Questionnaire Manufacturer Assessment

Questionnaire for manufacturer qualification according to - Pressure Equipment Directive 97/23/EC Annex I, Paragraph 4.3

in connection with AD 2000-Merkblatt HP 0 / TRD 201

- EN ISO 3834-2 - EN ISO 3834-3

Page 1 of 14

Reference/Inspection No.:

- please cross out not applicable parts

- please add supplementary description on a separate page, if the place in the question list is not sufficient

Application of the Manufacturer

Applicant Name:

Address:

Plant / Department / Production Place:

- Telephone No.:

- Fax No.:

- Internet:

- E-mail:

initial / renewed / supplementary manufacturer qualification according to

AD 2000-Merkblatt HP 0 / HP 100 R / TRD 201 / EN ISO 3834-2 / EN ISO 3834-3

Statements in the forms of this questionnaire are certified to be correct.

Date:

Stamp, Signature of Corporate Management:

Note: This questionnaire is valid for the qualification of pressure equipment manufacturers in accordance with Pressure Equipment Directive (PED) in connection with AD 2000-Rules. In case that other technical regulations or standards (e.g. EN 13445) instead of AD 2000 are used, you should refer to their respective paragraphs.



- EN ISO 3834-2 - EN ISO 3834-3

Page 2 of 14


1 General firm’s data Description Evaluation / Remarks



1.1 Responsible contact person for TÜV

1.2 Responsible person of Qualiy Assurance (QA)

Staff of QA

-

-

1.3 General manager

Production manager

1.4 Organization

- please add an actual organization chart



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1.5 Are there still certifications or recognitions as manufacturerer ?

Directive 97/23/EC: Module___

EN ISO 900__

EN ISO 3834–__

AD 2000-Merkblatt HP 0

DIN 6700/ EN 15085

others

- please enclose current certificates

1.6 Number of employees - Administration

- Production

1.7 Working area (approx.) roofed / roofless - for Manufacturing

- for Storage



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1.8 Total production scope (including non-PED items) - - - - -

1.9 Production scope which shall be examined - - - -

1.10 Manufactured products in the scope of Pressure Equipment Directive 97/237EC (PED),

Manufacturing acc. to module

Product Category Module

1.11 Parent metals (Groups according to CR ISO 15608)

1.13 Welding processes used (EN 24063)

1.14 Max. dimensions of the products

Wall thickness (welded): Diameter: Length: Weight:



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Page 5 of 14


2 Quality requirements acc. to EN ISO 3834-2/-3

Element Par. of Stand-ards

see also Description Evaluation/ Remarks



Contract review

Are procedures for contract review realized?

What items / requirements are considered at contract review?

5.2

E.g. to be clearly defined:

• application standard / technical regulation

• suplimentary specified requirements (structure, corrosion resistance, specification for the welding process, non-destructive testing, heat treatment, type of recognized welding process and personnel, involving of an independent inspection body)

• measures against climate influences

How are the proce-dures for contract re-view documented?

Are all necessary tech. regulations/standards available and known? Are procedures for handling changes and updates defined?

Design review

Are procedures for design review realized?

What aspects are considered at design review?

5.3

e.g: specifications for parent metals and welding consumables, welding sequence, accessibility of welds, quality and acceptance criteria for welds (HP 5/1, EN ISO 5817)

How are the procedures for design review documented?



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Sub-contracting

What measures are taken to ensure, that the sub-contractors comply with the quality requirements of this standard?

6

The sub-contractor has - to be informed by the manufacturer about all requirements - to be supplied with all relevant specifications / standards/ codes - to be audited and controlled by the manufacturer - to document all activities and procedures

Welders and welding operators

How is it ensured, that only approved welders are assigned for welding production?

7.2 EN.ISO 9606 (EN 287-1) EN ISO 14732 (EN 1418)

EN ISO 15618

AD 2000-HP 3 TRD 201, Anl. 1 VdTÜV-Mbl. 1164

Please add a list of qualified welders and welding operators. Usable form see enclosure 1.

e.g. approval certificates available on site, list of welders

Welding coordination personnel

for planning and supervising the welding production

7.3 EN ISO 14731

AD 2000-HP3

Please add a list of the nominated welding coordination personnel. Usable form see enclosure 2.

Please add qualification certificates.

The qualification (education in welding technology) of the welding coordination personnel has to be suitable for the intended production scope.

Non-destructive testing personnel

8.2 EN ISO 9712 (EN 473)

AD 2000-HP 4

Please add a list of the nominated supervisory and testing personnel for non-destructive testing (NDT) Usable form see enclosure 3.



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Personnel for quality control and other inspections

Which personnel are responsible for the other inspections (e.g. destructive and visual inspections, monitoring and controlling of heat treatment)?

8.1

Description of manufacturing and testing facilities

9.1 9.2

Please add a list of the major production and testing facilities including items of capacity and capability. Usabel form see enclosure 4.

Suitability of equipment

What is taken to ensure, that the equipment is adequate for the application concerned?

9.3

New equipment

What measures are taken after installation of new or refurbished equipment?

(only applicable to EN ISO 3834-2)

9.4

Maintenance

Are there documented plans for maintenance of equipment for production and testing?

(only applicable to EN ISO 3834-2)

9.5



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Calibration and validation of measuring, surveillance and testing equipment

Which methods are performed for cali-bration of equipment?

(kind of equipment, calibration authority, calibration intervals, marking, documentation)

16 EN ISO 17662

DVS-Mbl. 0714 und 3009

Production plan

Which criteria are defined for production planning?

10.1

Welding procedure specification (WPS)

Are there WPS for the welding production?

(applicable only for EN ISO 3834-2; or EN ISO 3834-3 in conjunction with AD 2000-HP2/1 /TRD)

10.2 EN ISO 15609

AD 2000-HP 2/1

TRD201, An. 1



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Welding procedure approval

Acc. to which part of EN ISO 15610 to 15614 are the welding procedures approved?

- for the manufacture acc. to AD 2000-HP0 / TRD 201:

- for the manufacture acc. to other rules:

Are other manufacturing procedures also approved (e.g. forming)?

If applicable, acc. to which rules/standards?

10.3 EN ISO 15607

EN ISO 15610

EN ISO 15611

EN ISO 15612

EN ISO 15613

EN ISO 15614

AD 2000-HP 2/1

TRD 201, An. 1

Please add a list of the approved procedures. Usable form see enclosure 5.

Work instructions

Are there also additional work instructions beside WPS?

How is it ensured, that these instructions include all necessary welding parameters and are in accordance with the WPS?

10.4



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Documentation of the welding procedures

Which procedures do exist for quality relevant documents?

Who is responsible for establishment and maintenance of documents (e.g. WPS, welding procedure, approval records, welders approval certificates)?

10.5

Storage and handling of filler metals

Which documented instructions exist for storage, if applicable for rebaking and handling of filler metals to avoid damage?

Are the supplier’s recommendations for processing available?

Is batch testing of filler metals performed? (only applicable for EN ISO 3834-2 and, if stated, in the contract/ specification)

11



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Storage of parent metals

What measures are taken to prevent adversely effects (e.g. damage, oxidation, soiling, loss of marking)?

12

Post-weld heat treatment

Which specifications for performance of any post weld heat treatment exist? Which influential variables are considered?

13 ISO/TR 17663 (DIN V 8540)

The compatibility with parent metals, welded joints and construction as well as the accordance with the application standard / code have to be considered.

How frequently / by whom is the heat treatment process checked?

How is the process of heat treatment documented?

Re-traceability of the heat treatment process is necessary.



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Welding related inspection and testing, General

14.1 Necessary range and frequency depend on the contract, application standard, the welding process, the type of construction. - an involvement of an independent inspection body may be necessary - planning of location and timing of the inspection

Welding related inspection and testing, before welding

What kind of inspections are performed?

14.2 EN 287, EN ISO 9606, EN 1418

EN ISO 15609

e.g.: suitability and validity of:

- welders and welding operators approval test certificates - welding procedure approvals, if required - welding procedure qualifications (WPS)

joint preparation

suitability of working conditions including evironment (air draught, temperature, special measures for manufacturing of ferritic/austenitic steels etc.)

Welding related inspection and testing, during welding


14.3

e.g.: control and, if necessary, documentation of

- welding parameters and preheating / interpass temperature

- cleaning, shape or runs and lyers, back gouging

- correct use and handling of filler metals

- any intermediate inspection (check of distortion, dimensions)

Welding related inspection and testing, after welding


14.4

e.g.: - visual inspection

- destructive and non-destructive tests,

- inspection of surface treatment (grinding, pickling etc.)



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Inspection and test status

How is the manufac-turing and inspection status of the product indicated?

14.5

e.g.: by use of routing card, production and inspection sequence plan with production related items

Non-conformities and corrective action

Which measures for control of non-con-forming products are defined? (e.g. procedures for separate storage, repair and/or rectification including reinspection)

What measures are assigned in order to identify and eliminate causes of non-conformities

(EN ISO 3834-2)

15



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Identification and traceability throughout the manu-facturing process

Which procedures are defined for identifi-cation and traceability of semifinished products, welding consumables, weld seams (incl. repairs) and products?

17

HP 0, Para. 4

Responsible personnel for markshift of materials

Please add a list of personnel, which shall be authorized for markshift. Usable form see enclosure 6. (only applicable for qualification acc. to AD 2000-HP 0 / TRD 201)

Which documentation for traceability of the welding operations is defined?

Quality records

Which records, certificates, approvals are defined?

Who is responsible for the establishment of quality records?

Which procedures are defined for cases of non-conformities?

What is the minimum period of retaining the quality records?

18



- EN ISO 3834-2 - EN ISO 3834-3

Enclosure 1 Page 1 of 1

Reference/Inspection No.

1 Welder

Only for PED: Is the personell approved in accordance to EN 287,EN ISO 9606 and EN 1418 in addition approved in accordance to PED by either a notified body or a recognized third party organization?.(Only for pressure equipment in categories II,III and IV. (Ifapplicable, please enclose certificates)

1.1 Manual welders (incl. welders for semimechanized welding processes, e.g. 131, 135, 136) Total number:

Examination group acc. EN 287-1 (steel) Number of qualified / approved welders

Examination group acc. EN ISO 9606-2 (Aluminium)

Number of qualified / approved welders

acc. to other standards:

Number of qualified / approved welders

1.2

Personnel for mechanized welding (with travelling carriage (e.g. 121), Orbit, Robot) qualified in accordance with AD 2000-HP 2/1 - HP 5/2 - TRD 201 - EN 1418

Welding process Parent metal Number of operators



- EN ISO 3834-2 - EN ISO 3834-3



1

Are welding and testing supervision performed by the same person? yes / no (please indicate)

2 Welding supervisor

Name:

Education in welding technology as (title):

at:

finished on (date):

Experience in welding:

employed at: as: from: till:

Position:

Range of responsability:

Substitute for the welding supervisor

Name:

Education in welding technology (title):

at:

finished on (date):

Experience in welding:


Position:


please enclose certificates about welding technology education

(Remark: The education should have been in accordance with applicalbe IIW or EWF guidelines.)



- EN ISO 3834-2 - EN ISO 3834-3



3 Supervisor for NonDestructive Testing (NDT)

Name: Stamp and

Signature:

Education in NDT as (title/level): Certificate EN 473 issued by:

at:

finished on (date): Level:

Experience NDT:


Position:

Range of responsibility:

Substitute of the supervisor for NDT

Name: Stamp and

Signature:

Education in NDT as (title): Certificate EN 473 issued by:

at:

finsihed on (date): Level:

Experience in NDT:


Position:


please enclose EN 473 certificates Only for PED: Is the personell for NDT (without VT) approved in accordance to EN 473 and in addition approved by a recognized third party organization? (Only for pressure equipment in categories III and IV,if applicalbe please enclose certificates)



- EN ISO 3834-2 - EN ISO 3834-3



4 List of personnel for NDT

Testing process Name Level acc. EN 473

Visual test (VT)

Dye penetrant test (PT)

Magnetic particle test (MT)

Radiographic test (RT)

Ultrasonic test (UT)



- EN ISO 3834-2 - EN ISO 3834-3



1 Processing machines

1.1 Bending mills

Quantity Bending length Kind of related heating equipment

Wall thickness range for rolling (depending on diameter)

cold: mm; hot: mm

1.2 Bending presses

Quantity Force max. Kind of related heating equipment

Wall thickness range for pressing

cold: mm; hot: mm

1.3 Other equipment for forming

Kind Quantity Remarks

1.4 Equipment for surface treatment and finishing

Kind of treatment Quantity (e.g. pickling, sand blasting, grinding, polishing)

1.5 Plate shears Quantity:

Thickness range for cutting for ferritic steel: mm; austenitic steel: mm

1.6 Equipment for thermal cutting Kind and quantity:

for ferritic steel: for austenitic steel:

1.7 Devices for handling

Rollers Quantity max. load capacity Kind of drive

Positioners Quantity max. load capacity Kind of drive

Other equipment:

Kind Quantity max. load capacity Kind of drive



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2 Welding equipment

Kind Quantity max. Current Generators

DC converters

Transformers

TIG welding machines

TIG pulse welding machines

Quantity max. Current MAG/MIG welding machines

MAG/MIG pulse welding machines

SAW welding machines

Oxy-fuel welding equipment

Further equipment (e.g. for plasma arc welding*)

Manipulators for welding machines*)

*) please describe on separate page

3 3.1

Drying equipment for welding consumables Drying / hot storing equipment for covered electrodes

Kind max. Temperature (oC) Quantity

3.2

Drying / hot storing equipment for flux-cored wires


3.3

Drying / hot storing equipment for flux




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4

Heat treatment equipment (stationary and/or transportable)

examined acc. to AD 2000-Merkblatt HP 7 or equivalent code:

Kind and quantity of equipment *) Examination No. Date

*) please add a description of the equipment concerning: size / capacity / kind of heating / furnace atmosphere / temperature range / kind of heat treatment / quantity of thermocouples for furnace temperature and component temperature / subcontractor for heat treatment (name and address)

5 Transportation devices for the assembly and transport of individual parts and components as well as for hot forming and heat treatment

Kind and quantity of transport. devices Load capacity

6 Particular other manufacturing devices



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Material testing equipment (e.g. tensile, bending, impact, hardness, pellini testing machines)

Quantity and type Measuring range Class acc. to EN ISO 7500-1, EN 10002-4

By whom and how often are the machines checked/ calibrated (external, incompany) (ref. DIN 51220)

Special equipment (e.g. straingage, elevated temp. and low temp. tensile test facilities)

Re-marks

Measurement equipment (for simple devices only total number may be listed)

Quantity and type Applicable range (in general)

By whom and how often is this equipment checked/calibrated

Remarks

Devices for pressure test, leak test and burst test

Type and quantity Applicable range Test-medium

max. test pressure

By whom and how often is this equipment checked/calibrated (e.g. manometer) *)

Remarks

Additional remarks:

*) manometers for the testing of pressure equipment shall be calibrated



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Equipment for metallographic examination (summary)

Type and Quantity (e.g. microscope) Remarks

Equipment for chemical analysis

Type and Quantity

Manufacturer, year of

construction

Elements to be determined

Are the relevant requirements for the analysis accuracy ful-filled? *)

Remarks

*) e.g. in acc. to German manual „Handbuch für das Eisenhüttenlaboratorium“

Information about further testing equipment and testing procedures (e.g. devices for identification check, corrosion tests)

Remarks



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Ultrasonic test equipment (UT)

Manufacturer and type Quantity Remarks (e.g. for calibration)

Kind of test probes / calibration blocks (summary)

Manufacturer and type Remarks

Radiographic test equipment (RT) (z.B. X-ray tubes, isotope inspection equipment, linear accelerator)

Kind Quantity Energy limit (EG)

or max. activity

Manufacturer and type Remarks

Equipment for film examination (e.g. densitimeter)

Kind Quantity Manufacturer and type Remarks



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Apparatures and devices for surface crack examination

Magnetic particle test equipment (MT)

Manufacturer and type max. capacity Remarks (e.g. for calibration)

- Yoke magnetization

- Magnetic current

- Other methods

Devices and test probes for the control of tangential magnetic field intensity and indicator liquid (e.g. Berhold-test probe)

Remarks

Dye penetrant test (PT)

Type (e.g. wet) Manufacturer and type Remarks



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Welding procedure approval tests performed No.

Parent metals / form

(material type / tube, plate etc.)

Filler metals, auxillary materials

Welding process

Welding position

Dimensional range (thickness, Ø)

mm

Heat treatment

Operating temperature max./min. *)

°C

Code Re- marks

Additonal remarks:

*) of welded items



- EN ISO 3834-2 - EN ISO 3834-3


Refernce/Inspection No.:

Responsible personnel for markshift

Name: Stamp and

Signature:

Education as:

at:

finsihed on (date):

Function:


Name: Stamp and

Signature:

Education as:

at:

finsihed on (date):

Function:


Name: Stamp and

Signature:

Education as:

at:

finsihed on (date):

Function:

The consent for the transfer of marking was given by TÜV ………………… on (date) ……………..

Documents

Questionnaire Manufacturer Assessment