EN 15085-2 PROCEDURE MANUAL

FOR CONSTRUCTION OF RAIL COMPONENTS WELDING AND FABRICATED PARTS THERE OF IN

ACCORDANCE WITH EN 15082-2
 TABLE OF CONTENTS

Sr. No. of
Title Document No
No. Pages

Facing Sheet 1

Table of Content 1

Amendment Sheet

1 Procedure for Control of Documents

2 Procedure for storage handling of welding consumables

3 Procedure for Handling of Nonconformities

4 Procedure for Inspection and Testing

5 Procedure for Identification and Traceability

 Amendment Sheet

Sl Sec Page Para Issue Rev

Date of Issue Amendment Details
No No No No No No
 1 Procedure for Control of Documents

1 Applicability
All Welding related documents.

2 Procedure
Procedure for control of documents is generally as per ISO 9001 and is described below :
2.1 The documents are controlled and issued by RWC. A master list is maintained by issuer to identify currency
of each document and the list is updated whenever there is an amendment.
2.2 A master copy of each document is maintained with the issuer.
2.3 Copy of the master document is issued as the controlled document to identified recipients. Records of issue
and receipt are maintained through an issue register which also records if the superseded document has been
returned and destroyed.
2.4 The superseded documents are destroyed but the master copy is maintained as record with a superseded
stamp on the front face.
2.5 It is ensured that appropriate documents are available at the point of use.
2.6 All documents carry a unique identification no. and currency status.
2.7 Records of changes/amendments shall be maintained in a document change register.
2.8 Documents of external origin shall be subject to same controls as described above.
2.9 Forms and formats shall be subject to same controls as described above.
2.10 To prevent the unintended use of obsolete documents, same shall be retrieved and destroyed.

3 Documents and records

a) All welding related documents

b) Master list (List of controlled documents with currency status)
c) Issue register
d) Document change register
 2 Procedure for handling of welding consumables:

1 Applicability:
All Welding consumables e.g., electrodes. MIG/MAG wires, Gas, etc.

2 Procedure
2.1 During storage & handling (in stores & shopfloor) care is taken to ensure that consumables are :
a) Handled and dried as per suppliers recommendation as per relevant WI. The relevant WI for drying shall
be available at the heating oven location for convenience.
b) All welding consumables including shielding gases shall be accompanied by test certificates as per
appropriate standards.
c) Once the MMA electrodes are taken out of the boxes, the same shall be dried/heated in a suitable oven
at appropriate temperature and duration as per suppliers recommendation, and put in the quivers from
where it shall be used directly to avoid contamination
d) Stored in a covered area and on dry racks and FIFO system shall be employed for issue
e) Mix up shall be avoided by maintaining identification by means of original carton/box/label, or any
other suitable method, during storage, till these are consumed in the shopfloor. Identification includes
supplier, batch no., cast no., test records, etc
f) The environment in the storage area (RH and Temperature) shall be monitored and corrected as
necessary.
g) Open boxes/spools/fluxes shall not be stored or taken back in store after partial use. Open boxes shall
be consumed as early as possible.
h) Identification includes supplier, batch no., cast no., test records, etc., as required, , from which these are
directly used at site.
i) All through the storage and production process, care is taken to avoid contact with water, dust and any
contamination.

3 Documents and records

a) Consumable approval records
b) Log of baking/drying oven
c) Work instruction for handling and storage as per suppliers recommendation.
d) Work instruction for FIFO system.
 3 Procedure for Handling of Nonconformities

1 Applicability:
For all repairs by welding not covered by the scope of the original WPQR (or another WPQR which enables the
same weld quality to be achieved) or not in accordance with the design, a report of non-conformance is
necessary.

2 Procedure
2.1 When nonconformity is observed in a welded joint, it is put on hold and identified in order to avoid
inadvertent use of the nonconforming material for further processing. Items detected as nonconforming shall
be, if possible, isolated in a specific area in order to prevent their use in production until resolution of the non-
conformance.
2.2 A corrective action report is generated for such nonconformities and approved by WC. The non-
conformance report shall contain a description of the anomaly, the cause, the actions decided upon for its
resolution and any corrective actions undertaken. Moreover, every non-conformity report shall include the
classification of the non-conformities, according to the following criteria:
a) non-conformities classified as “critical” if having an impact on safety;
b) non-conformities classified as “important” if having an impact on normal operation;
c) non-conformities classified as “secondary” if not included in the two above cases.
2.3 The eliminating of internal imperfections is also not considered as a repair operation, as long as the original
WPS or another WPS which results in the required weld quality is used. However, if in the welding coordinator’s
opinion the necessary repairs require the issuing of a new, specific WPS as it is not possible to follow the usual
operations prescribed initially in the production cycle, he shall analyze the problems of the case in question to
establish the most appropriate operating methods and ctivate the internal non-conformance process.
2.4 After repair, the items shall be re-inspected, tested and examined in accordance with the original
requirements, and accepted if found OK. At the discretion of the welding coordinator, other additional test
methods may be applied. For each test carried out after repair or rework, with the aim of ascertaining the
compliance of the product, a report shall be issued (e.g. non-destructive test report, dimensional check etc.) that
shall be annexed to the relative non-conformance report.
2.5 A brainstorming is done by RWC and XXXX to determine the root cause of the defect, and the solution to
prevent recurrence.
2.6 The corrective action for non recurrence of similar defects, as decided above, is then implemented, and
performance monitored, to see the effectiveness.
In the event of recurrent non-conformance that could affect safety, the company shall take all steps necessary
for ensuring that the causes are detected and corrected.

3 Documents and records

a) Non-conformance report
b) WPS for repair/rectification
c) Records of corrective action and closure of the NC.
d) Inspection reports
 4 Procedure for Inspection & Testing
1 Applicability
All welded joints

2 Procedure
Inspection & Testing shall be conducted before, during and after each welding, by appropriately qualified and
assigned persons.
2.1 Inspection before welding
2.1.1 Inspection before welding shall be done by the welder and supervised under the responsibility of the
WCO, following the work instruction.
2.1.2 Work Instructions shall be displayed at the work place and the WI shall be followed
2.2 Inspection during welding
2.2.1 Inspection during welding shall be done by the welder and supervised under the responsibility of the
WCO. following the work instruction.
2.2.2 Work Instructions shall be displayed at the work place and the WI shall be followed
2.3 Inspection after welding
2.3.1 Inspection after welding shall be done by designated inspectors following a checklist.
2.3.2 Inspection class corresponding to weld performance class shall determine the inspection requirements.
ISO 15085-3, Table-4 and Table-5 shall be guiding.
2.3.3 Sampling Plan as per ISO 15085-5, Table-1 shall be followed.
2.4 Non-acceptable imperfections : When non-acceptable imperfections are found during the tests indicated in
ISO 15085-5 Table 1, the procedure indicated below shall be followed.
2.4.1 Start/restart of production
The type of test indicated in Table 1 shall be applied over 100 % of the length of the weld with the non-
acceptable imperfections and also on the products welded after this first weld until such time as no more non-
acceptable imperfections are found. The presence of non-acceptable imperfections during the initial phase of
production shall be the subject of detailed examination with the aim of establishing any technical/practical
deficiencies and activating the corrective actions necessary for restoring the process.
2.4.2 Series production
The weld with the non-acceptable imperfections shall be retested with the same test methods as used for the
first test, on 100 % of the length of the two items immediately prior to and after (if already produced) the
nonconforming item. If even one of these two items turns out to have non-acceptable imperfections the tests
shall be extended using identical methods, to the two preceding and two subsequent units, subunits or
assemblies until ascertaining the absence of non-acceptable imperfections. If even one single item of these four
should turn out to be unacceptably defective the production shall be stopped until the causes of the non-
acceptable imperfections are clearly identified. The test shall be extended to the entire relevant production
batch.
3 Documents & Records
a) Work Instructions
b) Inspection Check list
c) Inspection Reports
 5 Procedure for Identification and Traceability

1 Applicability

All welded joints, and inputs related to the welding

2 Procedure
2.1 All welded joints are identified in the drawing/welding plan.
2.2 Identification and traceability requirements are specified as indicated below

1 identification of production drawings Unique number

2 identification of routing cards Unique number

3 identification of weld locations in construction Welding plan, drawing

identification of non-destructive testing procedures and
4
personnel
identification of welding consumable (e.g. designation, trade
5
name, manufacturer of consumables and batch or cast numbers)
identification and/or traceability of parent material (e.g. type,
6
cast number)
7 identification of location of repairs Production record sheet

8 identification of location of temporary attachments Welding plan/drawing

Welders’ id punch
9 traceability of welder and welding operators to specific welds
Job card/routing card
10 Traceability of welding-procedure specifications to specific welds. Welding plan/drawing

3 Documents and records

a) Job card/routing card
b) Inspection reports, checklists
c) Welders id on welding plan