WELDING MANUAL(WM) Page 1 of 19

WELDING MANUAL
Product Type: Manufacture of boilers, Boiler components, Piping, Pressure
vessel and steel structure

Product Standard: ASME Sec-I, ASME B 31.1, ASME B 31.3, ASME Sec-VIII Div.I, IBR
with Latest Amendment, EN-12952, EN-12953, EN-13445, EN ISO -
1090, EN-13480, EN ISO – 3834, client specifications

Welding and Inspection ASME Sec.I, ASME Sec.IV, ASME Sec.V, ASME Sec.IX, ISO 5817, ISO
Standards: 15614-1, ISO 9606-1, EN-14731 & EN-14732

Parent Materials: Material groups in accordance with ISO TR 15608-2013 – EN Group

1,4,5, 6, 8, 11

Welding and Allied: EN ISO 4063 – 111, 121, 131,136,135,141, 783

Responsible Welding Vishal Garg

coordinator

CHEEMA BOILERS LIMITED

HAD BAST NO. 123, BANMAJRA,
ROPAR, PUNJAB - 140103, INDIA
PHONE: + 91-160-5005803, 809, 801, 802, FAX: + 91-160-5005804
EMAIL: vishalgarg@cheemaboilers.com, qa@cheemaboilers.com, welding@cheemaboilers.com

Rev. No. 1
Prepared by Reviewed By Approved By

Amritpal Singh
QA Engineer
Name & Sign
Designation
Responsible Welding
Vishal Garg
coordinator
(HEAD QA/QC)
 WELDING MANUAL(WM) Page 2 of 19

TABLE OF CONTENTS
Page Title No. of Pages Remarks
Number
1 Cover Page 1

2 Table of Contents 1

3 Introduction 1

4 Statement of Authority and Responsibility 1

5 Purpose & Scope of Manual 1

6 Normative References 1
Review of requirements and technical
7-8 2
review
8 Sub-Contracting 1

8 Welding Personnel 1

9 Inspection and testing Personnel 1

9-10 Equipment 2

10-11 Welding and related activities 1

11 Welding consumables 1

11 Storage of parent material 1

11 Post weld heat treatment ( Excluded ) 1

11-12 Inspection and testing 1

12 Non-conformance and corrective action 1

Calibration and validation of measuring,
12 1
inspection and testing equipment
12 Identification and traceability 1

13-19 Quality Records 16

Copy No Distributed to

1 Quality In charge – Original Copy

2 Welding Coordinator

3 Certification Body

4 Head-Production

5 Process Design & Stores

 WELDING MANUAL(WM) Page 3 of 19

INTRODUCTION

Cheema Boilers Limited (CBL) has been awarded in recognition to exemplary growth and sustainable
success as one of the top 500 companies in the year November 2010 by A9.9 media initiative at its
2ndAnnual Inc India Awards along with IBEF (India Brand Equity Foundation). From the inception in
1999 with in a decade the company has grown 12 times. In this decade the company have achieved
various landmarks and to list few of them it’s among the one of the leading player in steam boilers
manufacturing segment and provides the quality and customer satisfaction at competitive market
price as compared to any leading players inthis segment, CBL has production capacity with 1 plant at
Banmajra in Punjab, it has taken the initiative in the field of slop fired boiler by encouraging R & D
and has the patent for the same, it has ventured in to EPC and also in erection of 3MW solar thermal
power plant in Bikaner in Rajasthan.
This has been possible under the leadership of Management with and strong team of professionals,
the company has ASME ( American Society of Mechanical Engineers) Certification mark“U” (For
manufacturing of Pressure Vessel) ,“S“ (For manufacturing of Power Boilers) and “H” (For

manufacturing of heating boilers) which is prerequisite for exports with Head Office in Mohali and

Regional Marketing Officers in Kolkata, Mumbai, Delhi, Hyderabad, Ahmadabad and Chennai the
company wants to increase its customer base allover India.
 WELDING MANUAL(WM) Page 4 of 19

FUSION WELDING:-
Fusion welding is a special process in the manufacturing companies. The products may range from
simple to complex. These processes exert a profound influence on the cost of manufacture and
quality of product. It is important to ensure that these processes are carried out in the most effective
way and that appropriate control is exercised over all aspects of operation. ISO 3834-2/HP0 is an
effective tool in this regard along with ISO 9001:2015; this emphasizes the requirements to meet the
quality of the product.

STATEMENT OF AUTHORITY AND RESPONSIBILITY

The quality objective of Cheema Boilers Limited is to achieve and sustain reputation for quality
products at competitive price in the national and international markets. In pursuance of this
objective, the company is constructing the boiler components in accordance with the Latest
European standards as EN ISO 3834.
This WM describes the Quality Requirements for Welding to be followed during the construction of
items in accordance with the ISO 3834/14731 at shop and erection sites.
The objective of the Welding Manual is to ensure compliance of materials, design, fabrication,
examination, inspection, testing and certification as per latest European Standards. The management
is totally committed to meet all requirements of the latest European Standards and this welding
manual shall be outlined during all phases of construction.
I hereby authorize RWC to co-ordinate and ensure that the items are constructed in accordance with
the requirements as per latest European Standards and this WM. RWC has the full support of
Management for implementing the quality system in the welding. He has the authority to prepare,
establish, implement and revise this WM. RWC shall have the authority and organizational freedom
to identify quality problems related to the aspects of welding, report to the undersigned and to
initiate, recommend and provide solutions. RWC has the right to stop any work which in his opinion
is not in accordance with the requirements as per latest European Standards and this WM.
In the event of any difference of opinion or any disagreement between RWC and any other person in
the organization regarding interpretation of the requirements of this WM, it shall be referred to the
attention of undersigned, bearing in mind that the requirements of the standards, jurisdiction /
regulatory authorities and this WM shall always prevail.
Some type of work such as welding forming, non-destructive examination, etc., may be performed by
sub-contractors. However, RWC and department heads shall be responsible to ensure that all such
work complies the requirements as per latest applicable European Standards.

DavinderPal Singh Brar Date:

Chief Executive Officer

Cheema Boilers Limited
Had Bast No. 123, Banmajra,
Ropar, Punjab, India- 140103
 WELDING MANUAL(WM) Page 5 of 19

PURPOSE & SCOPE OF MANUAL

PURPOSE
This Manual has been evolved for formulating the organization, responsibilities, & policies of Cheema
Boilers Limited for implementing the EN ISO 3834-2 (Quality requirements for fusion welding of
metallic materials) at all fabricated components of boilers, including steel structure.
SCOPE
This part of ISO 3834 defines comprehensive quality requirements for fusion welding of metallic
materials both in workshops and at field installation sites.
(A)
Industrial Plot No. D-188, Phase -8B (Sector 74),
Industrial focal point,
S.A.S Nagar, Mohali – 160074, Punjab, India
Tel : +91-172-5090 487,5055 666,
Fax : +91-172-5090 486
Web Site:www.cheemaboilers.com
(B)
Works: Had Bast No. 123, Banmajra,
Ropar, Punjab - 140103, India
Phone: + 91-160-5005803, 809, 801, 802, FAX: + 91-160-5005804
Email: Vishalgarg@Cheemaboilers.Com

( C ) Errection Sites
 WELDING MANUAL(WM) Page 6 of 19

NORMATIVE REFERENCES
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
USE OF THIS PART OF ISO3834
For general information on the use of this part of ISO 3834, ISO 3834-1 shall be used.
In order to fulfill the quality requirements given in this part of ISO 3834, the conformity to relevant
documents given in ISO 3834-5 shall be verified.

In certain situations, e.g. where manufacturing is more suited to ISO 3834-3 or ISO 3834-4, or where
particular operations, such as heat treatment, are not undertaken, the requirements detailed in this
part of ISO 3834 may be selectively amended or deleted.

Otherwise, the requirements contained within this part of ISO 3834 shall be adopted in full.

GENERAL REQUIREMENTS
CBL in order to qualify for the certification as per ISO 3834-2 shall demonstrate that they have full
control over the requirements mentioned in the standards of EN ISO 3834-2 through the following.
Accreditation by external certification body as per ISO 3834-2
Welders and welding operator’s qualification.
Welding process and mock up qualification.
 WELDING MANUAL(WM) Page 7 of 19

EXCLUSIONS AS PER PO
REVIEW OF REQUIREMENTS AND TECHNICAL REVIEW
Along with RWC in particular shall review the contractual requirements 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. CBL 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 CBL 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.
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 CBL to meet the prescribed requirements.
TECHNICAL REVIEW (PROCEDURE NO/FORMAT NO.F-PRP-03A & F-PRP-03B)
Technical requirements considered shall include the following:
• Parent material(s) specification and its weld ability.
• Welding consumables and its specification.
• Quality and acceptability and sequence of welds, including accessibility for inspection for non
destructive testing.
• 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.
 WELDING MANUAL(WM) Page 8 of 19

• Other welding requirements, e.g., batch testing of consumables, ferrite contents 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
• Environmental conditions (temperature).
• Handling of non-conformances.
Team members involved in contract/ technical review.
SUB-CONTRACTING
When a manufacturer intends to use sub-contracted services or activities (e.g. welding, inspection,
non- destructive testing, heat treatment), information necessary to meet applicable requirements
shall be supplied by the CBL to the sub-contractor. The sub-contractor shall provide such records and
documentation of his work as may be specified by the CBL.
A sub-contractor shall work under the order and responsibility of the manufacturer and shall fully
comply with the relevant requirements of this part of ISO 3834. The manufacturer shall ensure that
the sub-contractor can comply with the quality requirements as specified.
The information to be provided by the CBL to the sub-contractor shall include all relevant data from
the review of requirements and the technical review. Additional requirements may be specified as
necessary to assure sub-contractor compliance with technical requirements.
WELDING PERSONNEL
GENERAL
CBL shall have at its disposal sufficient and competent personnel or the planning, performing and
supervising of the welding production activity according to ISO 14731.
WELDERS AND WELDING OPERATORS
CBL have the welders qualified in accordance with, EN ISO 9606-1 or as per customer requirement.

RESPONSIBLE WELDING COORDINATION PERSONNEL

Responsible welding coordination personnel of CBL shall plan all welding related activities as per
customer Specification and drawings. He shall be assisted by trained deputy welding coordinators.
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. Responsible 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.
 WELDING MANUAL(WM) Page 9 of 19

The sequence of weld and control of activities in the shop-floor shall be discussed amongst
supervisors in the preliminary stages before the commencement of any project. He has to identify
the welding processes, NDT requirements from the drawing before the part is being produced. 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.
INSPECTION AND TESTING PERSONNEL
CBL 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 done by responsible welding coordinator along with the deputy welding coordinators. Supervising
the performance, inspection and testing shall be done by deputy welding coordinators. Non-
destructive testing personnel as per ISO 9712 / ASNT.
NDT testing to be performed by Level-II personnel. Acceptance criteria and code requirements shall
be considered for evaluating and interpreting results of VT & PT are referred as per defined NDT
procedures.
Training program or awareness program for welders/ welding operators shall be given regularly and
recorded.
EQUIPMENT
PRODUCTION AND TESTING EQUIPMENT
CBL has the following set of equipment. The details of these equipment’s like capacity, size should be
processed by.
Power sources and other related machineries.
CNC laser cutting machine and oxy-acetylene fuel cutting machine for joint and surface preparation.
Hand cutting torches (LPG & Oxygen) for preheating the base materials before start of weld.
Pug Cutter / Semi-Automatic Bevel Cutting Machine of bevel cutting for preparing weld joints (Only
for plates).
Suitable jigs and fixtures to control the welding distortion.
EOT cranes to load unload and move the heavy structures.
Personal protective equipments like helmets, goggles, gloves, shoes etc are made available during
production.
Grinding machines for surface cleaning.
Master list of machinery and equipment is documented.
CBL has maintained the records of installation and commissioning of new machines
NEW MACHINE INSTALLATION
If any new welding machine is installed at the shop floor for the production either
responsible/deputy welding coordinator has to be confirm the machine specification.
 WELDING MANUAL(WM) Page 10 of 19

Maintenance team confirms the commissioning report from the supplier and ensures the machine
details are updated in the master list of equipment.
New Machines calibration is as per manufacturer supplied certificate.
EQUIPMENT MAINTENANCE
CBL shall have documented plans for the maintenance of the equipment. As per the preventive
maintenance Calendar.
The plans are limited to those items which are essential for assuring the quality of the product.
Condition of guide ways, fixtures, cutting equipments, mechanized welding setups shall be
periodically checked.
Conditions of ammeter, voltmeter, flow meters. The same are periodically calibrated as per plan.nit,
Gas flow at the nozzle (check by using flow checker) etc.
Scheduled maintenance checklist of all welding and related requirements shall be recorded in
Preventive Maintenance Schedule F-MTC-101 & F-MTC-201.

BREAK DOWN MACHINE

If there is a machine breakdown due to some issue it is reported to the maintenance team through
Breakdown Request (F-MTC-02)
The break down machine is identified to be under Break down.
WELDING AND RELATED ACTIVITIES
PRODUCTION PLANNING [F-PRD-01)
CBL carries out the production planning periodically considering the following:
• Sequence of operations, process/s by which the construction shall be manufactured.
• Identification of individual processes like laser cutting, bending, rolling, machining, welding etc.
• Order and timing in which the individual processes are to be performed.
• Specification for inspection and testing, including the involvement of customer or independent
inspection body.
• Requirement of qualified welders and personnel qualified to carryout necessary non-destructive
testing on the equipment wherever required.
• Identification and traceability of the parts through serial numbers, batch numbers etc as per
customer specific requirement.
• CBL shall refer the relevant procedures for various processes or operations.
WELDING PROCEDURE SPECIFICATIONS
CBL shall prepare the welding procedure specifications as per applicable standards ISO 15609-1 shall
be made available at the work stations. Production supervisors and deputy welding coordinators
shall have one set of all relevant welding procedures at his disposal. They shall understand and
 WELDING MANUAL(WM) Page 11 of 19

demonstrate all essential variable parameters that are displayed in the document.

QUALIFICATION OF THE WELDING PROCEDURES

CBL shall qualify the welding procedures before start of production. The qualification procedures
shall be done in accordance with ISO 15614-1, ISO 15614-2, ISO 15613-1 and HP2/1.
WORK INSTRUCTIONS
CBL may prepare separate work instructions relevant to the part and use the document during
production for better understanding of the welders and welding operators.
All work instructions shall have the mention of relevant welding procedure specifications .
PROCEDURES FOR PREPARATION AND CONTROL OF DOCUMENTS
CBL has established and maintained the following procedures for the preparation and control of
relevant quality documents.
Welding Procedure Specifications are prepared by the welding coordinator, once the joint
configurations relevant to the drawing specifications are finalized.
Welding Procedure Qualification Records are prepared as per ISO 15614-1, ISO 15614-2, ISO 15613-1,
HP2/1.by preparing the test coupons clearly identified and tested in an NABL approved laboratories.
The tests, if required shall be witnessed by third party inspectors.
Performance qualification of welders/ welding operators shall be done referring to relevant
standards. Each welder shall be assigned with one internal identification which shall be mentioned in
all relevant quality records.
WELDING CONSUMABLES
CBL has established the procedure for controlling the storage of welding consumables as per
Procedure no CBL/WC/03 Rev.03
STORAGE OF PARENT MATERIAL
Parent material received from the suppliers including customer supplied material if any shall be
stored under protected environmental conditions. Each supply shall be identified during storage.
POST WELD HEAT TREATMENT [CBL/HT/01 REV.06 as per EN-17663]
CBL shall be responsible for the specification and the performance of any post-weld heat treatment,
if specified as per customer requirements. A record of the heat treatment shall be made during the
process.
INSPECTION AND TESTING
BEFORE WELDING (In process Request Cum Report: Exhibit No – 16)
• Suitability and validity of welders and welding operator’s qualification certification.
• Suitability of welding procedure specification.
• Identity of welding consumables.
• Joint preparation.
 WELDING MANUAL(WM) Page 12 of 19

• Surface preparation (Cleaning/Grinding/Sundering/ grit blasting) of welding joints.

• Fit-up, jigs and fixtures for tack welding to prevent weld distortion.
• In process inspection checklist as specified for fabrication/ painting/ dispatch before starting any welding.
• Raw material identification
• Ensure the Welding machine calibration, Flow meter calibration..etc.
• Ensure the material dimension reports are available with QC.

DURING WELDING (In process Request Cum Report: Exhibit No – 16)

• 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 and weld 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.
AFTER WELDING (Visual Inspection Request Cum Report : Exhibit No.18)
• Visual inspection (Visual Examination Procedure – CBL/NDE/VT/05 REV.04)
• Before NDE ensure the surface preparation such as grinding/machining/polishing etc.
• Non-destructive testing, PT.UT &MPI is done in house & RT is outsourced.
• Destructive testing (outsourced)
• Post weld heat treatment if specified
• Results and records of post weld operations.
• Inspection reports and test certificates shall be maintained.
• Qualified NDE personnel has to be ensure the NDT examination (VT,LPI,MT..etc)
• Ensure the weld metal thickness as per the drawing and dimension to be in line with the drawing.
• Check any non- linearity (Distortion) on the products.
NON-CONFORMANCE AND CORRECTIVE ACTION (Exhibit No – 23)
CBL has established the system of controlling the non-conformities and initiating corrective and preventive
actions for the non-conformed products. Repair if allowed has to be as per defined repair procedure and re
inspection is carried out as per the original inspection requirement, after each repair.
CALIBRATION AND VALIDATION OF MEASURING, INSPECTION AND TESTING EQUIPMENT (Master List of
Measuring and Test Equipment: F-CAL-02)
Calibration of measuring instruments and monitoring instruments are carried out as per the calibration
calendar.

IDENTIFICATION AND TRACEABILITY (Inward Weld Consumables Inspection Record – Exhibit – 29 )

CBL has established documented procedure for product identification and traceability.
 WELDING MANUAL(WM)
QUALITY RECORDS
Quality records includes, when applicable:
Quality Records :
 Record of requirement/technical
review.
 Inward Weld Consumables
Inspection Record
 Test certificate of Welding
Consumable.
 Welding-procedure specifications.
 Equipment maintenance records.
Page 13 of 19
Format No
- Qualification of welding process –WPS
- Technical Review Checklist – F-PRP-03A & F-PRP-03B
Exhibit - 29
Manufacturers Batch TC
 Qualification of welding process - WPS
 Visual Inspection Report Before Welding –Exhibit No
- 16
 Visual Inspection Report during Welding–
Exhibit No – 16
 Visual Inspection Report after Welding –
Exhibit No - 18
 Material Identification Report – Exhibit No - 13
 Pre welding Inspection (Fit-up) report –
Exhibit No - 16
 Master list of machines-F-MTC-51
 List of test and measuring equipment’s-F-CAL-02
 Maintenance checklist for all Machines –
F-MTC-04 to F-MTC-47
 Preventive maintenance Schedule –
F-MTC-101 & F-MTC-102
 New equipment Checklist–F-MTC-52
 WELDING MANUAL(WM) Page 14 of 19

 Welding-procedure qualification  Qualification of welding process- WPQR

 Visual Inspection Report Before Welding–
records (WPQR).
Exhibit No – 16
 Visual Inspection Report during Welding–
Exhibit No – 16
 Material Identification Report – Exhibit No - 13
 Pre welding Inspection (Fit-up) report-
Exhibit No - 16
 Liquid Penetrant Examination Report –
F-QAD-30
 Magnetic particle examination report of weld joints
– Exhibit No - 48
 Ultrasonic Examination Report – F-QAD-96
 Final Welding inspection report (Visual & Dimension)
[Exhibit No. 18 & Exhibit No. 16]

 Welder or welding-operator
Welder Performance Qualification Record
qualification certificates.

 Welder continuity record

Exhibit-27

 Welding consumables issue register GMAW FCAW Wire Issue Log Book (Exhibit – 42) &
Electrode Issue Log Book (Exhibit – 46)

 Welding consumables issue slip.

Exhibit-25
 Production plan.
Shop Loading Plan (F-PRD-01) & Shift Plan (F-PRD-02)
& Weekly Plan (F-PRD-03)

 Weld Plan.
Weld Plan (Exhibit-28)

 Weld Map.
Weld Map (Exhibit-47)

 Non-destructive testing personnel

certificates. List of Qualified NDT Persons
 WELDING MANUAL(WM) Page 15 of 19

All Quality records shall be retained for a minimum period of 10 years in Soft / hard form the absence of any
other specified requirements.

19- Linkages and ref documents, formats ISO 9001:2015 ISO Manual Linkage can be used

QM DEPARTM EN ISO 3834-2:2005 /

SR NO ISO 9001:2015 SECTION ENTAL Department EN 1090-2:2018 // -
Clause Title
PROCEDURE EN 1090-
NO'S. 1:2009+A1:2011

10.5 (Procedures for

Control of preparation and
1 7.5 ALL
Documents control of
(Documented documents) /
Information) - -
- 4.2.1 (Quality
Documentation) &
C.2.3
(Documentation)
Master
7.5.3 18 (Quality Records) / List of
Control of
2 (Control of - ALL C.2.3.3 (Execution Documen
Documented - Records Records) ts (L-DOC-
Information) 01)

3 9.3 MD Management C 2.1 (Management)

- -
(Management Review
Review)
7.2 Competence 7 (Welding The tasks,
(Competence) , Training Personnel), 8 responsibilities
& and (Inspection and and authority -
4 7.3 - HRD Awareness Testing Personnel) /
(Awareness) - 7.4.3 (Welding Ref: Organization
Coordination) chart
8.1 Maintenance 9.1(Production and - list of
(Operational of Testing Equipment), Machines
Planning and Maintenance Equipment : 9.2 (Description of (F-mtc-51)
Control), 8.2 Process Equipment), - Master List of
(Requirements Control 9.3 (Suitability of Measuring and
for products Equipment), 9.4 Test
and services) , (New Equipment), Equipment
5 9.5 (Equipment (F-CAL-02)
8.5
(Production Maintenance) // 6.3.3 - Maintenance
- (Equipment)
and service Checklist of all
provision) Machines
(F-MTC-04 to
- F-MTC-47)
- Preventive
maintenance
Schedule
(F-MTC-101 &
F-MTC-201)
 WELDING MANUAL(WM) Page 16 of 19

Welding Procedure
Quality 5.1(General), / Specification Index –
9.1 (Monitoring, Quality
Planning 4.2.2 (Quality Plan) (Exhibit-44)
measurement, Control
analysis and Qualified welder list
6 -
evaluation), 9.2 Qualified Operator
(Internal Audit) list Welder
- qualification record
Welder Qualification
data
Qualification of
Customer 5.2 (Review of welding process ,
7.2 (Competence) Marketing
Related requirements), Visual Inspection
& 7.4 - Process : 5.3(Technical Report Before
7 (Communication) Contract Review) // 5 Welding – Exhibit
Review and (Evaluation No-16 Visual
Communicati Methods) Inspection Report
- on during Welding –
Exhibit No-16Visual
Inspection Report
after Welding –
Exhibit No-18
(Fit-up) report-
Exhibit No-16
Design and
8 8.3 (Design and MKTG.
Develop
development of - -
- ment
products and
services)
10.2 Customer 15 (Non-conformance
9 (Nonconformity Quality Complaint and corrective
-
and corrective - Control / actions) // 6.3.8 -
action) External (Non-Conforming
Services products)

10 7.4 - Purchase Purchasing -

(Communication) -

- Supplier Evaluation
11 7.4 - Purchase / Purchasing : 6 (Sub-contracting // Cum Selection
(Communication) Vendor Sub - 5 (Evaluation Report (F-PUR-01)
-
Development Contracting Method) Supplier Rating Report
(F-PUR-03)
 WELDING MANUAL(WM) Page 17 of 19

7.5.1 Order
(Documented Monitoring
12 - MKTG. - -
Information / - Process
General) Control
Operation
8.1 (Operation - Activities
- - -
13 planning and Operation
control)
Qualification of
PPC Production 10.1 (Production welding process - WPS
6 (Planning) /
, Visual Inspection
14 7 (Support) Planning : Planning)
Report
Process Before Welding –
Control Exhibit No-16
, Visual Inspection
Report during Welding
– Exhibit No-16
, Visual Inspection
Report after Welding –
Exhibit No-18 Raw
- material inspection
report-Exhibit No-13
&.Pre welding
Inspection (Fit- up)
report- Exhibit No-16
Liquid Penetrant
Examination Report- F-
QAD-30 Magnetic
- Particle Examination
report – Exhibit No-48)
Ultrasonic
Examination Report- F-
QAD-96
7.5.1 Dispatch Preservation
15
(Documented - -
,Packaging
- -
Information / and Delivery
General)

16 7.5.1 Commissioni Servicing

(Documented - ng - -
-
Information /
General)
7.5.1 Production / Production
17 (Documented Fabrication Process :
Information / - Process
- - -
General) Control
 WELDING MANUAL(WM) Page 18 of 19

7.1, 7.2.7.3, 8.1,8.2, Welding Procedure

Fabrication 10.2 (Welding- Specification Index –
18 7.5.1 and Post Exhibit-44
procedure
/ 7.5.2 FAB. Fabrication specifications), PWHT Approved
Process : 10.3 (Qualification of Procedure –
Process the welding CBL/HT/01 Rev
Control procedures), No:04
7.5.1 - [Beams] 10.4 (Work
instructions),
13 (Post-weld heat
treatment) //
5,6 (Evaluation of
conformity),7
(Classification and -
designation),8
(Marking)
7.5.3 (Control Production Identification 17 (Identification and
19 of and traceability) / 12
- -
documented - Traceability (Inspection testing)
information) and correction)
Product 14.5 (Inspection and
20 7.5.3 (Control Q.C.
Status test status) /
of - -
- 12 (Inspection
documented testing)
information)
21 7.5 STORE 11.1 (General) ,11.
Handling,
(Documented 2 (Batch testing), 11.3
Storage and
information) (Storage and
Preservation handling)
12 (Storage of parent
- materials //5 -
- (Evaluation methods),
6 (Evaluation of
conformity),7
(Classification and
designation),8
(Marking)
Control and 16 (Calibration and Master List of
Quality
22 7.5 Monitoring of validation of Measuring and Test
Control / Measuring measuring, inspection Equipment (F-CAL-
(Documented
Maintenanc and Test
information) - and testing 02)
- e Equipment equipment) / 12
(Inspection, testing
and correction)
 WELDING MANUAL(WM) Page 19 of 19

Customer
23 7.4 (Customer Marketing 12
- Satisfaction -
communicatio -
n)
Internal
24 9.2 (Internal - ALL - -
- Audit
Audit)
8.2.4 (Changes
to Inspection
25 Q.C. / PRD. / and Testing
requirements - - -
FAB.
for products -
and services)
Inspection 14.1 (Inspection and Examination
and Testing & testing – General), Inspection & Test
26 8.2.4 Q.C. Plan ( Exhibit – 14)
weld repair 14.2 (Inspection and
Raw material
procedure testing before inspection Report -
- welding) , 14.3
(Inspection and
- testing during
welding), 14.4
(Inspection and
testing after welding),
14,5 (Inspection and
test status)/ 12

Control of
Non -
27 8.3 - PROD. -
- Conforming 15
Product
Statistical
- Technique - -
28 8.4 Q.C.
- and Analysis
of Data
Corrective
and
29 8.5 - ALL 15 -
- Preventive
Action
Continual
30 8.5 - ALL Improvement - -
-