),fortheseproductsIWqualificationmaybenotverysuitableand“productionweldtests”willmorebesuitableforshowingwelder’sskill.Operatingprocedureisthatresponsibleweldingengineerdesigntheitemsofproductionweldtestsandthenconsideredwelders’skillcraft,IWSorganizewelderstopractice.Theycanmanufactureactualproductsjustafterthattheinspectionandtestingoftheirproductionweldtestspiecesareacceptable.42.3焊接管理人員/Weldingcoordinators焊接主管必須符合EN15085-2的A級(jí)要求，一般由已取得國(guó)際焊接工程師證（IWE）的人員擔(dān)當(dāng)。焊接管理者代表可以由符合EN15085-2的A、B、C級(jí)人員擔(dān)當(dāng)。根據(jù)EN15085-2的附錄C，對(duì)于欲申請(qǐng)CL1級(jí)資質(zhì)的企業(yè)，除了必有焊接主管以外，還應(yīng)有“FurtherdeputIes”理解為焊接主管代表，或者，為了更好的理解，可以稱之為“副焊接主管；將A級(jí)人員擔(dān)當(dāng)，焊接管理者代表由B級(jí)或C級(jí)人員擔(dān)當(dāng)。另外，根據(jù)EN15085-2的附錄C，對(duì)于CL1管代表有A級(jí)人員資質(zhì)。但是，我公司要求必須具備A級(jí)焊接主管代表。ResponsibleweldingcoordinatormustbeinaccordancewithlevelAaccordingtoEN15085-2andgenerallyshallbeinternationalweldingengineer(IWE).DeputyoftheweldingcoordinatorcanbeactedbylevelA,levelBandlevelC.ForthemanufacturerpreparetoapplyforCL1certificationaccordingtotheannexCofEN15085-2,theyshallhavedeputyoftheweldingcoordinator.“Deputy”ofthistableshallbe“deputyoftheresponsiblecoordinator”and“furtherdeputies”shallbe“deputiesoftheweldingcoordinator”.Generally,thepanyhasonlyoneresponsibleweldingcoordinatorandonlyonedeputyoftheresponsibleweldingcoordinatorbuthasseveral“furtherdeputies”.ResponsibleweldingcoordinatorandhisdeputymustbelevelA,“furtherdeputies”canbelevelBorlevelC.Furthermore,thereisanoteinthetableofannexCthatlevelAdeputyisnotrequiredforsmallweldingmanufacturerswithasingleshopforCL1.應(yīng)按照EN15085-2附錄B對(duì)本單位焊接管理者的職責(zé)、權(quán)限進(jìn)行清晰的規(guī)定，具體見本手冊(cè)的附錄C。ResponsibilityandauthorityofweldingcoordinatorsshallbespecifiedaccordingtotheannexBofEN15085-2.AnnexCofthismanualdescribesthem.焊接主管人員應(yīng)能獨(dú)立履行職責(zé)，按ISO3834-2標(biāo)準(zhǔn)的要求監(jiān)督焊接管理過程的執(zhí)行。當(dāng)焊接主管不在現(xiàn)場(chǎng)時(shí)，應(yīng)由焊接主管代表代替行使職權(quán)。ResponsibleweldingcoordinatorshallcarryouthisresponsibilitiesindependentlyandsuperviseweldingmanagementprocessaccordingtoISO3834-2.Whenresponsibleweldingcoordinatorisoutofhisoffice(can’tattendanyweldingmanagementactivities)thedeputyofresponsibleweldingcoordinatorshallsubstituteforresponsibilitiesandauthorities.焊接管理者不得外聘，應(yīng)為本單位正式員工。Alltheweldingcoordinatorscan’tbepersonnelofotherpaniesororganizations.43試驗(yàn)及檢驗(yàn)人員/Inspectionandtestingpersonnel43.1總則/General試驗(yàn)和檢驗(yàn)人員、焊接監(jiān)督人員應(yīng)具備相應(yīng)的能力或資質(zhì)，以確保檢驗(yàn)和試驗(yàn)結(jié)果的公正性和準(zhǔn)確性。Inspectionandtestingpersonnelshallhavecorrespondingqualificationandexperiencetoensurethattheresultsofinspectionandtestingarefairandcorrect.如外觀檢驗(yàn)人員未取得國(guó)際焊接質(zhì)檢人員證書，應(yīng)由公司焊接主管人員確認(rèn)其工作能力。Ifthepersonnelperformedvisualinspectiondon’thaveinternationalweldinginspectionpersonnelcertificate,theymustbetrainedandqualifiedbyresponsibleweldingcoordinator.43.2無損檢測(cè)人員/Non-destructivetestingpersonnel.公司應(yīng)配備足夠的符合要求的相應(yīng)級(jí)別的無損檢測(cè)人員，以滿足焊接結(jié)構(gòu)件無損檢EN473VT通過IWE對(duì)其進(jìn)行VTIWIP證書則更好。Thepanyshallallocateadequatequalifiednon-destructivetestingpersonnelformeetingwiththetasksofweldingstructureproducts.Non-destructivetestingpersonnelshallbequalifiedaccordingtoEN473andgetcertificates.ThecertificateofVTpersonnelisn’tmandatorybutthepanymustprovetheirabilityatleast(e.g.IWEprovidesspecialtrainingatVTtothem).It’smoresuitableiftheyhaveIWIPcertificates.不同等級(jí)的無損檢測(cè)人員應(yīng)按EN473的要求實(shí)施其資質(zhì)所允許范圍內(nèi)的工作內(nèi)容。一級(jí)資質(zhì)的NDT人員可以執(zhí)行NDTNDTNDT執(zhí)行監(jiān)督。Allthenon-destructivetestingpersonnelshallperformtheirworkintheavailablescopedescribedontheircertificatesaccordingtoEN473.Thepersonnellevel1cancarryouttestsbutcan’tevaluatethetestingresultandissuetestreport.Thepersonnellevel2orlevel3canevaluateresultsandissuereportandtheycanberesponsiblepersonnelintheareaofnon-destructive,otherwiseonlyresponsibleweldingcoordinatorcanbeinchargeofabovetasks.無損檢測(cè)人員資質(zhì)證書由焊接中心或人力資源部保管，焊接中心按EN473標(biāo)準(zhǔn)的規(guī)定提供證書延期的證明文件，組織無損檢測(cè)人員質(zhì)資的重新認(rèn)證。NDTcertificatessavedbyWeldingcenterorHRdept.WeldingcentershallprovideevidenceforprolongingasspecifiedbyEN473andorganizerecertification.44設(shè)備/Equipment44.1生產(chǎn)和試驗(yàn)設(shè)備/Productionandtestingequipment為滿足焊接結(jié)構(gòu)件的生產(chǎn)制造，公司應(yīng)配備足夠、適用的生產(chǎn)和試驗(yàn)設(shè)備。結(jié)合產(chǎn)品生產(chǎn)任務(wù)量、生產(chǎn)周期以及產(chǎn)品的技術(shù)、質(zhì)量要求，公司應(yīng)識(shí)別、確定所需的設(shè)備，當(dāng)不能滿足要求，應(yīng)考慮提出設(shè)備需求的申請(qǐng)，并提供滿足需求的生產(chǎn)和試驗(yàn)設(shè)備。Thepanyshallprovideadequateandsuitableproductionandtestingequipment.Thepanyshallidentifyandconfirmthequantityandtypebasedonproductionextent,deliverycycleandtechnical,qualityrequirementofproducts.Whenequipmentsexistcan’tsatisfywithrequirementsthepanyshallpurchasenewequipment.焊接生產(chǎn)制造所需的設(shè)備應(yīng)包括：Thefollowingequipmentshallbeavailable,whennecessary:a）焊接電源及其它機(jī)器(powersourcesandothermachines(e.g.sootexhaustequipment)；b）滿足要求的坡口加工及切割（包括熱切割）設(shè)備；equipmentforjointandsurfacepreparationandforcutting,includingthermalcutting;c視、測(cè)量設(shè)備；equipmentforpreheatingandpost-heattreatmentincludingtemperatureindicatorasrequirementofproductorweldingprocedure;d）必要的夾具及固定機(jī)具；jigsandfixtures;e）必要的用于焊接生產(chǎn)的搬運(yùn)設(shè)備；cranesandhandlingequipmentusedfortheproduction;f）與焊接生產(chǎn)直接相關(guān)的個(gè)人勞保用品及其它安全設(shè)備；personnelprotectiveequipmentandothersafetyequipment,directlyassociatedwiththeapplicablemanufacturingprocess;g）表面清理設(shè)備；facilitiesforsurfacecleaning;h）破壞性試驗(yàn)及無損檢驗(yàn)設(shè)備。destructiveandnon-destructivetestingfacilities;44.2設(shè)施的表述/Descriptionofequipment要焊接生產(chǎn)設(shè)備、設(shè)備最大能力等。應(yīng)包括：Productiondepartmentshallmaintainalistofessentialequipmentandfacilitiesusedfortheproduction.Thislistshallidentifyitemsofmajorequipmentforproduction,capacityofequipmentandareaofworkshop,forexample:a）搬運(yùn)設(shè)備的能力；maximumcapacityofcranes;b）車間焊接加工產(chǎn)品的最大尺寸；sizeofponentsthattheworkshopisabletohandle;c）機(jī)械化或自動(dòng)化焊接設(shè)備的功率；capabilityofmechanizedorautomaticweldingequipment;d）焊后熱處理爐的最大尺寸和溫度(如果有)；dimensionsandmaximumtemperatureoffurnacesforpost-weldheattreatment(ifhave);e）沖切、彎曲及剪板機(jī)設(shè)備的加工能力；capacitiesofrolling,bendingandcuttingequipment；f)用于焊接方法的電源總數(shù)；totalnumberofpowersourcesforthedifferentprocesses.44.3設(shè)備的適用性/Suitabilityofequipment設(shè)備應(yīng)保證完好可正常使用，其能力應(yīng)能滿足焊接結(jié)構(gòu)件生產(chǎn)的技術(shù)、質(zhì)量要求。Theequipmentshallbeassuredingoodconditionandsuitableforusingandtheircapabilitysatisfywithtechnicalandqualityrequirementoftheproductionofweldmentsl.44.4新設(shè)備/Newequipment焊接新設(shè)備的購(gòu)置、驗(yàn)收，執(zhí)行公司相關(guān)設(shè)備管理規(guī)定，驗(yàn)收合格并經(jīng)負(fù)責(zé)焊接設(shè)Procurement,checkandacceptanceofnewequipmentshallbecarriedoutaccordingtothedocumentsformanagementofequipment.Allthenewweldingequipmentandrelevantequipmentareavailablejustafterweldingcoordinator’ssignaturethatinchargeoftheassuranceofweldingequipment.CheckandacceptancerecordsaresavedbyProductiondepartment.44.5設(shè)備維護(hù)/Equipmentmaintenance生產(chǎn)部負(fù)責(zé)建立設(shè)備的日常維護(hù)計(jì)劃，確保設(shè)備中那些控制焊接工藝規(guī)程參數(shù)的部項(xiàng)目，如：Productiondepartmentisinchargeofpreparingdocumentedplansforthemaintenanceofequipment.Theplanshallensuremaintenancechecksofthoseitemsintheequipmentwhichcontrolvariableslistedintherelevantprocedurespecifications.Theplansmaybelimitedtothoseitemswhichareessentialforassuringthequalityoftheproduct.Forexample:a）用于焊接設(shè)備操作的電流表、電壓表、保護(hù)氣壓力表、流量計(jì)的狀態(tài)；conditionofammetersandvoltmeters,flowmetersetc.usedfortheoperationoftheweldingequipment;b）電纜、軟管、接頭等的狀態(tài)；conditionofcables,hoses,connectors,etc.;c）機(jī)械化及(或)自動(dòng)化焊接設(shè)備中控制系統(tǒng)的狀態(tài);conditionofcontrolsysteminmechanizedand/orautomaticweldingunit;d）送絲機(jī)構(gòu)及導(dǎo)管的狀態(tài)。conditionofwirefeedersandconduits;e)測(cè)溫儀器的狀態(tài)conditionoftemperature-measurementinstruments.設(shè)備使用者負(fù)責(zé)日常的設(shè)備狀態(tài)檢查，填寫相應(yīng)的檢查記錄。對(duì)于生產(chǎn)過程中出現(xiàn)備。Theusersofweldingequipmentcarryoutdailyinspectionofweldingequipmentandfilloutcorrespondingtable.Fortemporarybreakdownofequipmentduringproductionprocess,themaintenancepersonnelshalldealwiththatonthetime.45焊接及相關(guān)活動(dòng)/Weldingandrelatedactivities45.1焊接生產(chǎn)計(jì)劃/Productionplanning根據(jù)ISO3834-5對(duì)應(yīng)條款要求，在產(chǎn)品技術(shù)準(zhǔn)備階段，公司應(yīng)對(duì)產(chǎn)品的焊接制造相關(guān)活動(dòng)進(jìn)行策劃，編制適宜的焊接生產(chǎn)計(jì)劃文件。文件的內(nèi)容至少應(yīng)包括：AccordingtocorrespondingclauseofISO3834-5,thepanyshallcarryoutplanningforrelatedweldingmanufacturingactivitiesofproductsandpreparesuitableweldingproductionplanningdocuments.Thecontentsofthedocumentsshallincludeatleast:a）結(jié)構(gòu)制造(即單件、組件及最終總裝件的)順序規(guī)定；Specificationofthesequencebywhichtheconstructionshallbemanufactured，e.g.assinglepartsorsub－assembliesandtheorderofsubsequentfinalassembly;b）制造結(jié)構(gòu)所要求的每種工藝方法標(biāo)識(shí)；identificationoftheindividualprocessesrequiredtomanufacturetheconstruction；c）相應(yīng)的焊接及相關(guān)工藝規(guī)程的編號(hào)；referencetotheappropriateprocedurespecificationsforweldingandalliedprocesses；d）焊縫的焊接順序；sequenceinwhichtheweldsaretobemade，ifapplicablee）實(shí)施每種工藝方法的指令及時(shí)間；orderandtiminginwhichtheindividualprocessesaretobeperformedf）試驗(yàn)及檢驗(yàn)規(guī)程(包括任何獨(dú)立檢驗(yàn)機(jī)構(gòu)的介入)；specificationforinspectionandtesting，includingtheinvolvementofanyindependentinspectionbody；g）環(huán)境條件，如防風(fēng)、防雨；environmentconditions，tectionfromwindandrainh）批量、元件或部件的項(xiàng)目標(biāo)識(shí)；identificationbybatches，ponentsorpartsasappropriatei）合格人員的指派；allocationofqualifiedpersonnel;j）工作試件的安排。arrangementforanyproductiontest.根據(jù)EN15085-4：2008，4．1條款，焊接計(jì)劃文件主要包括以下文件：制造過程計(jì)WPS離計(jì)劃、電子零件特殊指導(dǎo)等。Accordingtoclause4.1ofEN15085-4:2008,weldingplanningdocumentsbasicallyincludebelowdocuments:manufacturingprocessplans,weldingsequenceplans,testingplanningdocumentsandWPS.Furthermoretheymayincludeotherdocumentssuchastackingsequenceplans,repairingplans,documentsforjigsandtools,remarksforprotectionoflabourandhealth,plansforseparatingofdamagedparts,specialinstructionsforelectronicparts.綜合考慮ISO3834-2與EN15085-3、EN15085-4、EN15085-5,并結(jié)合我公司的實(shí)際情況，我們的焊接生產(chǎn)計(jì)劃應(yīng)包括以下文件：制造過程計(jì)劃、焊接順序計(jì)劃、接頭列表、焊接工藝規(guī)程（WPSComprehensivelyconsideringISO3834-2andEN15085-3,EN15085-4,EN15085-5andactualstatusofourpany,ourweldingproductionplanningdocumentsaredeterminedasfollowing:manufacturingprocessplans,weldingsequenceplans,jointlist,WPS,productionsweldtestsplans,inspectionandtestingplanningdocuments.以上計(jì)劃文件可當(dāng)做為技術(shù)文件，技術(shù)工藝部編制制造過程計(jì)劃，焊接中心編制其（WPS(WI)計(jì)劃等等。AboveplanningdocscanberecognizedastechnicaldocsandpreparedbyweldingtechniquedepartmentbesidesmanufacturingprocessplanbyTechnologydepartment.Weldingtechnicalpersonnelofweldingtechniquedepartmentarechargeofpreparingweldingsequenceplans,jointlist,WPS,productionsweldtestsplans,inspectionandtestingplanningdocument.Maybeadditionaltoworkinstructions(WI)andrepairingplansetc.isnecessary.對(duì)于a)-j)關(guān)系見下表。Aboveweldingproductionplanningdocumentscanincludealltherequirementsofitemsfroma)toj).Thecorrespondingrelationbetweendocumentationandaboveitemscanreferencebelowtable.文件類型/Typeofdocumentation可以涵蓋備注/Remark的條款/Itemscanbeincluded制造過程計(jì)劃/manufacturingprocessplanse),h),g)接頭列表/Jointlistb),c),i)格式參考EN15085-3附錄焊接順序計(jì)劃/weldingsequenceplansa),d)包括點(diǎn)固焊、/Includingtackingsequen工作試件計(jì)劃/productionsweldtestsplansj)參考EN15085-4第4．2條焊接產(chǎn)品檢驗(yàn)實(shí)驗(yàn)計(jì)劃f)參考EN15085-5/Referenc/Inspectionandtestingplanningdocuments.45.2焊接工藝規(guī)程（WPS）/WeldingprocedurespecificationsWPQR生產(chǎn)過程中得到正確使用。ResponsibleweldingcoordinatorisresponsiblefororganizingstafftoprepareWPSaccordingtoWPQRrecognizedbyqualificationbody(WTI-harbin).AlltheformalWPSsmustbedistributedtotheweldingsite.Weldingcoordinators(weldingspecialists)shallsuperviseandcheckweldingactivitiestoassurethepliancewithWPS.所有的WPS都必須有支撐的WPQR。AllWPSsmustbesupportedbyWPQR.45.3焊接工藝評(píng)定/QualificationoftheweldingproceduresISO15614標(biāo)準(zhǔn)組織實(shí)施焊接工藝評(píng)定試驗(yàn)。試驗(yàn)前應(yīng)先依據(jù)ISO15609PWPS再根據(jù)PWPS進(jìn)行試件焊接。試驗(yàn)完后將相關(guān)資料報(bào)送評(píng)審機(jī)構(gòu)（哈爾濱焊接技術(shù)培訓(xùn)中心）認(rèn)可，取得評(píng)審機(jī)構(gòu)簽發(fā)的實(shí)驗(yàn)報(bào)告后，焊接主管形成WPQR。Applicabilityofweldingproceduresshallbequalifiedpriortoproduction.WeldingtechniquedepartmentshallorganizerelevantstafftocarryoutweldingprocedurequalificationtestaccordingtoISO15614.Preliminaryweldingprocedurespecification(Pwps)shallbepreparedbeforetestingaccordingtoISO15609.AfterthatwelderweldingmanufacturetestpiecesaccordingtoPwps.AndthensendtestpiecesandpWPStoqualificationbody(WTI-harbin).ResponsibleweldingcoordinatorformatWPQRafterachievingtestreportfromqualificationbody.在今后的焊接生產(chǎn)制造過程中，如果母材、接頭形式、焊接方法等發(fā)生變化，不能覆蓋原有的工藝評(píng)定項(xiàng)目時(shí)，焊接技術(shù)中心應(yīng)按照ISO15614標(biāo)準(zhǔn)，執(zhí)行新的焊接工藝評(píng)定實(shí)驗(yàn)。Intheprocessofproduction,ifparent,jointtypeandweldingprocessetc.can’tbecoveredbypreviousWPQRWeldingtechniquedepartmentshallcarryoutnewqualificationtestaccordingtoISO15614.在符合要求的前提下，亦可按ISO15613對(duì)PWPS進(jìn)行評(píng)定。ForsomepWPS,themethodaccordingtoISO15613alsobeacceptable.45.4工作指令(WI)/Workinstructions在焊接結(jié)構(gòu)件的生產(chǎn)過程中，可以直接使用經(jīng)批準(zhǔn)且適用的焊接工藝規(guī)程做為焊工評(píng)定。Generallyspeaking,WPScanbeuseddirectlyforinstructionpurposeintheprocessofproduction.Whennecessarytoprepareworkinstructionforsomespecialproducts,weldingtechniquedepartmentshallprepareWIintheprocessoftechnicalpreparationofproductsandWImustderivefromqualifiedWPS.45.5文件的編制及控制程序/Proceduresforpreparationandcontrolofdocuments

焊接工藝規(guī)程及評(píng)定的一般原則見ISO15607,一般順序是編制pWPS→選擇評(píng)定方法標(biāo)準(zhǔn)→進(jìn)行評(píng)定實(shí)驗(yàn)→形成WPQR→編制WPS→必要時(shí)編制WIWPQRWPSWI由焊接中心統(tǒng)一保存。WPS、WI編制完成后，經(jīng)公司焊接主管批準(zhǔn)后，做為受控文件下發(fā)焊接工位執(zhí)行。焊工合格證書由公司焊接中心負(fù)責(zé)保管。焊接中心還應(yīng)編制專門針對(duì)焊接質(zhì)量(工藝)文件的編制及控制的程序文件。GeneralprincipleofpreparingWPSandqualificationofWPSplywithISO15607.Basicsequenceisthat–preparingpWPS→selectingthemethodofqualification→performingthequal