Transcript
QUALITY MANUAL FOR FUSION WELDING OF METALLIC MATERIAL QM-02 ISO 3834 – 2 : 2006 (E) Section – 0.1
Revision - 00
TITLE -COVER SHEET
Effective Date 01.06.2016
Page no.-1
Quality Manual Fusion Welding of Metallic Material Conformance Standard : ISO 3834-2:2006 (E) (QM-2) Comprehensive quality requirements ISO 9001-2008 (QM-1)
DOCUMENT NO. - QM: 02
Mr. Avinash Silimkar PREPARED BY
Mr. Vikas Dighe REVIEWED BY Page No. 1 of 34
Mr. Rahul Chaukhande APPROVED BY
QUALITY MANUAL FOR FUSION WELDING OF METALLIC MATERIAL QM-02 ISO 3834 – 2 : 2006 (E) Section – 0.2
Sr. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
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TITLE
TITLE –TABLE OF CONTENT
Effective Date 01.06.2016
COVER SHEET TABLE OF CONTENTS DISTRIBUTION OF MANUAL AMENDMENT HISTORY ABBREVIATION INTRODUCTION OF ORGANISATION & EXCLUSIONS CLAIMED INTRODUCTION OF ISO 3834-2 SCOPE NORMATIVE REFERENCE TERMS & DEFINITION GENERAL OUT LINE OF ISO 3834 REVIEW OF REQUIREMENT AND TECHNICAL REVIEW SUB-CONTRACTING WELDING & RELATED ACTIVITIES INSPECTION AND TESTING PERSONNEL EQUIPMENT WELDING CONSUMABLE STORAGE AND PERENT MATERIAL POST WELD HEAT TREATMENT INSPECTION AND TESTING NON-CONFIRMANCE& CORRECTIVE ACTION CALIBRATION AND VALIDATION OF MEASURING INSTRUMENTS IDENTIFICATION AND TRECEBILITY CONTROL OF DOCUMENTS & QUALITY RECORD
Section no. 0.1 0.2 0.3 0.4 0.5 0.6 0.7 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
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For Reference and application for ISO 3834-2
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Total Pages 1 1 1 1 1 3 1 2 1 1 1 1 2 4 1 2 1 2 1 2 1 1 1 1
Follow the ISO 9001-2008 Established Quality Manual / Work Instruction / Mandatory Procedure. Documentation requirement / control of document / Record / Formats / Infrastructure List / Mandatory procedure / work Instruction / statuary requirement / regularly requirement
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QUALITY MANUAL FOR FUSION WELDING OF METALLIC MATERIAL QM-02 ISO 3834 – 2 : 2006 (E) Section – 0.3
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TITLE –DISTRIBUTION OF QUALITY MANUAL 3834-2
DISTRIBUTION OF QUALITY MANUAL – ISO 3834-2 SR.NO. 1 2 3 4 5 6
Effective Date 01.06.2016
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TYPE OF COPY
DISTRIBUTE TO
DISTRIBUTE COPY
CONTROLLED COPY
WELDING CO-ORDINATOR
1 NO.
MASTER COPY
CONTROLLED COPY CONTROLLED COPY CONTROLLED COPY CONTROLLED COPY
Mr. Avinash Silimkar PREPARED BY
QC MANAGER.
MANAGER (PLANNING)
MANAGER (PRODUCTION) GENERAL MANAGER DIRECTOR
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1 NO. 1 NO. 1 NO. 1 NO. 1 NO
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QUALITY MANUAL FOR FUSION WELDING OF METALLIC MATERIAL QM-02 ISO 3834 – 2 : 2006 (E) Section – 0.4
Sr. No 1
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Section No.
TITLE –AMENDMENT HISTORY
Effective Date 01.06.2016
AMENDMENT HISTORY SHEET
Page No.
Existing Detail
2
Revised to
Effective Amendment Date
3 4 5 6 7 8 9
10 11 12
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Approved By
QUALITY MANUAL FOR FUSION WELDING OF METALLIC MATERIAL QM-02 ISO 3834 – 2 : 2006 (E) Section – 0.5
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0.5 ABBREVIATION SR.NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 32 33 34 35 36 37 38 39 40 41
ABBREVIATION
AI AWS ASME ASTM AC AMP DC FCAW GM GTAW GMAW ISO ITP DEPL LPT MRM MR MPT NDT PCN PROD PLG. PE PPM PQR QMS QAP QCE QCM RT SMAW SK SM TIG UT VOLT WPQR WPS IWE/IWT/IWS/WE WQT EN MDR
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TITLE – ABBREVIATION
Effective Date 01.06.2016
FULL FORM
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AUTHORISED INSPECTOR AMERICAN WELDING SOCIETY AMERICAN SOCIETY OF MECHANICAL ENGINEERS AMERICAN SOCIETY OF TESTING MATERIAL ALTERNATE CURRENT AMPEREAGE DIRECT CURRENT FLUX CORE ARC WELDING GENERAL MANAGER GAS TUNGSTEN ARC WELDING GAS METAL ARC WELDING INTERNATIONAL ORGANIZATION FOR STANDARDIZATION INSPECTION AND TEST PLAN DYNAXCEL ENGINEERS PVT. LTD. LIQUID PENETRENT TEST MANAGEMENT REVIEW MEETING MANAGEMENT REPRESENTATIVE MAGNETIC PARTICAL TEST NON DISTRICTIVE TESTING PERSONNEL CERTIFICATION IN NON-DESTRUCTIVE TESTING PRODUCTION PLANNING PRODUCTION ENGINEER PRODUCTION PLANNING MANAGER PROCEDURE QUALIFICATION RECORD QUALITY MANAGEMENT SYSTEM QUALITY ASSURANCE PLAN QUALITY CONTROL ENGINEER QUALITY CONTROL MANAGER RADIOGRAPHY TEST SHIELDED METAL ARC WELDING STORE KEEPER STORE MANAGER TUNGSTEN INERT GAS WELDING ULTRASONIC TEST VOLTAGE WELDER PROCEDURE QUALIFICATION RECORD WELDING PROCEDURE SPECIFICATION INTERNATIONAL WELDING ENGINEER/TECHNOLOGIST/ SPECIALIST/ ENGR WELDER QUALIFICATION RECORD EUROPIAN STANDARD MANUFACTURING DOSSIER RECORD Mr. Vikas Dighe REVIEWED BY Page No. 5 of 34
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QUALITY MANUAL FOR FUSION WELDING OF METALLIC MATERIAL QM-02 ISO 3834 – 2 : 2006 (E) Section – 0.6
0.6
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TITLE –INTORDUCTION OF ORGANISATION
INTRODUCTION OF ORGANISATION
Effective Date 01.06.2016
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Dynaxcel Engineers Pvt. Limited are ISO 9001:2008, ISO14001:2004, OHSAS 18001:1999 certified manufacturers of engineering equipment in various materials like Stainless Steel, Carbon steel, Nickel & its alloys, Copper, Titanium & its alloys etc. We have proficiency in manufacture & supply of fabricated metal equipment’s and engineering job works.
Heat exchangers, Pressure Vessels, Reactors Distillation columns, Condensers Bleaching towers, tubes, pulpers, de-aerators, UTM’s, SILO’s, Screen Vessels, and Drum washers, Disc Filters, Approach flow piping for paper industry. Textile dyeing machines, jiggers, dryers. Acoustic enclosures, silencers / baffles for power generation equipment. Fabrication of Heavy equipment’s up to 35 tons for power generation eqpt manufacturers.
We have the experience of doing jobs under the third party inspection agencies viz. Bureau Veritas, TUV India, ABS, Tata Projects Ltd., Lloyds Register etc.
DEPL maintains strict manufacturing & documents control of equipment’s. DEPL also specializes in executing projects at site along with mechanical design, fabrication & erection of equipment’s at site. We undertake projects consisting of stainless steel fabrication at our factory, delivered at site, part/full fabrication at site and erection & commissioning. We have a team of 80 skilled, semiskilled workers & experienced supervisors for execution of this activity.
In addition to this, we are working with OEM’s in Paper Machinery Suppliers for manufacture of paper pulp equipment in India. We also supply fabricated assemblies with critical machining to global market. We have exported process equipment like sludge mixers, agitators for flotation cell in effluent treatment plants, Pressure screen Housings , Bearing Columns, Refiners Housings to American & European OEM’s. DEPL is more concern for manufacturing Equipment related to Mining, Power sector, Paper Industry, Food Industry, filtration unit, process and chemical plants, structural work etc.
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QUALITY MANUAL FOR FUSION WELDING OF METALLIC MATERIAL QM-02 ISO 3834 – 2 : 2006 (E)
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QUALITY MANUAL FOR FUSION WELDING OF METALLIC MATERIAL QM-02 ISO 3834 – 2 : 2006 (E) ORGANIZATION CHART FOR QC DEPARTMENT MANAGING DIRECTOR
MANAGER (Q.A./ Q.C.)
WELDING ENGINEER+ WELDING COORDINATOR
Sr. Q. C. ENGINEER +DEPUTY WELDING CO-ORDINATOR
Q.C. ENGINEER +DEPUTY WELDING CO-ORDINATOR
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WELDING INSPECTOR +DEPUTY WELDING CO-ORDINATOR
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QUALITY MANUAL FOR FUSION WELDING OF METALLIC MATERIAL QM-02 ISO 3834 – 2 : 2006 (E) Section – 0.7
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TITLE – INTRODUCTION OF ISO 3834-2
0.7 INTRODUCTION OF ISO 3834-2
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Dynaxcel Engineers Pvt. limited has implemented ISO 3834-2 welding Quality management System for fusion welding which are widely used to Steel Structures as per the standard of EN ISO standards/ PED /ASME / API-2H / AWS D1.1. This will be particularly applicable for Structural Steel components designed as per Eurocode – 3 (EN1993), IS-800 & BS 5950 the standard ISO 3834-2 is applying only welding containing part. Products may range from simple to complex. These welding management processes exert a profound influence on the cost of manufacture and quality of the product. It is important, therefore, to ensure that these welding management processes are carried out in the most effective way and that appropriate control is exercised over all aspects of the operation. ISO 3834-2 is use full tool for welding & allied processes in ISO 9001-2008 QMS. Fusion Welding process is considered as special processes in ISO 9001:2008.
Dynaxcel Engineers Pvt. Ltd. will follow the client’s specification / Approved drawings / weld map and other special instruction for control the welding process. If nothing is specified in drawings, then Dynaxcel will work as per applicable minimum levels of applicable EN ISO standards. Refer standard welding quality plan no (QC/15 rev 01 Dt. 01/01/2015) Dynaxcel Engineers Pvt. Ltd. will follow the self-design of equipment drawing / weld map etc. to control the welding process. EXCLUSIONS CLAIMED No exclusions to EN ISO 3834-2 & ISO 9001: 2008 are claimed by the Organization. Similarly, for ISO 3834-2, Dynaxcel has included all processes in control of the organization for implementation.
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QUALITY MANUAL FOR FUSION WELDING OF METALLIC MATERIAL QM-02 ISO 3834 – 2 : 2006 (E) Section – 1
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1 SCOPE OF ISO 3834-2
TITLE – SCOPE OF ISO 3834-2
Effective Date 01.06.2016
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Clause No : 01
This part of ISO 3834 defines comprehensive quality requirements for fusion welding of metallic materials in workshops.
This part of ISO 3834 specifies the documents with which it is necessary to conform to claim conformity to the quality requirements of ISO 3834-2, ISO 3834-3 or ISO 3834-4. It can only be used in conjunction with ISO 3834-2, ISO 3834-3 or ISO 3834-4.
This part of ISO 3834 does not specify requirements for a total quality management system. However, Clause 6 identifies quality management system elements where their inclusion will complement ISO 3834. Scope
Equipment Covered
Welding and manufacturing & supply of fabricated metal equipment and engineering job works
• Heat exchangers, • Pressure Vessels, Reactors • Distillation columns, Condensers • Bleaching towers, tubes, pulpers, de-aerators, UTM’s, Silo’s, Screen Vessels, and Drum washers, Disc Filters, Approach flow piping for paper industry. • Textile dyeing machines, jiggers, dryers. • Acoustic enclosures, silencers / baffles for power generation equipment. • Fabrication of Heavy equipment’s up to 35 tons for power generation eqpt manufacturers. • Customer orientated equipment for list of Industry given in right side column.
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Industry Covered
Material
Railway, Mining, Power sector, Paper Industry, Food Industry, filtration unit, process and chemical plants, structural work etc.
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Ferrous e.g. Carbon Steel, Mild Steel and more as per approved WPS
Thickness Range 1.5 mm to 112 mm
Non Ferrous 1.15 mm e.g. Stainless to 100 mm Steel, Nickel & its alloys more as per approved WPS
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QUALITY MANUAL FOR FUSION WELDING OF METALLIC MATERIAL QM-02 ISO 3834 – 2 : 2006 (E) Clause 6 - Elements to be considered for a quality management system to complement ISO 3834 ISO 3834 contains many attributes that contribute to a quality management system (QMS). This clause Identifies those QMS elements that the DEPL has consider implementing to support the ISO 3834 quality requirements A) Control of documents and records (see ISO 9001:2008, 4.2.3, 4.2.4); B) Management responsibilities (see ISO 9001:2008, Clause 5); C) Provision of resources (see ISO 9001:2008, 6.1);
D) Competence, awareness and training of operational personnel [see ISO 9001:2008, 6.2.2, 7.5.2 b)]; E) Planning of product realization (see ISO 9001:2008, 7.1);
F) Determination of requirements related to the product (see ISO 9001:2008, 7.2.1); G) Review of requirements related to the product (see ISO 9001:2008, 7.2.2); H) Purchasing (see ISO 9001:2008, 7.4);
I) Validation of processes (see ISO 9001:2008, 7.5.2); J) Customer property (see ISO 9001:2008, 7.5.4); K) Internal audit (see ISO 9001:2008, 8.2.2);
L) Monitoring and measurement of product (see ISO 9001:2008, 8.2.4).
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QUALITY MANUAL FOR FUSION WELDING OF METALLIC MATERIAL QM-02 ISO 3834 – 2 : 2006 (E) Section – 2
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TITLE – NORMATIVE REFERANCE
2. NORMATIVE REFERENCE
Effective Date 01.06.2016
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Clause No : 02
The following referenced documents are indispensable for the application of this document. For dated References, only the edition cited applies. For undated references, the latest edition of the referenced Document (including any amendments) applies. ISO 9001:2008, Quality management systems — Fundamentals and vocabulary
The following referenced documents are indispensable for the application of this document. For dated References, only the edition cited applies. For undated references, the latest edition of the referenced Document (including any amendments) applies. ISO 3834-1, Quality requirements for fusion welding of metallic materials — Part 1: Criteria for the selection of the appropriate level of quality requirements
ISO 3834-5:2005, Quality requirements for fusion welding of metallic materials — Part 5: Documents with which it is necessary to conform to claim conformity to the quality requirements of ISO 3834-2, ISO 3834-3 or ISO 3834-4 ASME - AWS – AMERICAN WELDING SOCIETY ISO 9606-1, Qualification test of welders — Fusion welding — Part 1: Steels ISO 9712, Non-destructive testing — Qualification and certification of personnel ISO 14731, Welding coordination — Tasks and responsibilities ISO 14732, Welding personnel - Approval testing of welding operators for fusion welding and of resistance Weld setters for fully mechanized and automatic welding of metallic materials ISO 15607, Specification and qualification of welding procedures for metallic materials — General rules ISO 15609-1, Specification and qualification of welding procedures for metallic materials — welding Procedure specification — Part 1: Arc welding ISO 15610, Specification and qualification of welding procedures for metallic materials — Qualification based on tested welding consumables ISO 15611, Specification and qualification of welding procedures for metallic materials — Qualification based on previous welding experience ISO 15612, Specification and qualification of welding procedures for metallic materials — Qualification by Adoption of a standard welding procedure ISO 15613, Specification and qualification of welding procedures for metallic materials — Qualification based on pre-production welding test ISO 15614-1, Specification and qualification of welding procedures for metallic materials — welding Procedure test — Part 1: Arc and gas welding of steels and arc welding of nickel and nickel alloys ISO 17635, Non-destructive testing of welds — General rules for fusion welds in metallic materials ISO 17637, Non-destructive testing of welds — Visual testing of fusion-welded joints ISO 17638, Non-destructive testing of welds — Magnetic particle testing ISO 17639, Destructive tests on welds in metallic materials — Macroscopic and microscopic examination of Welds Quality manual # (DEPL/QM Rev-01 DT. 01/01/2009) OHS Manual # (DEPL/EHS Rev.00 DT. 01/01/2015) ENV Manual # (DEPL/EHS Rev.00 DT. 01/01/2015)
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QUALITY MANUAL FOR FUSION WELDING OF METALLIC MATERIAL QM-02 ISO 3834 – 2 : 2006 (E) Section – 3
3
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TITLE – TERMS AND DEFINITIONS
Terms and definitions
Effective Date 01.06.2016
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Clause No : 03
For the purposes of this document, the terms and definitions given in ISO 9000:2000 and the following apply.
3.1 Company/DEPL
DYNAXCEL ENGINEERS PVT LIMITED
3.2 Design specification
Requirements for products specified by customers or by the organization in anticipation of customer requirements, or by regulation NOTE:-the requirements for products and in some cases associated processes can be contained in, for example, technical specifications, product standards, process standards, contractual agreements and regulatory requirements.
3.3 Qualified person
Person whose competence and knowledge have been obtained by education, training and/or relevant practical experience NOTE:-In order to demonstrate the level of competence and knowledge, a qualification test may be required.
3.4 Construction
Product, structure or any other welded item.
3.5 Manufacturer/fabricator
Person or organization responsible for the welding production.
3.6 Sub-contractor
Supplier of products, services and/or activities to the DEPL in a contractual situation
3.7 welding operator
Person who performs fully mechanised or automatic fusion welding processes
3.8 Document
This is information and its supporting medium.
3.9 Non Conformity
Non-fulfilment of a requirement
3.10 Procedure
Specified way to carry out an activity or a process.
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QUALITY MANUAL FOR FUSION WELDING OF METALLIC MATERIAL QM-02 ISO 3834 – 2 : 2006 (E) Section – 4
Revision – 00
TITLE – GENERAL OUT LINE OF ISO 3834
4 GENERAL OUTLINE OF ISO 3834
Effective Date 01.06.2016
Clause No : 04
The requirements contained within ISO 3834-2 are adopted in full.
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QUALITY MANUAL FOR FUSION WELDING OF METALLIC MATERIAL QM-02 ISO 3834 – 2 : 2006 (E) Section – 5
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TITLE – REVIEW OF REQUIREMENTS & TECHNICAL REVIEW
5 Review of requirements and technical review 5.1 General
Effective Date 01.06.2016
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Clause No:-05
Dynaxcel Engineers Pvt. Ltd. (DEPL) review the contractual requirements and any other requirements, together with any technical data provided by the purchaser or in-house data when the construction is designed by the DEPL. Dynaxcel Engineers Pvt. Ltd. shall establish that all information necessary to carry out the manufacturing operations is complete and available prior to the commencement of the work. DEPL affirm capability to meet all requirements and shall ensure adequate planning of all quality-related activities. The review of requirements is carried out by the DEPL to verify that the work content is within its capability to perform, that sufficient resources are available to achieve delivery schedules and that documentation is clear and unambiguous. The DEPL shall ensure that any variations between the contract and any previous quotation are identified and the purchaser notified of any programme, cost or engineering changes that may result. Items in 5.2 are typically considered at or before the time of the review of requirements review. Items in 5.3 usually form part of the technical review and are considered during the initial planning stage. When a contract does not exist, e.g. items made for stock; DEPL is required to take into consideration the requirements of 5.2 while carrying out the technical review (see 5.3). The Responsible Planning Engineer shall review the contract requirements as per Document No:-PLAN/03 Rev.00 dt.01/06/2016.
5.2 Review of requirements
Aspects to be considered shall include the following: a) The product standard to be used, together with any supplementary requirements; b) Statutory and regulatory requirements; c) Any additional requirement determined by the DEPL; d)The capability of the DEPL to meet the prescribed requirements.
5.3 Technical review
Technical requirements to be considered shall include the following: a)Parent material(s) 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; d)The specification of welding procedures, non-destructive testing procedures and heat-treatment procedures; e)The approach to be used for the qualification of welding procedures; f) The qualification of personnel; g)Selection, identification and/or traceability (e.g. for materials, welds); h) quality-control arrangements, including any involvement of an independent inspection body; i)Inspection and testing; j)Sub-contracting; l)Other welding requirements, e.g. batch testing of consumables, ferrite content of weld metal, ageing, Hydrogen content, permanent backing, use of penning, 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 elsewh0ere; p)Environmental conditions relevant to the application of the process (e.g. very low-temperature ambient Conditions or any necessity to provide protection against adverse weather conditions); q)Handling of non-conformances. The Technical Review of Requirements shall be carried out by Designated Planning Engineer as perPLAN/02 Rev.00 dt.01/06/2016. Mr. Avinash Silimkar PREPARED BY
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QUALITY MANUAL FOR FUSION WELDING OF METALLIC MATERIAL QM-02 ISO 3834 – 2 : 2006 (E) Section – 6
Revision - 00
6. Sub-Contracting
TITLE – SUB CONTRACTING
Effective Date 01.06.2016
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Clause No :6
As a policy decision, Dynaxcel Engineers Pvt. Ltd. has decided not to outsource welding activities related to fabricated Structures and components. However following activities shall be hired for meeting the product requirement
1. Calibration of the measuring instruments
1.1 Scope –This Section describes all scope of work is in QMS Section No.: QM7.6 Rev 00 dt. 01/01/2009 (Doc No: Pur/02 Rev 01 Dt. 01/01/2013)
2 Non Destructive testing Material
2.1 Scope – This section describes requirements for NDE during Fabrication of Steel Structures. All NDE shall be performed in accordance with applicable NDE procedures duly reviewed & approved by qualified personnel with level III in accordance to ISO 9712/ ASNT. Evaluation of applicable NDE shall be done by qualified personnel with level II or III in accordance to ISO 9712/ ASNT. 2.2 Qualification of NDE Personnel – NDE Level III shall be appointed by Dynaxcel Engineers Pvt. Ltd.depending on the project specific requirements by Sub-contracting. Accordingly PCN / ASNT Level III personnel shall be appointed. The appointment of NDE Level III is based on his Education, Training and Qualification, Experience and ASNT / PCN Level III certification. NDE Level III shall be responsible for:
Training of NDE Level I/II personnel. Examination and Qualification of NDE Personnel. Certification of NDE Personnel is done by NDE level III and QCM. Maintaining Qualification and Certification records of NDE Personnel. Preparation and Approval of NDE Procedures. Guidance in Calibration of NDE equipment at shop and field sites. To assist in review and analysis of NDE documents with respect to applicable Code Edition.
2.3 NDE Procedures – All NDE shall be performed according to following procedures approved by ISO 9712/EN473/ASNT Level III. a. Liquid Penetrant Examination : DEPL/NDE/PT/01 b. Radiographic Examination : DEPL/NDE/RT/01 c. Ultrasonic Examination : DEPL/NDE/EN/UT/01 d. Magnetic particle testing : DEPL/NDE/EN/MPT/01 All NDE reports shall be reviewed and evaluated for acceptance by EN 473/ISO 9712 or Level II.
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QUALITY MANUAL FOR FUSION WELDING OF METALLIC MATERIAL QM-02 ISO 3834 – 2 : 2006 (E) Note NDE: At present RT method are not used at DYNAXCEL ENGG. PVT. LTD. However, when RT method is required to be used, the procedure for RT shall be developed and approved by EN ISO 9712/EN473/PCN Level III / Level II or ASNT’s SNT-TC-1A/ ISNT Level III / Level II prior to their use on job. Also the NDE personnel shall be trained, qualified and certified for these methods.
2.4 Performance of NDE –EN ISO 9712/EN473/PCN Level III / Level II or ASNT’s SNT-TC-1A/ ISNTLevel III / Level II shall review all applicable job documents and identify the required NDE procedures & Techniques. The NDE Level III/Level II shall select the applicable NDE procedures from the existing approved procedures provided they comply with the job requirements and the Code. On completion of the welding, Production Engineer shall offer the weld joint to QCE for visual examination. Extent of NDE shall be as per “Controlled Copy” drawing(s) and approved Weld Map. Based on ITP after ensuring that the previous examination stages are cleared and visually examining the weld joint, QCE shall fill the “Request for MPT” (Doc no:- QC/37 Rev.-00, Dt. 01/01/2016), “Request of UT” (Doc no:QC/37 Rev.-00, Dt. 01/01/2016“Request for PT” (Doc No:- QC/37 Rev.-00, Dt. 01/01/2016) and hand over to NDE Level II. 2.5 Subcontracting – NDE may be subcontracted to an organization whose written practice & personnel qualification comply with ISO 9712. All Subcontractors’ NDE personnel documentation shall be reviewed and approved by Dynaxcel ENGG. PVT. LTD’s QCM. All NDE Records shall be maintained by QCE / QCM. 2.6 Re-Qualification – The NDE Level III may ask for re-qualification of NDE procedures & NDE personnel at any time and for any changes to essential variables in NDE Procedures.
2.7 Calibration of NDE Equipment – The QCE shall monitor NDE Equipment for calibration and maintain its records.
2.8 NDE Reports – The results of NDE shall be recorded on Liquid Penetrant test report, Magnetic Particle Test report, Radiography Inspection Test Report& Ultrasonic Inspection Test Report. All NDE reports shall be filled by QCE in the job inspection File & shall be made available to the Inspector (as applicable) for Review. (Doc No: pur/02 Rev 01 Dt. 01/01/2013)
3 Destructive testing Material – Destructive Testing of material is carried out at NABL accredited Laboratory only on Raw materials & Test Pieces. (Doc No: pur/02 Rev 01 Dt. 01/01/2013)
4 Heat Treatment: Heat treatment of the material / PWHT carried out at Supplier place from approved supplier list (Doc No: - Pur/02 Rev.00 Dt. 01.10.2005) of Dynaxcel Engineer’s Pvt. Ltd as per procedure (Doc No:- DEPL/HT-01, Rev. 00 Dt. 01.06.2016) given by DEPL to the supplier. (Doc No: pur/02 Rev 01 Dt. 01/01/2013)
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QUALITY MANUAL FOR FUSION WELDING OF METALLIC MATERIAL QM-02 ISO 3834 – 2 : 2006 (E) Section – 7
Revision - 00
TITLE – WELDING PERSONNEL
7 Welding & Related Activities
Effective Date 01.06.2016
Page no.-1
7.1 General
The DEPL has at his disposal sufficient and competent personnel for the planning, performing and supervising of the welding production according to specified requirements.
All Welding Shall be performed by qualified welders, using qualified WPS in accordance with EN ISO 15609-1 and/or applicable requirements of Code of Construction (e.g. ASME/ AWS/ PED).
7.2 Welding Procedure Specifications (WPS)/pWPS
Clause No : 10.2& 10.3
The QC personnel are responsible for the preparation and qualification of pWPS. The Welding Inspector personnel shall approve WPS by signing after its successful qualification.
The QC personnel shall arrange for the qualification of each WPS, witness the welding of the test coupon and record the variables used for each qualification test in the PQR. Test coupons are welded under supervision of the internal welding inspector/ QC engineer or TPI arrange by DEPL. Preparation and testing of the test specimens are performed in accordance with EN ISO 15614-1/ applicable standards by testing laboratory. The test results report of the testing lab is reviewed by the QCE / QCM, and if test results are acceptable, he prepares and certifies the PQR by signature and date, recording actual variables used while making the weld coupon and test results of the weld coupon. Using certified PQR QCE/QCM prepares WPS. Completed WPS shall describe all the essential, nonessential, and when required supplementary essential variables for each welding process used in the WPS. The WPS shall have reference of the supporting PQR and is approved by QCE / QCM. The QCE files the PQR, All changes to nonessential variables of a WPS require a revision of the WPS which is signed, dated and controlled in the same way as the original without re-qualification.
When there is a change to an essential variables, and in-case of impact testing requirements a change in supplementary essential variables, the WPS shall be revised and re-qualified.
When defect in a weld is repaired prior to final acceptance, the repair will be considered part of the welding process as long as the same WPS is used. No NCR will be issued. A separate repair report shall be generated as per Doc. No: DEPL/REPAIR PROCEDURE/1 REV.00 Dt. 01/03/2013 & for Dish End DEPL/REPAIR PROCEDURE/2 REV.00 Dt. 01/08/2015 in-case any repair is to be carried out. The QCE is responsible to make qualified WPS available to the PPM/PE and welders in the shop.
Using “Controlled Copy” drawing(s), QCE prepares Weld Map (QC/20 Rev.0 Dt. 01/02/2013) and same is approved by QCM. The assignment of WPS to the respective weld joints shall be indicated on the Weld Map by QCE and shall be forwarded to PPM/PE for implementation.
When fabrication drawing(s) are revised, the Weld Map shall be reviewed for changes by QCE. If Weld Map is required to be revised due to revision in drawing, same shall be carried out by QCE appropriately.
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QUALITY MANUAL FOR FUSION WELDING OF METALLIC MATERIAL QM-02 ISO 3834 – 2 : 2006 (E) 7.3 Welders Qualification
Clause No : 7.2
The WE/QCM is responsible for training, qualification and certification of the welders.
All welders performing welds on Steel Structures are to be qualified according to the requirements of EN ISO 9606-1/other applicable standards & Codes & any additional requirement of the Code under the supervision of the QCE. Preparation and testing of the required specimens, or NDE test of welds, are conducted by a testing laboratory. The test report is reviewed by the QCE and if acceptable, he certifies the WPQ. The WPQ documents include the essential variables for performance qualification used for the test welds, and the ranges qualified for welding during fabrication. A WPQ is not required for welders who are performing test welds to qualify a WPS or re-qualify it.
7.4 Re-Qualification of Welders
Clause No : 7.2
Welder’s qualification shall be affected if one of the following conditions occurs:
A) If a welder has not welded with the specific process for six months or more, as identified in the Welder Continuity Log/Record (Doc no:-QC/40 Rev.0 Dt. 01/06/2016) and the Qualified Welder List (Doc No:-QC/39 Rev.0 Dt. 01/06/2016)then his qualification for that process shall expire unless: -
-
A welder has welded prior to expiration of his qualification using a manual or semiautomatic welding process which will maintain his qualification for manual and semiautomatic welding with that process for further six months.
The welding operator has welded prior to expiration of his qualification with that process using machine or automatic welding, under the supervision and control of the qualifying DEPL.
B) If there is a specific reason to question his ability to make welds that meet The Code requirements, then his qualifications which support the welding work in question shall only be re qualified. The successful test of a test coupon covering the planned fabrication, welding and testing as required by EN ISO 9606-1, renews his qualification.
C)
If anyone has reason to question a welder’s ability to make welds that meet the Code requirements, he may ask for re-qualification at any time.
D) If there is a change in variable of his qualification.
7.5 Qualified Welders List (QWL)
Clause No : 7.2
The QCE / WE is responsible for preparing and updating the Qualified Welders List (QWL) (Doc No:QC/39 Rev.0 Dt. 01/06/2016) at least every 3 Months or earlier in case of a new qualification or expiry of qualification and shall be approved by QCM. QCE / WE determines when welder’s qualification will expire. Copy of Qualified Welder List (QWL) is provided by QCE to PPM/PE and QCM.
7.6 Welders Identification
Clause No : 7.2
The QCE / WE shall assign to each qualified welder a unique identification number. If welder leaves the company, his unique identification number shall not be re-assigned. Mr. Avinash Silimkar PREPARED BY
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QUALITY MANUAL FOR FUSION WELDING OF METALLIC MATERIAL QM-02 ISO 3834 – 2 : 2006 (E) 7.7 Welding Coordination Personnel Sr Name No 1 Rahul Chaukhande
NDT & Welding Coordinator Personnel Details Designation
Quality Control Manager Welding Engineer+ Welding Coordinator
NDT Qualification ASNT Level II (PT,RT)
2
Vikas Dighe
3
Utereshwar Miskin
Sr. QC Engineer + Deputy Welding Coordinator
4
Avinash Silimkar
QC Engineer + Deputy Welding Coordinator
ASNT Level II (UT, RT, MT, PT,VT) CSWIP 3.1 Welding Inspector
5
Navid Omne
QC Engineer + Deputy Welding Coordinator
ASNT Level II (VT,UT, RT,MT)
Mr. Avinash Silimkar PREPARED BY
Clause No : 7.3
ASNT NDT Level III UT, RT, MT, PT & VT. International Welding Engineer. Certified Welding Inspector. Certified Quality Manager ASNT Level II (UT)
Mr. Vikas Dighe REVIEWED BY Page No. 20 of 34
Experience Details 10 years hand on experience in overall quality management in fabrication & team handling.
28 years’ experience in metallurgy, Quality management, assurance & Control in manufacturing Engineering industries like Automobiles, heavy engineering, renewable energy, & Professional services. Five years’ experience in production & quality of fabrication of heat exchanger, pressure vessels, boilers, storage tanks, piping & structures Five years’ experience in Constructional & Fabrication field involves Welding’s and NDT of heat exchanger, pressure vessels, boilers, storage tanks, piping & structures 4 year experience in NDT & welding of Casting, heat exchanger, pressure vessels, boilers, storage tanks, piping & structures.
Mr. Rahul Chaukhande APPROVED BY
QUALITY MANUAL FOR FUSION WELDING OF METALLIC MATERIAL QM-02 ISO 3834 – 2 : 2006 (E) 7.8 Production Planning
Clause No : 10.1
a) The QCE / WE is responsible for making qualified WPS available to the PPM/PE and welders in the shop. b) Weld Map is prepared by QCE and approved by QCM for each item. c) Weld Map shall be forwarded to PPM/PE by QCE for implementation on each item. d) The QCE shall prepare and update the QWL at least every 3 months and obtain approval from QCM. QWL shall be provided to PPM/PE and QCM by Quality Engineer. e) PPM/PE assigns qualified welders on job using QWL and Weld Map for Code work.
The Production Planning Items to be considered shall include at least:
1- Specification of the sequence by which the construction shall be manufactured (e.g. as single parts or sub-assemblies, and the order of subsequent final assembly);(As per attached Document noPLAN/01Rev.00Dt.01/01/2012) 2-identification of the individual processes required to manufacture the construction; (As per attached Document no - PLAN/01 Rev.00 Dt.01/01/2012) 3- Reference to the appropriate procedure specifications for welding and allied processes;(As per Doc no:- QC/20 Rev.0 Dt. 01/02/2013) 4- Sequence in which the welds are to be made; (As per Doc no:- QC/20 Rev.0 Dt. 01/02/2013) 5- Order and timing in which the individual processes are to be performed; 6- Specification for inspection and testing, including the involvement of any independent inspection body; (As per Client Approved ITP) 7- Environmental conditions (e.g. protection from wind and rain); 8- Identification by batches, components or parts, as appropriate; 9- Allocation of qualified personnel; (As per Section 0.6 of manual QM-02) 10- Arrangement for any production test.
7.9 Work instructions
Clause No : 10.4
7.10 Procedures for preparation and control of documents
Clause No : 10.5
The DEPL use the welding-procedure specification directly for instruction purposes. Alternatively, Dedicated work instructions may be used. Such dedicated work instructions shall be prepared from a qualified Welding-procedure specification and do not require separate qualification. If any additional instructions are to be issued, the same shall only be issued by QCE / QCM to WE. The necessary instructions shall only be prepared in accordance to Approved WPS-PQR, Relevant codes & Standards & Specification. This Work instruction is made in local languages for better understandings. DEPL establish and maintain procedures for the preparation and control of relevant quality Documents as per Master List of WPS (Doc No.: QC/45 Rev.00 Dt. 01/06/2016) as per relevant standards.
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QUALITY MANUAL FOR FUSION WELDING OF METALLIC MATERIAL QM-02 ISO 3834 – 2 : 2006 (E) Section – 8
Revision - 00
TITLE – INSPECTION AND TESTING PERSONNEL
8 Inspection and testing personnel
Effective Date 01.06.2016
Page no.-1
Clause No : 08
8.1 General The manufacturer shall have at his disposal sufficient and competent personnel for planning, performing, and supervising the inspection and testing of the welding production according to specified requirements.
8.2 Non-destructive testing personnel
The non-destructive testing personnel shall be qualified in accordance to EN ISO 9712/EN473/ ASNT’s SNT-TC-1A/ ISNT. For visual testing, a qualification test may not be required. When a qualification test is not required, competence shall be verified by the DEPL. The ISO documents to which it is required to conform to fulfil the quality requirements are specified in ISO 3834-5:2005, Table 3, for arc welding, electron beam welding, laser beam welding and gas welding, and in ISO 3834-5:2005, Table 10, for other fusion welding processes.
DEPL has decided to outsource this activities from approved NDT supplier from approved supplier List(Doc No.: Pur/02 Rev.01 Dt. 01/01/2013)& Non-destructive testing personnel qualification List (Doc No.: QC/46 Rev.00 Dt. 01/07/2016).
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QUALITY MANUAL FOR FUSION WELDING OF METALLIC MATERIAL QM-02 ISO 3834 – 2 : 2006 (E) Section – 9
Revision - 00
TITLE –EQUIPMENTS
9 Equipment
Effective Date 01.06.2016
Page no.-1
Clause No : 09
9.1 Production and testing equipment
The following equipment shall be available, when necessary: 1 - Power sources and other machines (as per Doc. No. –MM-01 Rev.00 Dt.01/06/2016); 2 - Equipment for joint and surface preparation and for cutting, including thermal cutting (as per Doc. No. - MM-01 Rev.00 Dt.01/06/2016); 3 - Equipment for preheating and post-heat treatment including temperature indicator; 4 - Jigs and fixtures; 5 - Cranes and handling equipment used for the production (as per Doc. No. - MM-01 Rev.00 Dt.01/06/2016); 6 - Personal protective equipment and other safety equipment, directly associated with the applicable Manufacturing process (as per Doc. No. - MM-01 Rev.00 Dt.01/06/2016):1-Ovens, quivers, etc. used for treatment of welding consumables (as per Doc. No. - MM-01 Rev.00 Dt.01/06/2016); 2-Facilities for surface cleaning (as per Doc. No. - MM-01 Rev.00 Dt.01/06/2016); 3-Destructive and non-destructive testing facilities.
9.2 Description of equipment
DEPL maintain a list of essential equipment, used for the production. This list shall identify items of major equipment, essential for an evaluation of workshop capacity and capability. This includes, for Example: 1-Maximum capacity of crane(s) (as per Doc. No. - MM-01 Rev.00 Dt.01/06/2016); 2-Size of components that the workshop is able to handle (As per MCC Certificate); 3-Capability of mechanised or automatic welding equipment (as per Doc. No.-MM-01Rev.00 Dt.01/06/2016); 4-Dimensions and maximum temperature of furnaces for post-weld heat treatment; 5-Capacities of rolling, bending and cutting equipment (as per Doc. No. - MM-01 Rev.00 Dt.01/06/2016). Other equipment only needs to be specified by approximate total numbers which cover each general type (E.g. total number of power sources for the different processes).
9.3 Suitability of equipment
The equipment has been checked & found adequate for the application concerned.
9.4 New equipment
After installation of new (or refurbished) equipment appropriate tests of the equipment shall be performed by supplier services engineer.
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QUALITY MANUAL FOR FUSION WELDING OF METALLIC MATERIAL QM-02 ISO 3834 – 2 : 2006 (E) 9.5 Equipment maintenance
DEPL has documented plans for the maintenance of equipment. The plan shall ensure Maintenance checks of those items in the equipment which control variables listed in the relevant procedure specifications. The maintenance plan is shown in #MAIN/01 Rev. 00 Dt. 01/01/2014. Defective equipment shall not be used& shall be tagged ‘SCRAP’ / ‘UNDER MAINTENANCE’.
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QUALITY MANUAL FOR FUSION WELDING OF METALLIC MATERIAL QM-02 ISO 3834 – 2 : 2006 (E) Section – 10
Revision - 00
TITLE – WELDING CONSUMABLE
10 Welding consumables (ML: Pur/05 Dt. 01/08/2016)
Effective Date 01.06.2016
Page no.-1
Clause No : 11
10.1 General
Responsibilities and procedures for control of welding consumables are specified. Following Documents shall be maintained:1. Welding Consumable Inspection Report – QC/41 Rev 00 Dt. 01/06/2016 2. Material Issue Slip – Doc No. PROD/12 REV. 00 Dt. 01/05/2016 3. Welding Consumable Requision Slip – Store/06 Rev 00 Dt.01/07/2016 4. Welding Consumable Issue File – DEPL/STORE/05-F Rev.00 Dt. 01/06/2016 5. Welding Electrode Baking File – Doc No DEPL/STORE/07-F Rev.00 Dt. 01/06/2016
10.2 Batch testing
Batch testing of welding consumables shall be required only if specified in Contract.
10.3 Storage and handling 1.1
Scope –This procedure describes the minimum requirements to be complied with for receipt, storage, issue, handling, and treatment of welding consumables prior to use in order to ensure acceptable weld quality during fabrication & erection is as per procedure no DEPL/WCP-01 Rev.00 Dt.01/06/2016.
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QUALITY MANUAL FOR FUSION WELDING OF METALLIC MATERIAL QM-02 ISO 3834 – 2 : 2006 (E) Section – 11
Revision - 00
TITLE – STORAGE OF PERENT MATERIAL
11Storage of parent materials
Effective Date 01.00.2016
Page no.-1
Clause No : 12
Storage shall be such that the material, including material supplied by the client (if any), will not be adversely affected. Identification shall be maintained during storage& manufacturing. SK is responsible to check the material and the delivery challan for compliance with the PI / P.O. as follows but not limited to A) Quantity and transit damage if any. B) Packaging (Defects) C) General Condition D) MTR/MTC Status
Store Keeper (SK) prepares Goods Receipt Note (GRN) (Doc No - STORE/03 REV.00 Dt.01/05/2016) upon receipt of the material and forwards GRN with necessary attachments to QCE/WE for receiving inspection.
The QCE/WE upon notification from SK shall verify that material is correctly marked in accordance with the Material Purchase Specification (MPS) and material specification as per the Code and Issue CT number (Doc No: QC/30 Rev. 00 Dt.01/10/2013) to material. QCE/WE shall verify the markings as per the Code requirements and shall record their observation on the Incoming Material Inspection Report (IMIR) (Doc No - QC/42 Rev. 00 Dt. 01/06/2016). After Identified & clearance from QCE by verification of Physical copy of MTC & Visual then CT Number will be given to them to as identity for production and it shall be marked by preferably permanent paint marker.
11.1 Material Release:-
The QCE checks the MTR/MTC against the Material Purchase Specification (MPA). The MTR/MTC is checked for compliance with the requirements of Code. Acceptable Material is released by QCE / QCM by Signing the IMIR.
When the material is found to be acceptable, approval for usage shall be given by signature and date of the QCM/QCE on the IMIR Acceptable material shall be attached with a tag/sticker “ACCEPTED” (Exhibit No. 6.08) and shall be allowed to be kept in stores.
If the material does not conform to the requirements of the Code, specification & P.O. then QCE will put the remarks on the IMIR & it shall be considered as Non Conformity and to be handled as per Section 12 (Correction of Nonconformities) of the QC Manual – QM-02.
All materials which do not conform to the Code, specification/P.O. or specified requirements shall be attached with a tag/sticker “HOLD“(Exhibit No. 6.08) until NCR is resolved. Rejected material shall be attached with a tag/sticker “REJECTED” (Exhibit No. 6.08) and shall not be allowed to enter in store & shall be kept outside of stores at separate identified area.
Hard stamping shall not be applied to ferrous material less than ¼” (6 mm) and nonferrous material less than ½” (13 mm) thickness. In this case marking shall be done preferably by etching or engraving or by permanent paint marker. Available stock materials shall be inspected by QCE. He will review available marking to verify compliance with applicable Code requirements. Where necessary MTR / MTC and any additional Mr. Avinash Silimkar PREPARED BY
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QUALITY MANUAL FOR FUSION WELDING OF METALLIC MATERIAL QM-02 ISO 3834 – 2 : 2006 (E) material or inspection requirement shall be validated to ensure conformance to the requirements of Code. If current Edition of the Specification calls for additional tests, the same shall be undertaken as necessary.
11.2 Material Issuance:-
The SK/QCE shall be responsible for controlled issuance of material. Production Engineer (PE) shall arrange to mark accepted material with proper stamping (E.g. Job No., Part No., Material Spec. & Grade & Heat No. etc.). The PE shall raise the Material Issue Slip (Doc No:-Prod/12 Rev.00 Dt. 01/05/2016) in order to issue the material from the stores
11.3 Marking Transfer:-
Before material is cut into two or more pieces, or the original marking is cut out or obliterated, either the complete Code required markings or a minimum of following marks shall be transferred by hard punching for proper Traceability of materials on each piece. PLATE: Material Specification, Grade/Type/Class as applicable, CT No., Project Name (If required) PIPE: Material Specification, Grade/Type/Class as applicable, CT No., Project Name (If required). FORGING: Material Specification, Grade/Type/Class as applicable, Size, Rating, Heat/Lot No. Note: If the Size of the part does not permit complete marking as above, part shall be identified with the relevant Part No., material P No. or Material grade. Other details of such parts i.e. Heat No, Plate No. etc. shall be documented on Material Heat Chart (Doc No:-QC/10 Rev 00 Dt. 01/10/2005) for the job.
If the hard stamping is not permitted or not possible, the marking shall be done by Permanent Marker or any other suitable method. The QCE shall confirm the proper transfer of marking as per above.
11.4 Non-Conforming Material:-
Nonconforming material shall be handled as described in Section 14 (Correction of Nonconformities).
11.5 Material Testing:-
When supplementary material testing is required (e.g. impact testing) the QCM shall be responsible for subcontracting to laboratory complying with the Code requirements for calibration and certification.
11.6 Incoming Material Inspection Report (IMIR):-
All IMIR mentioned in this Section are made available by the QCM with all accepted test results for review to the AI (if applicable) and are filed in the job file.
11.7 Rejection of Materials:-
Materials which do not conform to Code requirements shall be rejected by QCE in concurrence with the QCM with the appropriate comments on the corresponding NCR (QC/16 Rev. 01 dt. 01/01/2016). Rejected materials shall be identified with “REJECTED” (Exhibit No. 6.08) tag and will be stored at separate identified location.
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QUALITY MANUAL FOR FUSION WELDING OF METALLIC MATERIAL QM-02 ISO 3834 – 2 : 2006 (E) Section – 12
Revision - 00
TITLE – POST WELD HEAT TREATMENT
Effective Date 01.06.2016
12Post-weld heat treatment (ML# Pur/02 Rev01 Dt.01/01/2013)
Page no.-1
Clause No:13
Heat treatment of the material / PWHT carried out at Supplier place from approved supplier list (Doc No: - Pur/02 Rev.00 Dt. 01.10.2005) of Dynaxcel Engineer’s Pvt. Ltd as per procedure (Doc No:- DEPL/HT-01, Rev. 00 Dt. 01.06.2016) given by DEPL to the supplier.
Mr. Avinash Silimkar PREPARED BY
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QUALITY MANUAL FOR FUSION WELDING OF METALLIC MATERIAL QM-02 ISO 3834 – 2 : 2006 (E) Section – 13
Revision - 00
TITLE – INSPECTION AND TESTING
13Inspection and testing
Effective Date 01.06.2016
Page no.-1
Clause No : 14
13.1 General
Applicable inspections and tests shall be implemented at appropriate points in the manufacturing process to assure conformity with contract requirements. Location and frequency of such inspections and/or tests will depend on the Standard Quality Plan (QC/15 Rev01 Dt. 01/01/2012) NOTE DEPL may carry out additional tests without restriction. Reporting of such tests is not required.
13.2 Inspection and testing before welding
Before the start of welding, the following shall be checked: 1-Suitability and validity of welders’ and welding operators’ qualification certificates (As per Doc No QC/39 Rev.0 Dt. 01/06/2016); 2-Suitability of welding-procedure specification (As per Doc No - QC/20 Rev.0 Dt. 01/02/2013); 3-Identity of parent material (As per Approved Drawings); 4-Identity of welding consumables (As per batch no.); 5-Joint preparation (e.g. shape and dimensions) – As per Doc No - QC/43 Rev.00 Dt. 19/07/2016; 6-fit-up, jigging and tacking 7-Any special requirements in the welding-procedure specification (e.g. prevention of distortion); 8-Suitability of working conditions for welding, including environment (As per Doc No - QC/43 Rev.00 Dt. 19/07/2016).
13.3 Inspection and testing during welding
During welding, the following shall be checked at suitable intervals or by continuous monitoring: 1-Essential welding parameters (e.g. welding current, arc voltage and travel speed); 2-preheating/interposes temperature; 3-Cleaning and shape of runs and layers of weld metal; 4-Back gouging; 5-Welding sequence; 6-Correct use and handling of welding consumables; 7-Control of distortion; 8- And intermediate examination (e.g. checking of dimensions).
All the above parameters shall be recorded in Document No - As per Doc no:- Form no: QC/43 Rev.00 Dt. 19/07/2016.
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QUALITY MANUAL FOR FUSION WELDING OF METALLIC MATERIAL QM-02 ISO 3834 – 2 : 2006 (E) 13.4 Inspection and testing after welding
After welding, the compliance with relevant acceptance criteria shall be checked: 1-by visual inspection (As per Doc no - QC/11 REV.00. DT. 01/10/05); 2-by non-destructive testing (As per approved NDT report formats in NDT Procedure No DEPL/NDE/PT/01; DEPL/NDE/RT/01; DEPL/NDE/UT/01; DEPL/NDE/MPT/01 3-by destructive testing (Lab Test Reports – If Applicable); 4-Form, shape and dimensions of the construction (As per Doc no - QC/9 REV.01 REV. DT. 01/07/2012); 5-Results and records of post-weld operations (e.g. post-weld heat treatment, ageing).
13.5 Inspection and test status
Measures shall be taken, as appropriate, to indicate, e.g. by marking of the item, the status of inspection and test of the welded construction, Welding History Chart.
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QUALITY MANUAL FOR FUSION WELDING OF METALLIC MATERIAL QM-02 ISO 3834 – 2 : 2006 (E) Section – 14
Revision - 00
TITLE – NON CONFIRMANCE AND CORRECTIVE ACTION
14Non-conformance and corrective actions
Effective Date 01.06.2016
Page no.-1
Clause No : 15
14.1 Definition:-
Nonconformity is any condition which does not comply with the applicable rules of the Code, the QC Manual, or other specified requirements. Non conformities must be corrected before the completed component can be considered to comply with the Code. All NCRs shall be closed out before the QCM certifies the MDR.
14.2 Nonconformity Identification:-
Scope –This Section describes all scope of work is in QMS Section No.: QM8.3 Rev.00 Dt. 01/01/2009, as per procedure no P/05/MR rev.00 Dt. 01/01/2009
14.3 Corrective Action:1.1
Scope –This Section describes all scope of work is in procedure no. P/04/MR Rev.00, Dt. 01/01/2009
14.4 Preventive Action:-
When the proposed corrective action has been completed and verified by the QCM, the NCR shall be signed by the QCM for acceptance of NCR Closure. The QCE then shall remove the “Hold” tag from the item.
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QUALITY MANUAL FOR FUSION WELDING OF METALLIC MATERIAL QM-02 ISO 3834 – 2 : 2006 (E) Section – 15
Revision 01
TITLE – CALIBRATION AND VALIDATION OF MEASURING / INSPECTION / TESTING EQUIPMENT
Effective Date 01.06.2016
Page no.-1
Clause No : 16 15Calibration and validation of measuring, inspection and testing equipment 15.1 Scope:1.1
This Section describes the calibration of examination, measurement and test equipment used in fulfillment of applicable Code requirements& all scope of work describe in QMS Section No.: QM7.6 Rev.00, dated 01/01/2009
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QUALITY MANUAL FOR FUSION WELDING OF METALLIC MATERIAL QM-02 ISO 3834 – 2 : 2006 (E) Section – 16
Revision - 00
TITLE – IDENTIFICATION AND TRECEBILITY
16Identification and traceability
Effective Date 01.06.2016
Page no.-1
Clause No : 17
Identification and traceability shall be maintained throughout the manufacturing process, if required. Documented systems to ensure identification and traceability of the welding operations shall include, if Required:
1-Identification of production plans 2-Identification of routing cards 3-Identification of weld locations in construction 4-Identification of non-destructive testing procedures and personnel (As per Clause – 6 sub clause 2 of manual QM-02); 5-Identification of welding consumable (E.g. designation, trade name, manufacturer of consumables and Batch or cast numbers)(As per Doc No:- QC/41 Rev.00 Dt. 01/06/2016); 6-Identification and/or traceability of parent material (e.g. type, cast number)(As per Doc No:- QC/30 Rev.00 Dt.01/10/2013);
7-Identification of location of repairs 8-Traceability for fully mechanised and automatic welding units to specific welds 9-Traceability of welder and welding operators to specific welds (As per Doc No:- QC/20 Rev.00 Dt. 01/02/2013)); 10-Traceability of welding-procedure specifications to specific welds(As per Doc No:- QC/20 Rev.00 Dt. 01/02/2013).
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QUALITY MANUAL FOR FUSION WELDING OF METALLIC MATERIAL QM-02 ISO 3834 – 2 : 2006 (E) Section – 17
Revision - 00
17Quality records
TITLE – QUALITY RECORD
Effective Date 01.06.2016
Page no.-1
Clause No : 18
Quality records shall include, when applicable: 1-Record of requirement/technical review(As per Doc No:- PLAN/03 Rev.00 dt.01/06/2016&(As per Doc No:- PLAN/02 Rev.00 dt.01/06/2016) 2-Material inspection documents(As per Doc No:- QC/42 Rev. 00 Dt. 01/06/2016) 3-Welding consumable inspection documents(As per Doc No:- QC/41 Rev 00 Dt. 01/06/2016)
4-Welding-procedure specifications (As per Clause – 7.2 of manual QM-02) 5-Equipment maintenance records 6-Welding-procedure qualification records (WPQR) 7-Welder or welding-operator qualification certificates (As per Clause – 7.3 & 7.4 of manual QM-02) 8-Production plan(As per Doc No:-Prod/03 Rev.00, Dt. 01/10/2005) 9-Non-destructive testing personnel certificates (As per Clause – 6 sub clause 2 of manual QM-02) 10-heat-treatment procedure specification and records 11-non-destructive testing and destructive testing procedures and reports (As per Clause – 6 sub clause 2 of manual QM-02) 12-Dimensional reports(As per Doc No:-QC/09 Rev 01 Dt. 01/07/2012) 13-Records of repairs and non-conformance reports(As per Doc No:- QC/06 Rev 01 Dt. 01/01/2008) 14-Other documents, if required. Quality records shall be retained for a minimum period of five years in the absence of any other specified Requirements.
Mr. Avinash Silimkar PREPARED BY
Mr. Vikas Dighe REVIEWED BY Page No. 34 of 34
Mr. Rahul Chaukhande APPROVED BY
