Donaldson Abu Dhabi

Welding Quality Manual

DONALDSON/WQM/01 Rev 00

Issue Date: March 19th 2021 Prepared by: Deepu Mohan

Revision Date March 19th 2021 Authorized by: Steve Dodd

Donalson Filteration

Sharjah P.O Box 32478 United Arab Emirates

Welding Quality Manual

Document No- DONALDSON/WQM/01 Rev 00

This manual is prepared This manual has been

by: reviewed by:

Donalson QA/QC Manager

DONALDSON Director

This manual is approved by:

Donalson Vice President

 Donaldson Abu Dhabi
Welding Quality Manual

DONALDSON/WQM/01 Rev 00

Issue Date: March 19th 2021 Prepared by: Deepu Mohan

Revision Date March 19th 2021 Authorized by: Steve Dodd

Welding Quality Manual Revision Record

CHANGE
ISSUE REVISION REVISION DATE COMMENTS
NOTE
01 00 10 Oct 2011 FIRST ISSUE

Controlled Posting & Consulting:

The Manual Master Copy, the attachments, and the QA procedures are stored in the QA
PUBLIC folder of the Company server where all employees can access them. All are
prompted to read and understand the latest revisions, download the files and print them
when deemed necessary.

The QA/QC Manager with the approval of the Vice President controls the updating of these
documents. Upon issue of the revised documents, the QA/QC Manager will issue a "Quality
Management Controlled Document List" (form DONALDSON/070), which will be distributed
to all employees. Receipt of the new list by the employee shall be acknowledged by signing
the "Controlled Documents List Distribution" form (DONALDSON-071).

Note: - Manual revisions will be identified by typing the revised text in bold and
italics. Only the latest revision will be indicated in the Manual. However,
typographical and formatting changes are not normally indicated.
 Donaldson Abu Dhabi
Welding Quality Manual

DONALDSON/WQM/01 Rev 00

Issue Date: March 19th 2021 Prepared by: Deepu Mohan

Revision Date March 19th 2021 Authorized by: Steve Dodd

Contents
Welding Quality Manual Revision Record..........................................................................................2

1.0 Scope..............................................................................................5

2.0 Normative references...........................................................................5

3.0 Terms and definitions.......................................................................... 6

4.0 Use of this document...........................................................................6

5.0 Review of requirements and technical review.............................................6

5.1 General........................................................................................................................................6
5.2 Review of requirements..............................................................................................................7
5.3 Technical review..........................................................................................................................7

6.0 Sub-contracting..................................................................................8

7.0 Welding personnel.............................................................................. 8

7.1 General........................................................................................................................................8
7.2 Welders and welding operators...................................................................................................8
7.3 Welding coordination personnel.................................................................................................8

8.0 Inspection and testing personnel.............................................................9

8.1 General........................................................................................................................................9
8.2 Non-destructive testing personnel..............................................................................................9

9.0 Equipment........................................................................................9
9.1 Production and test equipment...................................................................................................9
9.2 Description of production equipment.........................................................................................9
9.3 Suitability of equipment............................................................................................................10
9.4 New equipment.........................................................................................................................10
9.5 Maintenance of equipment.......................................................................................................10

10.0 Welding and related activities.............................................................10

10.1 Production planning................................................................................................................10
10.2 Welding procedure specifications............................................................................................11
10.3 Qualification of the welding procedures..................................................................................11
10.4 Work instructions....................................................................................................................11
 Donaldson Abu Dhabi
Welding Quality Manual

DONALDSON/WQM/01 Rev 00

Issue Date: March 19th 2021 Prepared by: Deepu Mohan

Revision Date March 19th 2021 Authorized by: Steve Dodd

10.5 Procedures for preparation and control of documents...........................................................11

11.0 Welding consumables........................................................................11

11.1 Batch testing............................................................................................................................11

12.0 Storage of parent materials................................................................11

13.0 Post-weld heat treatment (PWHT)........................................................12

14.0 Inspection and testing.......................................................................12

14.1 General....................................................................................................................................12
14.2 Inspection and test status........................................................................................................12

15.0 Non-conformance and corrective actions................................................12

16.0 Calibration and validation of measuring, inspection and test equipment...........13

17.0 Identification and traceability.............................................................13

18.0 Quality records............................................................................... 13

Attachment 1 Company Structure Organization

Charts Attachment 2 Welding Coordinator

Chart
 Donaldson Abu Dhabi
Welding Quality Manual

DONALDSON/WQM/01 Rev 00

Issue Date: March 19th 2021 Prepared by: Deepu Mohan

Revision Date March 19th 2021 Authorized by: Steve Dodd

1.0 Scope
Scope of this Manual to establish and execute the Performance in comply with the ISO 3834-2
and to meet the requirement of CE certification norms, this document shall be read in
conjunction with Donaldson (DONALDSON) Quality Manual [DONALDSON-QM-01], System
procedures and Work Instructions.

Authorized location
This Manual describes the Quality Management System of DONALDSON at following
locations, in compliance with ISO 3834-2.
Donaldson Filtration
Sharjah P.O Box 32478 UNITED ARAB EMIRATES
Company Location-1

This Manual satisfies the requirement of the ISO3834-2 standard. DONALDSON Welding
Quality Manual specifies requirements for the execution of structural steel work as structures or
as manufactured components, produced from material grade groups ranging from 1.1 to 3.2 as
per ISO 15608;

2.0 Normative references

The following documents are referred to in the text in such a way that some or all of their
content constitutes requirements of this manual. 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 3834-2, Quality requirements for fusion welding of metallic materials — Part 2:
Comprehensive quality requirements

ISO 3834-5, 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
ISO3834-2, ISO 3834-3 or ISO 3834-4
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Welding Quality Manual

DONALDSON/WQM/01 Rev 00

Issue Date: March 19th 2021 Prepared by: Deepu Mohan

Revision Date March 19th 2021 Authorized by: Steve Dodd

ISO 3834-6, Quality requirements for fusion welding of metallic materials — Part 6: Guidelines
on implementing ISO 3834

3.0 Terms and definitions

For the purposes of this manual, the terms and definitions given in ISO 3834-1 apply.

4.0 Use of this document

For general information on the use of this manual, ISO 3834-1 shall be used.

In order to fulfil the quality requirements given in this manual, the conformity to relevant
standards & 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 manual may be selectively amended or deleted.

Otherwise, the requirements contained within this manual shall be adopted in full.

5.0 Review of requirements and technical review

5.1 General
DONALDSON shall review the contractual requirements and any other requirements, together
with any technical data provided by the customer / client or in-house data when the construction
is designed by DONALDSON. DONALDSON shall establish that all information necessary to
carry out the manufacturing operations is complete and available prior to the commencement of
the work. DONALDSON shall affirm its capability to meet all requirements and shall ensure
adequate planning of all quality-related activities.

As per DONALDSON Engineering procedure no. Design Review - ENG 041 GTS, Rev-1 the
review of requirements is carried out by DONALDSON to verify with respective to that:

 the work content is within its capability to perform,

 sufficient resources are available to achieve delivery schedules, and
 documentation is clear and unambiguous.
Items in 5.2 are typically considered at or before the time of the review of requirements. Items in
5.3 usually from part of the technical review and are considered during the quotation review.
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Welding Quality Manual

DONALDSON/WQM/01 Rev 00

Issue Date: March 19th 2021 Prepared by: Deepu Mohan

Revision Date March 19th 2021 Authorized by: Steve Dodd

When a contract does not exist, e.g., items made for stock, the manufacturer is required to take
into consideration the requirements of 5.2 while carrying out the technical review (see 5.3).

5.2 Review of requirements

The following aspects shall be considered:

 the product standard to be used, together with any supplementary requirements.

 statutory and regulatory requirements.

 any additional requirement determined by DONALDSON.

 the capability of DONALDSON to meet the prescribed requirements.

5.3 Technical review

The following technical requirements shall be considered:

 Parent material (s) specification and welded joint properties

 Quality and acceptance requirements for welds;
 Location, accessibility and sequence of welds, including accessibility for inspection and
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;
 The qualification of personnel;
 Selection, identification and/or traceability (e.g., for materials, welds);
 Quality-control arrangements, including any involvement of an independent inspection
body;
 Inspection and testing;
 Sub-contracting;
 Post-weld heat treatment;
 Other welding requirements, e.g., batch testing of consumables, ferrite content of weld
metal, ageing, hydrogen content, permanent backing, use of peening, surface finish,
weld profile;
 Use of special methods (e.g., to achieve full penetration without backing when welded
from one side only);
 Dimensions and details of joint preparation and completed weld;
 Welds which are to be made in the workshop, or elsewhere;
 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);
 Handling of non-conformances.
 Donaldson Abu Dhabi
Welding Quality Manual

DONALDSON/WQM/01 Rev 00

Issue Date: March 19th 2021 Prepared by: Deepu Mohan

Revision Date March 19th 2021 Authorized by: Steve Dodd

6.0 Sub-contracting
When DONALDSON intends to use sub-contract services or activities (e.g., Inspection, non-
destructive testing, heat treatment), information necessary to meet applicable requirements
shall be supplied by DONALDSON to the sub- contractor. The sub-contractor shall provide such
records and documentation of her/his work as can be specified by DONALDSON.

A sub-contractor shall work under the order and responsibility of DONALDSON and shall fully
comply with the relevant requirements of this document. DONALDSON shall ensure that the
sub- contractor can comply with the quality requirements as specified.

The information to be provided by DONALDSON to the sub-contractor shall include all relevant
data from the review of requirements (see 5.2) and the technical review (see 5.3). Additional
requirements may be specified as necessary to assure sub-contractor compliance with
technical requirements.

Sub-contractor shall be selected based on the DONALDSON Engineering procedure no.

Identification of potential Subcontractors and Strategic Suppliers ENG 037 GTS, Rev-0 which
is the Procedure for managing supplier and purchase.

7.0 Welding personnel

7.1 General
DONALDSON shall have at her/his disposal sufficient and competent personnel for the
planning, performing and supervising of the welding production according to specified
requirements.

7.2 Welders and welding operators

Welders and welding operators shall be qualified as per ISO 9606-1 For MMAW (111), FCAW
(136) and as per ISO 14732 for SAW (121) welding processes.

7.3 Welding coordination personnel

DONALDSON shall have at her/his disposal appropriate welding coordination personnel. Such
people having responsibility for quality activities shall have sufficient authority to enable any
necessary action to be taken. The tasks and responsibilities of such persons shall be clearly
defined in the Welding coordinator responsibility matrix – Doc. No. DONALDSON. Either one of
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Welding Quality Manual

DONALDSON/WQM/01 Rev 00

Issue Date: March 19th 2021 Prepared by: Deepu Mohan

Revision Date March 19th 2021 Authorized by: Steve Dodd

the Welding Coordination personnel shall be qualified as per ISO 14731.

8.0 Inspection and testing personnel

8.1 General
DONALDSON shall have at her/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 as per ISO 9712 or PCN. For visual
testing, a qualification test is not required. Competence of such visual NDE personnel shall be
verified by DONALDSON.

9.0 Equipment
9.1 Production and test equipment
The following equipment shall be available, when necessary:

 Power sources and other machines;

 Equipment for joint and surface preparation and for cutting, including thermal cutting;
 Equipment for preheating and post-weld heat treatment including temperature indicator;
 Jigs and fixtures;
 Cranes and handling equipment used for the production;
 Personal protective equipment and other safety equipment, directly associated with the
applicable manufacturing process;
 Ovens, quivers used for treatment of welding consumables;
 Facilities for surface cleaning;
 Facilities for destructive and non-destructive testing.

9.2 Description of production equipment

DONALDSON is maintaining a list of machineries as per DONALDSON Maintenance
procedures DMEF MAT 001, Rev-3 with capacities used for the production. This list shall identify
items of major equipment, essential for an evaluation of workshop capacity and capability. This
includes:

 Maximum capacity of crane(s);

 Size of components that the workshop can handle;
 Capability of mechanized or automatic welding equipment;
 Capacities of rolling, bending and cutting equipment.
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Welding Quality Manual

DONALDSON/WQM/01 Rev 00

Issue Date: March 19th 2021 Prepared by: Deepu Mohan

Revision Date March 19th 2021 Authorized by: Steve Dodd

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 shall be adequate for the application concerned.

NOTE Qualification of the welding and heating equipment is not normally required unless
otherwise specified.

9.4 New equipment

After installation of new (or refurbished) equipment, operational tests of the equipment shall be
performed. The tests shall verify the correct function of the equipment. The tests shall be carried
out and once performance is found satisfactory equipment identification will be provided and will
be listed.
9.5 Maintenance of equipment
DONALDSON have documented preventive maintenance procedure DONALDSON
Maintenance DMEF MAT 001, Rev-3 for equipment. Preventive maintenance plan shall ensure
maintenance checks as per preventive maintenance record (DONALDSON balance form) for
items listed in the form DONALDSON. The plans are limited to those items which are essential
for assuring the quality of the product.

Defective equipment shall be identified with REPAIR or NOT IN USE tag and isolated such that
it will not be used.

10.0 Welding and related activities

10.1 Production planning
DONALDSON shall carry out adequate production planning before start of the project by
conducting a tool box talk in shop floor to detail the project / client requirements in terms of the
following items:

 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).
 Identification of the individual processes required to the construction.
 Reference to the appropriate procedure specifications for welding and allied processes.
 Sequence in which the welds are to be made.
 Order and timing in which the individual processes are to be performed.
 Specification for inspection and testing, including the involvement of any independent
inspection body.
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Welding Quality Manual

DONALDSON/WQM/01 Rev 00

Issue Date: March 19th 2021 Prepared by: Deepu Mohan

Revision Date March 19th 2021 Authorized by: Steve Dodd

 Environmental conditions (e.g., protection from wind and rain).

 Identification by batches, components or parts, as appropriate.
 Allocation of qualified personnel.
 Arrangement for any production test.

10.2 Welding procedure specifications

DONALDSON shall prepare the welding procedure specification(s) as per ISO 15609-1 and
ensure that they are used correctly in production.

10.3 Qualification of the welding procedures

Welding procedures need to be qualified prior to production. The method of qualification shall be
in accordance with the applicable series of ISO 15614.
NOTE Qualification of other procedures can be required in the relevant product standards and/or
the specification(s).
10.4 Work instructions
DONALDSON will 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 if required and do not require
separate qualification.

10.5 Procedures for preparation and control of documents

DONALDSON has established and maintain for the preparation and control of relevant quality
documents refer document number DONALDSON Cooperate procedures Document Control
CORP GEN 001, Rev-1 (e.g., welding procedure specification, welding procedure qualification
record, welders and welding operator’s qualification documents)

11.0 Welding consumables

DONALDSON has established and maintain procedure for welding consumables storage and
handling in procedure number DONALDSON Welding Consumable Control DNAD STORE 004,
Rev-0 .

11.1 Batch testing

Batch testing of welding consumables shall be performed only if specified or required.
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Welding Quality Manual

DONALDSON/WQM/01 Rev 00

Issue Date: March 19th 2021 Prepared by: Deepu Mohan

Revision Date March 19th 2021 Authorized by: Steve Dodd

12.0 Storage of parent materials

Parent materials will be stored in the designated storage areas like CS Material Storage, SS/AL
Material Storage and stores. Customer property will be handled as per the procedure number
DONALDSON Material Storage Control DNAD STORE 003, Rev-5.

13.0 Post-weld heat treatment (PWHT)

Whenever required by Client / Customer specification / Code, DONALDSON shall be fully
responsible for the specification and the performance of any post-weld heat treatment.
DONALDSON shall sub contract the PWHT process to approved subcontractor. The procedure
compatibility with the parent material, welded joint, construction will be reviewed by Internal
Welding Coordinator. It shall be in accordance with the product standard and/or specified
requirements. A record of the heat treatment shall be kept during the process. The report shall
demonstrate that the specification has been followed and shall be traceable to the particular
product.

14.0 Inspection and testing

14.1 General
If no specific requirement or Inspection and Test Plan (ITP) provided from customer / Client
DONALDSON does inspection as per procedure DONALDSON Quality Inspection DNAD QUAL
004, Rev-0 PROCEDURE FOR INSPECTION AND TESTING.

Applicable inspections and tests shall be defined and followed as per ITP in the manufacturing
process to ensure conformity with contract requirements. Location and frequency of such
inspections and/or tests depend on the ITP and/or product standard, the welding process and
the type of construction (see 5.2 and 5.3).

DONALDSON may carry out additional tests without restriction. Reporting of such tests is not
required.
14.2 Inspection and test status
DONALDSON follows by marking on the item to indicate the status of inspection and test of the
welded construction.
 Donaldson Abu Dhabi
Welding Quality Manual

DONALDSON/WQM/01 Rev 00

Issue Date: March 19th 2021 Prepared by: Deepu Mohan

Revision Date March 19th 2021 Authorized by: Steve Dodd

15.0 Non-conformance and corrective actions

Measures shall be implemented to control items or activities which do not conform to specified
requirements in order to prevent their inadvertent acceptance. Refer DONALDSON Control of
Non-Conforming Product & Services procedure DONALDSON- Control of Non-Conforming
Product CORP QUAL 003, Rev-10 is available at all workstations where repair or rectification is
performed. When repair is carried out, the items shall be re-inspected and re-tested in
accordance with the original requirements. Measures shall also be implemented to avoid
recurrence of non-conformances.

16.0 Calibration and validation of measuring, inspection and test

equipment
DONALDSON does calibration or validation of measuring, inspection or test equipment as
specified in ISO 17662. All measuring, inspection and test equipment used to assess the quality
of the constructions shall be suitably controlled and calibrated or validated at one-year interval.

DONALDSON prepared and maintains a Master List of Measuring Instrument & Calibration
Record DONALDSON Quality Procedure for Calibration DNAD QUAL 002, Rev-0 and same will
be reviewed monthly once.

Compliance with the welding procedure specification is verified by using validated measuring,
inspection and test equipment.

17.0 Identification and traceability

DONALDSON will follow Identification and traceability by DONALDSON Quality procedures
Incoming Material Inspection DNAD QUAL 001, Rev-1, Control of Material Certificates DNAD
QUAL 003, Rev-1 maintained throughout the manufacturing process.

18.0 Quality records

Quality records shall include, when applicable:

 Record of requirement/technical review;

 Material inspection documents;
 Welding consumable inspection documents;
 Welding procedure specifications;
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Welding Quality Manual

DONALDSON/WQM/01 Rev 00

Issue Date: March 19th 2021 Prepared by: Deepu Mohan

Revision Date March 19th 2021 Authorized by: Steve Dodd

 Equipment maintenance records;

 Welding procedure qualification records (WPQR);
 Welder or welding operator qualification documents;
 Production plan;
 Non-destructive testing personnel documents;
 Heat treatment procedure specification and records;
 Non-destructive testing and destructive testing procedures and reports;
 Dimensional reports;
 Records of repairs and non-conformance reports;
 Other documents, if required Quality records is retained for a period of five years in the
absence of any other specified requirements.