QCP For Control of Welding Consumables
QCP For Control of Welding Consumables
QCP For Control of Welding Consumables
Control
A
REV.
DATE
ORIGINATOR
REVIEWED
APPROVED
DESCRIPTION
CONTRACTOR:
SUB CONTRACTOR :
DOC. No :
ORIGINATOR No.
PAGE : 1 of 9
Rev. A
Date :
TABLE OF CONTENTS
1
Purpose..
Scope ....
References..................
Definitions / Abbreviations......
Responsibilities.....
Methodology.
HSE Requirements...
Resources. ...
10 Attachments..
DOCUMENT TITLE:
Quality Control Procedure For Welding Consumables
Control
ORIGINATOR No.
DOC. NO.
PAGE : 2 of 9
Rev A
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
DOCUMENT TITLE:
Quality Control Procedure For Welding Consumables
Control
ORIGINATOR No.
DOC. NO.
PAGE : 3 of 9
Rev A
Date :
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
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 : 5 of 9
Rev A
Date :
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.
DOCUMENT TITLE:
Quality Control Procedure For Welding Consumables
Control
ORIGINATOR No.
DOC. NO.
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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.
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
DOCUMENT TITLE:
Quality Control Procedure For Welding Consumables
Control
ORIGINATOR No.
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Rev A
Date :
DOCUMENT TITLE:
Quality Control Procedure For Welding Consumables
Control
ORIGINATOR No.
DOC. NO.
PAGE : 9 of 9
Rev A
Date :