Quality Control Procedure For Welding Consumables

Control

A
REV.

DATE

ORIGINATOR

REVIEWED

APPROVED

DESCRIPTION

CONTRACTOR:
SUB CONTRACTOR :

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ORIGINATOR No.

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TABLE OF CONTENTS
1

Purpose..

Scope ....

References..................

Definitions / Abbreviations......

Responsibilities.....

Methodology.

Quality Control Requirements........

HSE Requirements...

Resources. ...

10 Attachments..

DOCUMENT TITLE:
Quality Control Procedure For Welding Consumables
Control

ORIGINATOR No.

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Date :

1. PURPOSE
The purpose of this procedure is to provide guidelines for the handling and storage of
welding filler metals, electrodes and other consumables & accessories to be used at site/shop
facilities for welding activities.
2. SCOPE
This Procedure describes the minimum requirement 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 and erection.
3. REFERENCES

ASME B31.3:
ASME Section II Part C
Project Specifications

4. DEFINITIONS/ ABBREVATIONS
Verification
Monitor
Approval
PM
CM
PQI
WI
QMS
CS
SS
HSE
TRA
MS
QA
PPE
PTW
TSF
RFI
WPS
PQR
WPQ
UT
WPS

: Process of cross checking on sample basis by

: Process of random checking that specified parameters are adhered
: Acceptance / clearance for further action and generally
: Project Manager
: Construction Manager
: Project Quality Incharge
: Welding Inspector
: Quality Management System
: Carbon Steel
: Stainless Steel
: Healthy, Safety, and Environment
: Task Risk Assessment
: Method Statement
: Quality Assurance
: Personal Protective Equipment
: Permit to Work
: Temporary Site Facility
: Request for Inspection
: Welding Procedure Specification
: Procedure Qualification Record
: Welder Performance Qualification
: Ultrasonic Testing
: Welding procedure Specification

DOCUMENT TITLE:
Quality Control Procedure For Welding Consumables
Control

ORIGINATOR No.

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5. RESPONSIBILTIES
Project / Construction Manager:
He is responsible for the arrangement of necessary
equipment, area for storage and ensuring that procedure is implemented.
Storage Incharge/ Store Keeper: His duty includes the following:
Verify the batch/Lot Nos. of the consumables received with the batch/ Lot certificates.
Inspect the incoming welding consumable received with regard to type, size, quantities and
any visible damage and sign off delivery note from supplier/ procurement department.
Offer the QA/QC to inspect the consumables.
Stores the consumables passed by QA/QC in the store.
Store the various consumables in store with proper Identified and clean areas.
Before Issuance of Low hydrogen electrode bake properly as per Manufacturer
recommendations
Register welding electrodes baking details on welding Consumables baking register
Issuance of electrode to welder through Consumable Issuance request
Segregate the collected unused electrode at the end of shift and re-baking.
Ensure that the re-baked electrodes are issued prior to issuing electrodes baked for the first
time by storing the re-baked electrodes in separate section in the holding oven.
Maintain the calibration certificates record for baking ovens.
Site Supervisor (Welding): The site supervisor is responsible for the following:
Arrange the issuance of the correct type, size and quantity of consumables to the welders as
required.
Arrange the collection of unused electrodes at the end of each shift and return the same for
re-baking. If any of the re-baked electrodes are not used, they must be returned back for
disposal.
Ensure the welders under his control store the electrodes in heated quivers and that quivers
are in good working condition with calibrating tag.
Welding Inspector: The Welding Inspector is responsible for the following:
Inspect the incoming consumables.
Check the welding consumables are stored, treated and issued in accordance with this
procedure.
Review of MTCs for consumables.
Verify storing and welding activities.
Check the baking and holding temperatures and also check the baking ovens, holding ovens
and quivers working properly and also calibrated in routine inspection.
Inform the concerned personal for any discrepancy or deviation from the specified baking
cycle and holding temperature.
6. METHODOLOGY
6.1 Basic requirements
The following principles shall be implemented:
DOCUMENT TITLE:
Quality Control Procedure For Welding Consumables
Control

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Welding consumables shall be purchased from manufacturers operating a quality system

based on ISO 9001 or EN 12074.
Unless specified agreed by the Contractor, Welding consumables shall be manufactured to
meet the requirements of the relevant ISO/EN consumables standards (e.g. ISO 18274,
EN499, EN 756, EN 757, EN 760, EN 12070 or EN 12535), the ASME SFA 5 series or the
AWS A5 series.
Welding consumables shall be certified in accordance with EN 10204, 3.1,
Unless specifically agreed by the contractor, welding consumables shall be supplied in
accordance with ISO 14344/ ASME SFA 5.01/AWS A5.01 lot classification as follows:
1- Welding consumables shall be supplied with lot certification to ASME SFA 5.01/ AWS
A5.01 schedule H or ISO 14344 schedule 3 as a minimum.
2- For critical applications, lot certification shall also include, as a minimum weld metal
tensile, impact toughness and soundness (Volumetric Non-destructive testing
Radiography) data. Additional project specific testing may be required by the project
specification/ engineering data.
3- G type welding consumables (e.g. SMAWEXXXX-G electrodes, FCAW EXXXT-GS
wires) shall be supplied with lot certifications which includes, as a minimum weld metal
chemistry, tensile and impact toughness data.
4- Solid wires shall be supplied in accordance with requirements of lot classification Class
S3.
For carbon and ferritic steel SMAW and FCAW welding consumables, except cellulosic
SMAW electrodes, certifications shall be available from the manufacturer stating the as
deposited weld metal diffuse able hydrogen level determined in accordance with ISO 3690 or
AWS A4.3.
Welding consumables proposed for use on any given construction shall be qualified for use in
accordance with applicable relevant design codes.
The number of different welding consumables to be used on a particular fabrication or in
specific fabrication areas shall be minimized. Additionally, consumables should be used on a
lot by lot basis, a new lot only being used after supply from the initial lot has been exhausted.
Segregation of materials during fabrication;
1- Different materials (including parent metal components or materials, as well as welding
consumables) shall be segregated during fabrication.
2- Thus specific areas should be established for the fabrication of carbon steel, low alloy
steel, stainless steel, nickel alloys, copper-nickel alloys or titanium.
3- In certain instances, it may be necessary to further segregate specific grades of material
(e.g., normal grades and low temperature grades and low temperatures grades of carbon
steel and austenitic and duplex grades of stainless steel.)
If the construction specifications require positive material identification (to be used during
fabrication, deposited weld metals shall be included in the sampling routine agreed with the
company).
Measuring devices and instruments required for implementations of consumable storage and
control procedure shall be included in the list of equipment requiring regular calibration under
fabricator quality assurance procedure.

6.2 Consumables Inspection and Issuance

A flowchart for a typical consumables control procedure is showing in Fig.1.

DOCUMENT TITLE:
Quality Control Procedure For Welding Consumables
Control

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Welding consumables shall be supplied in clearly marked packing. Each SMAW electrode,
straight wire length, consumable spool shall be supplied as individually marked and identified
by the manufacturer.
Exceptionally and if specifically agreed by the Contractor, spooled solid wire consumables
may be cut into individual lengths for use with GTAW welding. In such cases, the individual
lengths of wire shall be clearly identified.
On receipt, welding consumables shall be held in a weather protected quarantine area until:
1- Compliance with the purchase order has been verified.
2- Full certifications details (including supplier, manufacturer, brand name, lot number,
quantity received and delivery date) have been recorded.
3- Certificates have been checked and filed.
4- Consumables deliveries shall be specifically examined for packing damage. Any damage
that has resulted in the perforation of vacuum or hermetically sealed packaging or has
resulted in the perforation or other damage to flux sacks shall be cause of rejection.
Storage would be as follows:
1- Following receipt and inspection, consumables should be promptly transferred to the
storage area.
2- Storage area shall be dry and heated in accordance with manufacturer recommendations.
3- Typically, the storage area should be humidity controlled (not exceeding 60% RH) and
minimum temperatures of 20 C (68 F) should be maintained.
4- The temperature within the welding consumables store should not be lower than the
ambient temperature of the fabrication shop/ site.
5- Humidity and temperature shall be recorded regularly at a minimum frequency of twice
per day.
Consumables shall be transferred to the workshop or other secondary storage areas only as
they are required for use as follows;
1- This transfer shall take place at the issuance request of the welding supervisor and full
details of each issuance shall be recorded in both of the storage areas concerned.
2- For vacuum or hermetically sealed packing, the packing shall be again inspected for
damage on receipt at the workshop or secondary storage. Damage seals shall be a
cause for rejection and the consumables shall be returned to quarantine area.
3- The temperature and humidity of secondary storage areas should be humidity controlled
(not exceeding 60% RH) and minimum temperatures of 20 C (68 F) should be
maintained.
For Cellulosic SMAW consumables, the electrodes shall not be:
1- Subjected to any drying treatment.
2- Exposed to temperature greater than 50 C (122 F) or the maximum recommended by
manufacturer.
3- Subjected to any form of uncontrolled or unapproved treatment.
If hydrogen controlled SMAW electrodes are to be used for fabrication, preference should be
given to use of vacuum packed consumables.
If vacuum packed hydrogen controlled SMAW consumables are used, the welding engineer
shall issue a procedure concerning storage and handling of the consumables and the
maximum time the consumables may be exposed to the atmosphere once the vacuum seal is
broken as follows;
1- This procedure shall be based on manufacturer recommendations and shall require the
time of opening each packet to be recorded.
2- Any consumables either exceeding the agreed exposure time or remaining at the end of
the work period shall be removed from the contractor work site; unless a specific redrying cycle has been agreed by the Contractor.
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Quality Control Procedure For Welding Consumables
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Re-drying of low-hydrogen shall be as follows;

1- Drying and elevated temperature storage (holding) shall be performed in purpose built;
thermostatically controlled ovens located within the secondary storage area. These ovens
shall be vented and have temperature indicator.
2- These ovens shall be not overloaded and individual shelves shall contain no more than
four layers of electrodes.
3- Each type and size of consumables shall be clearly marked and segregated within the
drying and storage (holding) ovens.
4- Contents of each oven shall be clearly marked on the outside of the oven door.
5- Procedure for SMAW electrodes baking and issue shall include the requirement to record
the time and temperature spent in baking / holding ovens.
6- SMAW electrodes should not be subject to more than two baking and holding cycles.
7- The maximum time for SMAW electrodes spend in the holding oven should not exceed 7
days.
8- If electric power outages to the baking / holding oven exceed 2 hr, the electrodes shall
either be;
a. Re- back if it was first baking cycle, or
b. Scraped , if this was the second baking cycles
A recording system shall be in place, which records the welding consumables issued to
welders based on production of a requisition endorsed by the fabrication and welding
supervisory staff on at least daily basis. The recording system shall list full details of the job,
including application, designated WPS and joint number (if appropriate), consumable type
and quantity required for the work period (i.e., one shift maximum) as follows;
1- Cellulosic and other non-hydrogen controlled SMAW electrodes shall be issued in
manufacturer packing or in a dry and appropriately labeled quiver.
2- Vacuum packed SMAW hydrogen controlled electrodes shall be issued in manufacture
packing or in a dry and appropriately labeled quiver.
3- Dried SMAW hydrogen controlled electrodes shall be issued in quivers heated to and
subsequently maintained at 70 C to 100 C (158 F to 212 F). The quivers shall be
appropriately labeled.
4- GTAW welding wire should be issued in either the manufacturer container or in an
appropriately labeled tabular plastic container.
Consumables for one welding procedure shall only be issued to a welder or welding operator
at any given time, and a record of consumables issued shall be maintained at the point of
issue.
Welding Consumables remaining at the end of a work period shall be returned to the store
and treated as follows;
1- Returns shall be recorded and shelves.
2- SMAW electrodes which are in good condition shall be paint marked at the stub end prior
reissue. These electrodes shall be issued first before the issuance of new electrodes.
3- Re-drying of SMAW electrodes shall be in accordance with manufacturer
recommendations prior to re-issue. These electrodes shall be issued first before the
issuance of new electrodes.
4- Hydrogen controlled SMAW electrodes shall not be re-dried, unless a specific re-drying
cycle has been agreed by the Contractor responsible engineer.
5- Returned SMAW electrodes that have previously been subjected to two baking/drying
cycles shall be scrapped.
Spooled welding consumables shall be returned to the store upon completion of the job for
which they were issued. Unless directed otherwise by manufacturer recommendations,
DOCUMENT TITLE:
Quality Control Procedure For Welding Consumables
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consumables shall also be returned to the store if the welding equipment will stand idle for
more than 12 hr.
Any Unidentified, contaminated, or otherwise damaged consumables, including those
suspected of being damp, that are found in any storage or fabrication area shall be
immediately transfer to quarantine area and properly labeled under control of the welding
supervisor.

7. QUALITY CONTROL REQUIREMENTS

Inspection of all Welding Consumables handling, storage and issuance activities will be carried
out as per this procedure.
8. HSE REQUIREMENTS

HIRA (Hazard Identification & Risk Assessment) shall be implemented.

All personnel involved will use necessary PPE as required.
Work permit shall be obtained prior to any work being carried out and shall commence in
accordance with specification measure itemized on permit.
Safety notice board will be installed.
All equipment will be inspected by HSE prior to use, on safety aspects.
Access and good housekeeping should be maintained at site.
Proper storage, handling and use of gas cylinders will be observed.
All cylinders shall be kept in trolleys and in an upright position.
Welding sets should be checked and maintained regularly for wear and tear.
Waste Management procedure shall be strictly followed to keep the job site neat and clean.

9. RESOURCES

Calibrated baking and holding ovens/quivers shall be used for Low hydrogen Electrodes at
shop/site facilities.
Shielding Gas cylinders must be in proper working conditions.

10. ATTACHEMENTS

Welding Consumable Baking register (Document No. MF/F-047).

Welding Consumable Return register (Document No. MF/F-033).
ESAB Handbook for storage & Handling recommendations for Consumables.
Treatment Welding Consumables (Figure-1).

DOCUMENT TITLE:
Quality Control Procedure For Welding Consumables
Control

ORIGINATOR No.

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Rev A

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DOCUMENT TITLE:
Quality Control Procedure For Welding Consumables
Control

ORIGINATOR No.

DOC. NO.
PAGE : 9 of 9
Rev A

Date :