Sample - Welding Manual

DOC NO: RLL/WM/01
WELDING MANUAL Issue No.-00

EN ISO 3834-3/ DIN EN 15085-2 Revision No. 00
PAGE NO: 1 of 1
TITLE PAGE Effective Date- 1-11-2016
WELDING MANUAL
Copy No. : 01
MR
Copy Issued to :
PREPARED BY: RASIK TANK APPROVED BY : M.K.PANDYA

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DOC NO: RLL/WM/02
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CONTENTS Effective Date- 1-11-2016
CONTENTS
DOC NO. TITLE NO. OF PAGES ISSUE NO.
WM-1/1 TITLE PAGE 1 00
WM-1/2 CONTENTS 2 00
WM-1/3 AMENDMENT RECORDS 1 00
WM-1/4 DISTRIBUTION LIST 1 00
WM-1/5 INTRODUCTION & SCOPE 2 00
WM-1/6 CONTRACT REVIEW 2 00
WM-1/7 SUB CONTRACTING 1 00
WM-1/8 WELDING COORDINATION 5 00

PERSONNEL
WM-1/9 INSPECTION AND TESTING 1 00
PERSONNEL
WM-1/10 EQUIPMENT 2 00
WM-1/11 WELDING AND RELATED ACTIVITIES 2 00
WM-1/12 STORAGE OF PARENT MATERIALS 1 00
WM-1/13 STORAGE & HANDLING OF 1 00

WELDING CONSUMABLES
WM-1/14 INSPECTION AND TESTING 2 00
WM-1/15 REPAIR PROCEDURE 1 00
WM-1/16 SAFETY INSTRUCTIONS 1 00
WM-1/17 ANNEXURES LIST 9 00
WM- /18 MANUFACTURING TOLERANCES 1 00

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DOC NO: RLL/WM/2
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CONTENTS Effective Date- 1-11-2016
DOC NO. TITLE NO. OF PAGES ISSUE NO.

WM- /19 SPECIAL PROCESS APPROVAL 1 00
WM- /20 PAINTING QUALIFICATION 1 00
WM- /21 THERMAL CUTTING 1 00
WM/22 QUALITY RECORDS RETAINTION 1 00

PERIOD

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DOC NO: RLL/WM/03
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AMENDMENT RECORDS Effective Date- 1-11-2016
ISSUE REV PAGE NO. DOC NO. REMARKS

NO/DATE NO/DATE

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DOC NO: RLL/WM/04
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DISTRIBUTION LIST Effective Date- 1-11-2016
COPY NO COPY HELD BY

01 Master copy with MR
02 Unit Head
03 Welding Coordinator
04 Production
05 Q.A.

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DOC NO: RLL/WM/05
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INTRODUCTION & SCOPE Effective Date- 1-11-2016
This welding manual defines comprehensive quality requirements for welding of metallic
materials in RLLs shop floor as per EN ISO 3834-3and/or DIN EN 15085-2 standard.
1.1INTRODUCTION:
1.2 RISHI LASER LTD engaged in manufacturing & Supply of sheet metal fabrications & railway
components. The main customers include BOMBARDIER TRANSPORTATION & CROMPTION GREAWES
LTD
1.12 SCOPE:
Fabrication, machining, shot Blasting, painting of Power Sector oil & gas ,Wind mill, railway & other heavy
components. The material grades & thickness ranges are as follows.
Sr. No. Type of Component Material Grade Mtl. Thk. Range
1 Railway Components S355J2, A588 Gr B 3 70 mm
2 Other fabrication component. IS 2062,ASME A36,ASTM 3-50mm

514/S690QL
1.13 NORMATIVE REFERENCES:

The following referenced documents are indispensable for the application of this
document.EN ISO 3834-3and/or DIN EN 15085-2 & also applicable standards as per
Annexure R1

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DOC NO: RLL/WM/06
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Effective Date- 1-11-2016
INTRODUCTION & SCOPE
1.14 GENERAL REQUIREMENTS:

All documents are in order to qualify for the certification as per EN ISO 3834-3and/or
DIN EN 15085-2 shall demonstrate that they have full control over the requirements
mentioned in the standards of EN ISO 3834-3and/or DIN EN 15085-2 through the following,
Accreditation by external certification body as per ENISO 3834-3and/or DIN EN-15085-2
Qualified welding coordinator/welding supervisor
Qualified NDT Personnel
Welders and welding operators qualification
Required guideline/ work instruction
Welding process and mock up qualification.

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DOC NO: RLL/WM/07
PAGE NO: 2 of 2
Effective Date- 1-11-2016
INTRODUCTION & SCOPE
1.15 QUALITY REQUIREMENTS:
The quality requirements to carry out welding work on Metro Bogie parts & other
fabrications and subassemblies are as per EN ISO 3834. All requirements of ISO 3834 are to
be fulfilled in principle (refer Annexure R1)
The quality requirements to carry out welding work on Railway component Metro Bogie
parts are as per DIN EN 15085. All requirements of DIN EN 15085 are to be fulfilled in
principle. (Refer Annexure R1) and requirements of ISO 3834-2
1.16 STAFF REQUIREMENTS:
- Welders are to be qualified in accordance with EN ISO 9606-1 for steel and welders
shall be qualified as per ISO 157614-1. Appropriate welders shall be selected for jobs
that require special attention by looking at their past records and qualification
certificates. Refer consolidated list
1.17 TECHNICAL REQUIREMENTS:
RLL has got following suitable technical equipments according to EN ISO 3834-3and/or DIN
EN 15085-2. The requirements as per EN ISO 3834-3and/or DIN EN 15085 which RLLs
possesses are as follows,
Roofed, dry, ventilated and sufficiently lit work shops and working places.
Storage area for consumables.
Suitable power requirements (refer Annexure R 3)
Work platforms (machined bed plates) for details (refer Annexure R 3 A)
Clamping devices for welding sub assembly parts.& Devices for straightening

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DOC NO: RLL/WM/08
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CONTRACT REVIEW Effective Date- 1-11-2016
2.1 GENERAL:s
RLL shall review the contractual requirements (refer procedure doc. No. DI:PROCESS:MKT:01 ) and
any other requirements, together with any technical data provided by the customer. It is required
to establish that all information necessary to carry out the manufacturing operations is complete
and available prior to the commencement of work. RLL shall affirm its capability to meet all
requirements and shall ensure adequate planning of all quality related activities.
The review of requirements is carried out by Asst. Manager Marketing to verify that the work
content is within its capability to perform, that sufficient resources are available to achieve
delivery schedules and that the documentation is clear and unambiguous. RLL shall ensure that
any variations in changes, cost, program and schedule are brought to the notice of customer.
2.2 REVIEW OF REQUIREMENTS:
Aspects to be considered shall include the following:
The product standard to be used. Together with any supplementary requirements.
Statutory and regulatory requirements.
Any additional requirements identified by customer
The capability of RLL to meet the prescribed requirements.

2.3 TECHNICAL REVIEW:
Technical requirements considered shall include the following:
Parent material specification and its weldability.
Welding consumables and its specification.
Quality and acceptance requirements for welds.
Location, accessibility and sequence of welds, including accessibility for inspection and for
non destructive testing.

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DOC NO: RLL/WM/08
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The specification of welding procedures, non destructive testing procedures and heat
treatment procedures.
The approach to be used for the qualification of welding procedures.
Joint location with relation to the design requirements.
Requirements for weld performance class.
The qualification of welders/welding operators
Selection, identification and / or traceability ( e.g. for materials, welds)
Quality control requirements, including any involvement of an inspection body.
Inspection and testing.
Sub contracting.
Other welding requirements, eg. Batch testing of consumables, ferrite content of
weld metal, ageing, hydrogen content, permanent backing, surface finish, weld
profile.
Use of special methods ( e.g to achieve full penetration without backing when
welded from one side only)
Dimensions and details of joint preparation and completed weld.
Welds which are to be made in the RLL shop floor.
Environmental conditions (temperature)

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DOC NO: RLL/WM/09
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All contract / technical review documents shall be maintained in formats doc. no

F:MKT:01
Client Name :
Enquiry No/Reference No :
Sr No Aspects to be reviewed Remarks
Aspects to be considered,
a) The product standard to b used, together with any supplementary requirements;
b) Statutory and regulatory requirements;
c) Any additional requirement determined by the manufacture;
d) The capability of the manufacturer to meet the prescribed requirement.
Technical review
Technical requirements to be considered,
a) Parent material specification and welded joint properties;

b) Quality and acceptance requirements for welds;
c) Location, accessibility and sequence of welds, including accessibility for inspection
and for non-destructive testing;

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d) The specification of welding procedures, non-destructive testing procedures and

heat-treatment procedures;
e) The approaches to be used for the qualification of welding procedures;
f) The qualification of personnel;
g) Selection, identification and/or traceability(eg. For material,welds);

h) Quality control arrangements, including any involvement of an independent
inspection body;
i) Inspection and testing;
j) Sub-contracting;
k) Post-weld heat treatment;
l) Other welding requirements, e.g. batch testing of consumables, ferrite content of
weld metal, ageing, hydrogen content, permanent backing, use of peening, surface
finish,weld profile;
m) Use of special methods(e.g. to achieve full penetration without backing when welded
from one side only);
n) Dimensions and details of joint preparation and completed weld;
o) Welds which are to be made in the workshop, or elsewhere;
p) Environmental condition or any necessity to provide protection against adverse
weather condition);
q) Handling f non-conformances.
Team members involved in contract/technical review are as in Annexure R4
References: PO (Contract Review) procedure doc. no. DI:PROCESS:MKT: 01

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DOC NO: RLL/WM/10
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SUB CONTRACTING Effective Date- 1-11-2016
3.1 SUB CONTRACTING:

When RLL intends to use sub contracted services or activities (e.g. NDT,), information
necessary to meet applicable requirements shall be supplied by RLL to the subcontractor.
The sub-contractor shall provide such records and documentation of his works as may be
specified by RLL. At the same time RLL shall ensure that sub-contractor can comply with the
quality requirements as specified.
Some of the approved sub-contractors by RLL are listed in annexure R5 for various services
or activities required.
NDT Method (RT,PT & DT)
MET HEAT ENGINEERS PVT LTD-BARODA
TCR ADVANCED ENGINEERING PVT LTD-BARODA

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DOC NO: RLL/WM/12
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WELDING COORDINATION PERSONNEL Effective Date- 1-11-2016
4.1 WELDING COORDINATION PERSONNEL

RLL shall have at its disposal sufficient and competent personnel for the planning,
performing and supervising of the welding production activity according to ISO 14731.
Welding coordination personnel of RLL shall plan all welding related activities as per
customer specification and drgs. He shall be assisted a suitable deputy welding
coordinators/Welding supervisor. They shall demonstrate adequate technical knowledge to
enable all tasks assigned to be performed satisfactorily.
The coordinators having responsibility for quality activities shall have sufficient authority to
enable any necessary action to be taken.
Welding coordination personnel shall introduce all possible types of welding fixtures to
minimize distortion during welding. Sequence the process of weld to see that the job does
not get over heated. Their main responsibility is to ensure that the proper execution of plan
at ground level. The sequence of weld and control of activities in shop floor shall be
discussed amongst supervisors in the preliminary stages before the commencement of any
project. He has to analyze the drawing before giving it for production (for welding), assign
NDT stops. First sample prepared has to be approved by the welding coordinator. He shall
be responsible to track the continuity of welders working regularly. Appropriate welders
shall be selected for jobs that require special attention by looking at their past records and
qualification certificates. Based on their track records, he shall decide the continuity of
welders to execute the jobs.
Welding coordinator with comprehensive, Specific & Basic technical knowledge
International welding technologist (IWT) Level B
Deputy welding coordinator (DME) Level C

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Deputy welding coordinator Level C
Refer Annexure - R 7 for details of welding coordination personnels.
Tasks and areas of competence of the welding coordinator
Tasks and areas of competence of the welding coordinator Welding coordinator
Related clause
from EN ISO Tasks and areas of competence for rail vehicle building Level Level Level
14731:2006, A B C
Annex B
B.1 Review of - product standard to be used, together with any
X (X) (X)
requirements supplementary requirements
- parent material(s) specification and welded joints X (X) (X)
properties
- joint location with relation to the design requirements X X (X)
- requirements for weld performance class X (X) (X)
- location, accessibility and sequence of welds, including X X (X)

B.2 Technical accessibility for inspection and nondestructive testing
review
- other welding requirements, e.g. batch testing of
consumables, ferrite content of weld metal, ageing, X (X) -
hydrogen content, permanent backing, use of peening,
surface finish, weld profile
- dimensions and detail of joint preparation and X X (X)

completed weld
B.3 Sub- With regard to sub-contracting, the suitability of any sub- X (X) (X)
contracting contractor for welding fabrication shall be ensured.
B.4 Welding
With regard to welding personnel, the qualification of
personnel
welders and welding operators shall be carried out X X (X)
(including training, instuction, performance and assessment)

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DOC NO: RLL/WM/13
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WELDING COORDINATION PERSONNEL Effective Date-1-12-2016
B.5 the suitability of welding and associated equipment shall be

X (X) (X)
Equipment ensured.
- reference to the appropriate procedure specifications
B.6
for welding
Production X X (X)
planning
- allocations of qualified personnel
- method range of Qualification with regard to the
B.7 X (X) -
qualification of the welding procedures
Qualification
of the welding
- performance and assessment of welding procedure
procedures X X -
qualification
B.8 Welding
With regard to welding procedure specifications, the range
procedure X (X) (X)
of qualification shall be determined
specifications
B.9 Work With regard to work instructions, the issuing and use of
X (X) (X)
instructions work instructions shall be determined
Related clause
from EN ISO Tasks and areas of competence for rail vehicle building Level Level Level
14731:2006, A B C
Annex B
B.10 Welding
- compatibility X X (X)
consumables
- delivery condition X (X) (X)
- any supplementary requirements in the welding X (X) (X)
consumables purchasing specifications, including the
types of welding consumable inspection document
- storage and handling of welding consumables X X (X)
B.11 - any supplementary requirements in the material X (X) (X)
Materials purchasing specifications, including the types of
inspection document for the material
- storage and handling of the parent material X X X

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DOC NO: RLL/WM/14
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B.12
Inspection and - suitability and validity of welder's and welding X X (X)
testing operators qualifications certificates
before - validity of the welding procedure specification X (X) (X)
welding - identity of the parent material and welding X X X
consumables
- joint preparations, fit-up, jigging and tacking X X X
- any special requirements in the welding procedure X X X
specification (e.g. prevention of distortion)
- suitability of working conditions for welding, including X X X
the environment
- performance and assessment of mock-ups X X (X)
B.13
- essential welding parameters X X X
Inspection and
- preheating/inter pass temperature X X X
testing during
- cleaning and shape of runs and layers of weld metal X X X
welding
- back gouging X X X
- welding sequence X X X
- correct use and handling of welding consumables X X X
B.14 and B.15 - use of visual inspection
inspection and X X (X)
- use of non-destructive testing
testing X (X) -
- use of destructive testing
after welding X (X) -
- results and records of post-operations
X (X) (X)
(e.g. post-weld heat treatment, ageing)
B.16
With regards to non-conformance and corrective actions,
Non-
the necessary measures and actions (e.g. weld repairs, X (X) (X)
conformance
reassessment of repaird welds, corrective actions) shall
and corrective
be determined.
actions
B.17
Calibration &
validation of
The necessary methods and actions shall be determined. X (X)
measuring,
inspection and
testing
equipment

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B.18
Identification
The applicable actions shall be determined. X (X) (X)
and
traceability
B.19 Quality Preparations and release of the necessary welding
X (X) (X)
records records and documents shall be carried out.
Explanations:
X Fully authorized.
(X) For certification level CL 2 Fully authorized.
- not authorized .

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DOC NO: RLL/WM/15
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INSPECTION AND TESTING Effective Date- 1-11-2016
5.1 INSPECTION AND TESTING PERSONNEL

RLL shall have sufficient and competent personnel for planning, performing and supervising
the inspection and testing of the welding production according to specified requirements.
Planning shall be made by welding coordinator along with deputy welding coordinator 1.
Supervising the performance, inspection and testing shall be done next level deputies 2 and
3.
Non destructive testing personnel are as listed in annexure R6. Penetrate test and visual
test shall be carried out by EN / ISO 9712 Level ll operators in case of requirements.
Radiographic Testing, Magnetic particle testing are outsourced. These procedures,
approved by level III are to be reviewed by RLLs personnel (level II/III). He has to witness
the performance of the operator during testing.
Training program or awareness program for welders/welding operators shall be given

regularly and recorded by H.R. department

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EQUIPMENT Effective Date-
6.1 EQUIPMENT:
RLL has got following set of equipments.
The details of these equipments are in Annexure R8
Power sources and other related machineries.
Laser cutting, CNC plasma and oxy fuel cutting machine.
Bending machines,400 Tonn-1Nos & 200 Tonn-3Nos capacity
Equipments like hand cutting torches (LPG & Oxygen) for preheating some of the
base materials before start of weld.
Jigs and fixtures.
MIG/MAG welding machines, TIG welding machines. Power tools and pneumatic
tools such as grinding machines, sandering machines.
Roofs for production activities.
Protective equipments like helmets, goggles, gloves, sleeves, aprons, and welding
screens are made available during production.
6.3: EQUIPMENT MAINTENANCE

RLL shall have documented plans for the maintenance of equipment. The plan shall
ensure maintenance checks of those in the equipment which control variables listed in
the relevant procedure specifications. Details are as in Annexure R8

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DOC NO: RLL/WM/17
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EQUIPMENT Effective Date- 1-11-2016
The plans are limited to those items which are essential for assuring the quality of the
product.
Condition of fixtures, cutting equipments shall be periodically checked.
Conditions of ammeter, voltmeters, flow meters etc (has to be calibrated

internally/externally) used for the operation of the welding equipment.
Conditions of cables, hoses, connectors etc.
Conditions of control systems in mechanized welding unit.
Conditions of wire feeders and circuits.
Gas flow at nozzle.
Scheduled maintenance check list of all welding and related requirements shall be
recorded by maintenance department.
Calibration of welding equipments shall be carried out by internal / external

agencies & Records maintained.

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DOC NO: RLL/WM/18
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WELDING AND RELATED ACTIVITIES Effective Date- 1-11-2016
7.1 PRODUCTION PLANNING
Items to be considered during planning shall include the following,

Sequential work in process instructions for setup, welding and allied process.
Identification of individual process like leveling, bending, machining etc required to
manufacture the construction.
Reference to appropriate procedure specifications for the welding.
Order in which the individual processes are to be performed.
Specification for inspection and testing, including the involvement of any
independent inspection body. Allocation of qualified personnel.
Environmental conditions.
For the above mentioned detailed planning refer annexure 3 for relevant work
instructions.
7.2 WELDING PROCEDURE SPECIFICATION
RLL shall prepare the welding procedure specifications as per applicable standards ISO
15609-1. Shop floor supervisor / deputy welding coordinator will have one set of all
relevant welding procedures at his disposal. He shall clearly demonstrate or make
welders easily understand all essential variable parameters that are displayed in WPS.
List of WPS is as per annexure R2
7.3 QUALIFICATION OF WELDING PROCEDURES
RLL shall qualify welding procedures prior to production. The method of qualification
shall be in accordance with relevant standards or as stated in the specifications. RLL
shall qualify all welding procedures as per ISO 15614-1 (for Carbon Steel) as mentioned
in table - 5 of ISO 3834 -5. List of WPQR is as per Annex R2.

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DOC NO: RLL/WM/19
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WELDING AND RELATED ACTIVITIES Effective Date-1-12-2016
7.4 WORK INSTRUCTIONS

Work instructions shall be clearly displayed in the area of interest. Relevant work
instructions Refer annexure 9 for ------ ------s shall establish and maintain procedures for the
preparation and control of relevant quality documents. Once the joint configurations that
appear in drawings /specifications are clearly understood, relevant Welding Procedure
Specification (WPS) shall be prepared by welding coordinator.
Procedure qualifications (WPQR) shall be made by preparing proper test coupons as per
standards ISO 15614-1. Test coupons are properly identified & shall be send to approved
NDT services mentioned .Followed by destructive testing at any of the approved NABL
labs.
Performance qualification of welders / welding operators shall be done referring

established PQRs. Each welder shall be assigned with one internal identification
numbers like UW1, UW2 Preceding numbers shall be assigned to new welders based
on WPQs.

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STORAGE OF PARENT MATERIALS Effective Date-1-12-2016
8.1 STORAGE OF PARENT MATERIALS:
Purchase indent is to be given to the purchase department with all relevant details of
material required. This should contain details of required material standard (such as
IS, ISO, EN etc.,), size, make, finish, and quantity.
Purchase order is to be made in accordance with the requirements of purchase

indent. This P.O should specify the standard of material required, size, finish and
quantity of plates. Order should also specify that all materials should confirm to
required standards such as IS, EN, ISO etc. This has to be verified during incoming
inspection of materials.
Storage of parent material, with the original mill test certificates shall be done.
Proper identification like heat numbers, plate no. shall be verified and stamp
transferred.
After doing verification of TC and inspection, providing one unique no as per store
work instruction for Raw material tractability.
All drawings received by customers shall be maintained and documented with quality
department. Traceability shall be established for materials being transformed into
cut parts. Cross verification of these materials against respective test certificate has
to be done.

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STORAGE & HANDLING OF WELDING Effective Date- 1-11-2016
CONSUMABLES
9.1 STORAGE & HANDLING OF WELDING CONSUMABLES
All welding consumables shall be stored in spaces designed for this purpose
under room temperature conditions. Welding consumable shall be stored in
original, undamaged package. The stores shall be kept neat and clean. Ovens
shall be used to bake the electrodes before welding if required.
The control/receipt /storage/issue of welding consumables is the responsibility

of stores and the procedures followed shall be the same as in ISO 9001:2015. &
Work Instruction DI:PROCESS:STR:02.

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10.1 INSPECTION AND TESTING

BEFORE WELDING
Suitability and validity of welders and welding operators qualification

certificates.
Suitability of welding procedure specification.
Identity of welding consumables.
Joint preparation.
Surface preparation (sandering/grit blasting) of welding joints.
Fit-up. Jigs and fixtures and tacking (e.g. prevention of distortion).
DURING WELDING
Essential welding parameters (welding current, arc voltage, gas flow rate and
travel speed).
Preheating /inter pass temperature.
Cleaning and shape of runs and layers of weld metal.
Back gouging. Welding sequence.
Correct use and handling of consumables. Control of distortion.
Any intermediate checking of dimensions to assess severity of distortion.
Welding sequence shall be maintained.

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AFTER WELDING
Visual inspection.
Non-destructive testing if applicable.
Destructive testing.(out sourced) if applicable.
Reference documents record (VT report no XX/GE/PT/ YY/Sr no&

XX/GE/PT/YY/Sr No..).

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REPAIR PROCEDURE Effective Date- 1-11-2016
11.1 REPAIR PROCEDURE

This part of the document refers to the repair procedure to be followed when a non
conformance is observed. Below is the table defining the repair procedure for
various production activities.
PROCESS NATURE OF NCS REFERENCES ACTION PLAN
Raw material Material defect, Material standards NCS to be recorded. If the problem is
inspection laminations, rust, mill based on drgs repeatedly arising. Vendor needs to be
scales etc audited and instructed regarding
requirements.
CNC cutting Wrong cutting/taper Approved CNC Operator to be provided with correct CNC drgs
cutting drgs to cut the materials. Machine settings to be
altered to suit the requirements.
Assembly of In correct components, Customer drgs, Use check list to identify the sub parts. Record
Components wrong fit ups, specs the NCs. Display the NCs which are critical.
dimensional errors. Use suitable template, jigs and fixtures. Fitters
to be trained if NCs are repeatedly arising.
Welding Weld Defects Customer drgs, Refer WPS for repair. Procedure for repairing
WPS, specs of weld. RLL/WELD REPAIR/001/00

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SAFETY INSTRUCTIONS Effective Date- 1-11-2016
Following are the safety instructions to be followed during welding process.
SAFETY GEARS:
WELDING HEAD GEAR WITH RESPIRATORY MASK, EAR PLUG AND PHOTOSENSITIVE GLASS
LEATHER HAND GLOVES
LEATHER HAND SLEEVES
LEATHER BODY APRON
SAFETY SHOES

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ANNEXURES Effective Date- 1-11-2016
ANNEXURE R1
QUALITY REQUIREMENTS
LIST OF APPLICABLE STANDARDS
Sr No Standard Name Description Edition
01 EN 15085-1 Railway applications Welding of railway 29 June 2013
vehicles and components ( Part 1: General)
vehicles and components
(Part 2: Quality requirements and certification of

welding manufacturer)
(Part 3: Design requirements)
(Part 4: Production requirements)
(Part 5: Inspection, testing and documentation)
06 ISO 3834-1 Quality requirements for fusion welding of metallic December 2005
material
Part 1: Criteria for the selection of the appropriate

level of quality requirements
07 EN ISO 9606-1 Qualification of welders-fusion welding- part : steels 2013

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material
Part 2: comprehensive quality requirements
material
Part 3: Standard quality requirements
material
Part 4: Elementary quality requirements
material
Part 5: Document with which it is necessary to

conform to claim conformity to the quality
requirements of ISO 3834-2,3 OR 4.
12 ISO 5817 Welding- Fusion welded joints in steel,nickel,titanium Second Edition

and their alloys(Beam welding excluded)-Quality
levels for imperfections. 01-10-2003
13 EN 15614-1 Specification and Qualification of welding Procedures June 2004

for metallic Material welding Procedure test.
14 EN 1011-1 Welding Recommendations for welding of metallic February 1998

materials
Part 1: General guidance for arc welding
15 EN 1011-2 Welding Recommendations for welding of metallic December 2003

materials. Part 2: Arc welding of ferritic steels

materials
Part 3: Arc welding of Stainless Steel

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materials
Part 4: Arc welding of Aluminium and aluminium alloy
18 EN 1011-7 Welding Recommendations for welding of metallic July 2004

materials
Part 7: Electron beam welding
19 EN 1011-8 Welding Recommendations for welding of metallic November 2004

materials
Part 8: Welding of Cast Iron
20 EN 12062 Non-destructive testing of welds September 2002
21 EN 13479 Welding consumables-General product standard for December 2004

filter metals and flux for fusion welding for metallic
material
22 EN 13920 General tolerance for weld construction November 1996
23 EN 14532 Welding consumables Test methods and November 2004

quality requirements
24 EN 14731 Welding coordination Tasks and responsibilities October 2006
25 EN 29962 Metal arc welding with covered electrode, gas- February 1994
shielded metal arc welding and gas welding
26 EN 10025-1 Hot rolled products of structural steels November 2004
Part 1: General technical delivery conditions

27 EN 9013 Thermal cutting Classification of thermal September 2002
cuts Geometrical product specification
and quality tolerances
28 EN ISO 9001:2008 Quality Management system

RWC UNIT HEAD
DOC NO: RLL/WM/27
PAGE NO: 1 of 1
ANNEXURE R 2
List of WPQR & WPS as per attached list
RISHI LASER LIMITED

Plot No. 580, GIDC MANJUSAR, TAL.SAVLI,vadodara - 391775
LIST OF WELDING PROCEDURE
SR TEST THK RANGE OF
PROCE JOINT MATERIAL GROUP (ISO POSI
N WPS NO PQR NO PIECE RANGE QUALIFICATI
SS TYPE 15608) TION
O. THK. QUALI ON(GROUP)
1 WPS/RISHI/SV/2017/01 PQR/RISHI/SV/2017/01 141 BUTT 5MM 3 TO 10 Group 8.1 to Group 8.1 8c-8 PA
2.5MM
2 WPS/RISHI/SV/2017/015 PQR/RISHI/SV/2017/02 141 FILLET 5MM S.S TO 6 MM Group 8.1 to Group 8.1 8c-8 PA
3MM TO
3 WPS/RISHI/SV/2017/010 PQR/RISHI/SV/2017/03 131 BUTT 5MM S.S 10 MM Group 8.1 to Group 8.1 8c-8 PA
2.5MM
1.4MM
TO
5 WPS/RISHI/SV/2017/012 PQR/RISHI/SV/2017/05 141 BUTT 2MM S.S 2.6MM Group 8.1 to Group 8.1 8c-8 PA
1.4MM
1.4MM
TO
7 WPS/RISHI/SV/2017/05 PQR/RISHI/SV/2017/07 131 BUTT 2MM S.S 2.6MM Group 8.1 to Group 8.1 8c-8 PA
1.4MM
8 WPS/RISHI/SV/2017/2O PQR/RISHI/SV/2017/08 131 FILLET 2MM S.S TO 4 MM Group 8.1 to Group 8.1 8c-8 PA
1.4MM
TO
9 WPS/RISHI/SV/2017/08 PQR/RISHI/SV/2017/09 135 BUTT 2MM MS 2.6MM Group 1.1 to Group 1.1 1a-1 PA
3MM TO
10 WPS/RISHI/SV/2017/09 PQR/RISHI/SV/2017/10 135 BUTT 6MM MS 12 MM Group 1.1 to Group 1.1 1a-1 PA
1.4MM to
11 WPS/RISHI/SV/2017/29 PQR/RISHI/SV/2017/11 135 FILLET 2MM MS 4MM Group 1.1 to Group 1.1 1a-1 PA
10 MM 5MM TO
12 WPS/RISHI/SV/2017/31 PQR/RISHI/SV/2017/12 135 FILLET MS 20 MM Group 1.1 to Group 1.1 1a-1 PA
(a)Covers the equal or lower specified yield strength steels of the same group
(c)Covers steels in the same sub-group

RWC UNIT HEAD
DOC NO: RLL/WM/28
PAGE NO: 1 of 1
ANNEXURE - R3
SLN POWER DETAILS BACK UP POWER

(GENERATORS)
250 KVA DG- 250 KVA
ANNEXURE - R3 A
SLN WELDING MACHINES NOS
1 Set up 16 nos
ANNEXURE R4
Sr no Contract review involvement
1 M.K PANDYA- Unit Head
2 Marketing
3 QA
4 Welding Coordinator
5 Production

RWC UNIT HEAD
DOC NO: RLL/WM/29
PAGE NO: 1 of 1
ANNEXURES Effective Date-1-12-2016
ANNEXURE-R4
ORGANISATION CHART

RWC UNIT HEAD
SLN DESIGNATION NAME
1 GM
2 COMM. & MKTG.
3 M.R.
4 PURCHASE
5 New Product Development
6 PURCHASE ASST
7 STORES
8 H.R Head
9 H.R ASST
10 Design Head
11 PRODUCTION MANAGER
12 Q.A /NDT Head
13 QA ------
14 MAINTENANCE
15 WELDING CO-ORDINATOR
16 DEPUTY W.C
17 Welding Supervisor
18 Welding Supervisor

RWC UNIT HEAD
DOC NO: RLL/WM/30
PAGE NO: 1 OF 1
ANNEXURES Effective Date-1-12-2016
ANNEXURE R5 (Approved Vendors List)
Refer Format no

RWC UNIT HEAD
DOC NO: RLL/WM/31
PAGE NO: 1 of 1
ANNEXURE R6
Details of NDT Personnels

NDT ACTIVITY SUB- CONTRACTED
NDT (PT,MPI,UT& RT)
MET HEAT ENGINEERS PVT LTD-BARODA

RWC UNIT HEAD
DOC NO: RLL/WM/32
PAGE NO: 1 of 1
ANNEXURE R7 (List of Welding Coordinators)
Sr. No. Name of the WC Certified by Remarks

1 HEMANT PATHAK IIW RWC
2 PUSPENDRASINH CHAUHAN DME Dy. WC
List of Welding supervisor
Sr. No. Name of the WC Work Remarks

experience
1
2
3
ANNEXURE R8 (List of Machineries)
List of Machines Documents No...

RWC UNIT HEAD
DOC NO: RLL/WM/33
PAGE NO: 1 of 1
ANNEXURE R9
SL DESCRIPTION DOCUMENT REFERENCE

NO
1 Quality Assurance Plan
2 Incoming Inspection
3 Contract Review & Technical feasibility Report
4 Work Instruction for Bending
5 Work instruction for Laser cutting
6 Work instruction for CNC Gas Cutting
7 Work instruction for cold straightening
8 Work Instruction for best welding practices
9 Work Instruction for Visual inspection
10 Work Instruction for Penetrate testing
11 Work Instruction for raw material traceability
12 Work Instruction for Edge preparation
13 Work instruction for consumable handling
14 Procedure for ------sonic testing
15 Procedure for Penetrant Testing
16 Procedure for Magnetic Particle Testing

RWC UNIT HEAD
DOC NO: RLL/WM/34
PAGE NO: 1 of 1
Manufacturing Tolerance - As per customer specification & Drg
Laser cutting & bending DI:PROCESS:PDN:01

RWC UNIT HEAD
DOC NO: RLL/WM/35
PAGE NO: 1 of
Quality records, (Clause -18, As per ISO 3834-2)
Quality records retention for a minimum period of five years for ISO 3834-3& EN 15085-2
Documents & as per customer requirements.

RWC UNIT HEAD

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DOC NO: RLL/WM/01

WELDING MANUAL Issue No.-00

PREPARED BY: RASIK TANK APPROVED BY : M.K.PANDYA

WM-1/3 AMENDMENT RECORDS 1 00

WM-1/4 DISTRIBUTION LIST 1 00

WM-1/5 INTRODUCTION & SCOPE 2 00

WM-1/6 CONTRACT REVIEW 2 00

WM-1/7 SUB CONTRACTING 1 00

WM-1/8 WELDING COORDINATION 5 00

WM-1/11 WELDING AND RELATED ACTIVITIES 2 00

WM-1/12 STORAGE OF PARENT MATERIALS 1 00

WM-1/13 STORAGE & HANDLING OF 1 00

WM-1/15 REPAIR PROCEDURE 1 00

WM-1/16 SAFETY INSTRUCTIONS 1 00

WM-1/17 ANNEXURES LIST 9 00

WM- /18 MANUFACTURING TOLERANCES 1 00

PREPARED BY: RASIK TANK APPROVED BY : M.K.PANDYA

DOC NO. TITLE NO. OF PAGES ISSUE NO.

WM- /20 PAINTING QUALIFICATION 1 00

WM- /21 THERMAL CUTTING 1 00

WM/22 QUALITY RECORDS RETAINTION 1 00

PREPARED BY: RASIK TANK APPROVED BY : M.K.PANDYA

ISSUE REV PAGE NO. DOC NO. REMARKS

PREPARED BY: RASIK TANK APPROVED BY : M.K.PANDYA

COPY NO COPY HELD BY

PREPARED BY: RASIK TANK APPROVED BY : M.K.PANDYA

Sr. No. Type of Component Material Grade Mtl. Thk. Range

1 Railway Components S355J2, A588 Gr B 3 70 mm

2 Other fabrication component. IS 2062,ASME A36,ASTM 3-50mm

1.13 NORMATIVE REFERENCES:

PREPARED BY: RASIK TANK APPROVED BY : M.K.PANDYA

1.14 GENERAL REQUIREMENTS:

PREPARED BY: RASIK TANK APPROVED BY : M.K.PANDYA

1.16 STAFF REQUIREMENTS:

1.17 TECHNICAL REQUIREMENTS:

Storage area for consumables.

Suitable power requirements (refer Annexure R 3)

Work platforms (machined bed plates) for details (refer Annexure R 3 A)

PREPARED BY: RASIK TANK APPROVED BY : M.K.PANDYA

Aspects to be considered shall include the following:

The product standard to be used. Together with any supplementary requirements.

Statutory and regulatory requirements.

Any additional requirements identified by customer

The capability of RLL to meet the prescribed requirements.

Technical requirements considered shall include the following:

Parent material specification and its weldability.

Welding consumables and its specification.

Quality and acceptance requirements for welds.

PREPARED BY: RASIK TANK APPROVED BY : M.K.PANDYA

PREPARED BY: RASIK TANK APPROVED BY : M.K.PANDYA

All contract / technical review documents shall be maintained in formats doc. no

Sr No Aspects to be reviewed Remarks

a) Parent material specification and welded joint properties;

PREPARED BY: RASIK TANK APPROVED BY : M.K.PANDYA

d) The specification of welding procedures, non-destructive testing procedures and

g) Selection, identification and/or traceability(eg. For material,welds);

PREPARED BY: RASIK TANK APPROVED BY : M.K.PANDYA

3.1 SUB CONTRACTING:

NDT Method (RT,PT & DT)

MET HEAT ENGINEERS PVT LTD-BARODA

TCR ADVANCED ENGINEERING PVT LTD-BARODA

PREPARED BY: RASIK TANK APPROVED BY : M.K.PANDYA

4.1 WELDING COORDINATION PERSONNEL

Welding coordinator with comprehensive, Specific & Basic technical knowledge