Quality Control Procedure For Welding ConsumablesControlAREV. DATEORIGINATOR REVIEWEDAPPROVED DESCRIPTIONCONTRACTOR: SUB CONTRACTOR : DOC. No :PAG : 1of9OR!G!NATOR No.Re". A Date : TA#$ OF CONTNT% & Pur'ose(((((.((((((((((((((((((((((.((((((( )

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6 Resources((((((((. (.(((((((((((((((((((((((.. 4&7 Attac1ments((((((((((((((((((((((((((((((((.. 4DOC80NT T!T$: Quality Control Procedure For Welding ConsumablesControlDOC. NO. PAG :2of9OR!G!NATOR No.Re" A Date : 1. PURPOSET1e'ur'oseo+t1is'rocedureisto'ro"ideguidelines+ort1e1andlingandstorageo+9elding+illermetals:electrodesandot1erconsumables ;accessoriestobeusedatsite-s1o'+acilities +or 9elding acti"ities.2. SCOPET1isProceduredescribest1eminimumre3uirement tobecom'lied9it1+or recei't: storage:issue: 1andling and treatment o+ 9elding consumables 'rior to use in order to ensure acce'table9eld 3uality during +abrication and erection.3. REFERENCES A%0 #)&.): A%0 %ection !! Part C Proing t1at s'eci+ied 'arameters are ad1ered A''ro"al: Acce'tance - clearance +or +urt1er action and generallyP0 : ProT%F : Tem'orary %ite FacilityRF! : Re3uest +or !ns'ectionWP% : Welding Procedure %'eci+icationPQR : Procedure Quali+ication RecordWPQ : Welder Per+ormance Quali+ication8T : 8ltrasonic TestingWP%: Welding 'rocedure %'eci+icationDOC80NT T!T$: Quality Control Procedure For Welding ConsumablesControlDOC. NO. PAG :3of9OR!G!NATOR No.Re" A Date : 5. RESPONSIBILTIESPro!"# / Co$%#r&"#'o$ ()$)*!r:5e is res'onsible +or t1e arrangement o+ necessarye3ui'ment: area +or storage and ensuring t1at 'rocedure is im'lemented.S#or)*! I$"+)r*!/ S#or! ,!!-!r: 5is duty includes t1e +ollo9ing: =eri+y t1e batc1-$ot Nos. o+ t1e consumables recei"ed 9it1 t1e batc1- $ot certi+icates. !ns'ect t1e incoming 9elding consumable recei"ed 9it1 regard to ty'e: si?e: 3uantities and any "isible damage and sign o++ deli"ery note +rom su''lier- 'rocurement de'artment. O++er t1e QA-QC to ins'ect t1e consumables. %tores t1e consumables 'assed by QA-QC in t1e store. %tore t1e "arious consumables in store 9it1 'ro'er !denti+ied and clean areas. #e+ore !ssuance o+ $o9 1ydrogen electrode ba>e 'ro'erly as 'er 0anu+acturer recommendations Register 9elding electrodes ba>ing details on 9elding Consumables ba>ing register !ssuance o+ electrode to 9elder t1roug1 @Consumable !ssuance re3uestA %egregate t1e collected unused electrode at t1e end o+ s1i+t and reBba>ing. nsure t1at t1e reBba>ed electrodes are issued 'rior to issuing electrodes ba>ed +or t1e +irst time by storing t1e reBba>ed electrodes in se'arate section in t1e 1olding o"en. 0aintain t1e calibration certi+icates record +or ba>ing o"ens. S'#! S&-!r.'%or /W!01'$*2: T1e site su'er"isor is res'onsible +or t1e +ollo9ing: Arrange t1e issuance o+ t1e correct ty'e: si?e and 3uantity o+ consumables to t1e 9elders as re3uired. Arrange t1e collection o+ unused electrodes at t1e end o+ eac1 s1i+t and return t1e same +or reBba>ing. !+ any o+ t1e reBba>ed electrodes are not used: t1ey must be returned bac> +or dis'osal. nsure t1e 9elders under 1is control store t1e electrodes in 1eated 3ui"ers and t1at 3ui"ers are in good 9or>ing condition 9it1 calibrating tag.W!01'$* I$%-!"#or: T1e Welding !ns'ector is res'onsible +or t1e +ollo9ing: !ns'ect t1e incoming consumables. C1ec> t1e 9elding consumables are stored: treated and issued in accordance 9it1 t1is 'rocedure. Re"ie9 o+ 0TCs +or consumables. =eri+y storing and 9elding acti"ities. C1ec> t1e ba>ing and 1olding tem'eratures and also c1ec> t1e ba>ing o"ens: 1olding o"ens and 3ui"ers 9or>ing 'ro'erly and also calibrated in routine ins'ection. !n+orm t1e concerned 'ersonal +or any discre'ancy or de"iation +rom t1e s'eci+ied ba>ing cycle and 1olding tem'erature.3. (ET4ODOLOG53.1B)%'" r!6&'r!7!$#% T1e +ollo9ing 'rinci'les s1all be im'lemented:DOC80NT T!T$: Quality Control Procedure For Welding ConsumablesControlDOC. NO. PAG :4of9OR!G!NATOR No.Re" A Date : Weldingconsumabless1all be'urc1ased+rommanu+acturerso'eratinga3ualitysystembased on !%O 677& or N &*72,. 8nless s'eci+ied agreed by t1e Contractor: Welding consumables s1all be manu+actured tomeet t1ere3uirementso+ t1erele"ant !%O-NconsumablesstandardsCe.g. !%O&4*2,:N,66: N 2./: N 2.2: N 2/7: N &*727 or N &*.).D: t1e A%0 %FA . series or t1eAW% A. series. Welding consumables s1all be certi+ied in accordance 9it1 N &7*7,: ).&: 8nlesss'eci+icallyagreedbyt1econtractor: 9eldingconsumabless1all besu''liedinaccordance 9it1 !%O &,),,- A%0 %FA ..7&-AW% A..7& lot classi+ication as +ollo9s:&B Weldingconsumabless1all besu''lied9it1lot certi+icationto A%0%FA ..7&-AW%A..7& sc1edule 5 or !%O &,),, sc1edule ) as a minimum.*B For critical a''lications: lot certi+ications1all alsoinclude: asaminimum9eldmetaltensile: im'act toug1ness and soundness C=olumetric NonBdestructi"e testingRadiogra'1yD data. Additional 'roing. ac1 %0AW electrode:straig1t 9ire lengt1: consumable s'ool s1all be su''lied as indi"idually mar>ed and identi+iedby t1e manu+acturer. Fce'tionally and i+ s'eci+ically agreed by t1e Contractor:s'ooled solid 9ire consumablesmay be cut into indi"idual lengt1s +or use 9it1 GTAW 9elding. !n suc1 cases: t1e indi"iduallengt1s o+ 9ire s1all be clearly identi+ied. On recei't: 9elding consumables s1all be 1eld in a 9eat1er 'rotected 3uarantine area until:&B Com'liance 9it1 t1e 'urc1ase order 1as been "eri+ied.*B Full certi+ications details Cincluding su''lier: manu+acturer: brand name: lot number:3uantity recei"ed and deli"ery dateD 1a"e been recorded.)B Certi+icates 1a"e been c1ec>ed and +iled.,B Consumables deli"eries s1all be s'eci+ically eFamined +or 'ac>ing damage. Any damaget1at 1as resulted in t1e 'er+oration o+ "acuum or 1ermetically sealed 'ac>aging or 1asresulted in t1e 'er+oration or ot1er damage to +luF sac>s s1all be cause o+ ree 'lace at t1e issuance re3uest o+ t1e 9elding su'er"isor and +ulldetails o+ eac1 issuance s1all be recorded in bot1 o+ t1e storage areas concerned.*B For "acuumor 1ermeticallysealed'ac>ing: t1e'ac>ings1all beagainins'ected+ordamageonrecei't at t1e9or>s1o'or secondarystorage. Damagesealss1all beacause +or resiteG unlessas'eci+icreBdrying cycle 1as been agreed by t1e Contractor.DOC80NT T!T$: Quality Control Procedure For Welding ConsumablesControlDOC. NO. PAG :3of9OR!G!NATOR No.Re" A Date : ReBdrying o+ lo9B1ydrogen s1all be as +ollo9sG&B Drying and ele"ated tem'erature storage C1oldingD s1allbe 'er+ormed in 'ur'ose builtGt1ermostatically controlled o"ens located 9it1in t1e secondary storage area. T1ese o"enss1all be "ented and 1a"e tem'erature indicator.*B T1ese o"ens s1all be not o"erloaded and indi"idual s1el"es s1all contain no more t1an+our layers o+ electrodes.)B ac1 ty'e and si?e o+ consumables s1allbe clearly mar>ed and segregated 9it1in t1edrying and storage C1oldingD o"ens.,B Contents o+ eac1 o"en s1all be clearly mar>ed on t1e outside o+ t1e o"en door..B Procedure +or %0AW electrodes ba>ing and issue s1all include t1e re3uirement to recordt1e time and tem'erature s'ent in ba>ing - 1olding o"ens./B %0AW electrodes s1ould not be subing and 1olding cycles.2B T1e maFimum time +or %0AW electrodes s'end in t1e 1olding o"en s1ould not eFceed 2days.4B !+ electric 'o9er outages to t1e ba>ing - 1olding o"en eFceed * 1r: t1e electrodes s1alleit1erbeGa. ReB bac> i+ it 9as +irst ba>ing cycle: orb. %cra'ed : i+ t1is 9as t1e second ba>ing cycles A recordingsystems1all bein'lace: 91ic1recordst1e9eldingconsumablesissuedto9elders basedon'roductiono+ are3uisition endorsedby t1e+abrication and9eldingsu'er"isory sta++ on at least daily basis. T1e recording system s1all list +ull details o+ t1e ing or in a dry and a''ro'riately labeled 3ui"er.*B =acuum 'ac>ed %0AW1ydrogen controlled electrodes s1allbeissuedin manu+acture'ac>ing or in a dry and a''ro'riately labeled 3ui"er.)B Dried%0AW1ydrogencontrolledelectrodess1all beissuedin3ui"ers1eatedtoandsubse3uentlymaintainedat27 ICto &77ICC&.4IFto*&* IFD. T1e3ui"ers s1allbea''ro'riately labeled.,B GTAW9elding9ires1ouldbeissuedineit1er t1emanu+acturer container or inana''ro'riately labeled tabular 'lastic container. Consumables +or one 9elding 'rocedure s1all only be issued to a 9elder or 9elding o'eratorat any gi"en time: and a record o+ consumables issued s1allbe maintained at t1e 'oint o+issue. Welding Consumables remaining at t1e end o+ a 9or> 'eriod s1all be returned to t1e storeand treated as +ollo9sG&B Returns s1all be recorded and s1el"es.*B %0AW electrodes 91ic1 are in good condition s1all be 'aint mar>ed at t1e stub end 'riorreissue. T1ese electrodes s1all be issued +irst be+ore t1e issuance o+ ne9 electrodes.)B ReBdrying o+ %0AW electrodes s1all be in accordance 9it1 manu+acturerrecommendations'rior toreBissue. T1eseelectrodess1all beissued+irst be+oret1eissuance o+ ne9 electrodes.,B 5ydrogen controlled %0AW electrodes s1all not be reBdried: unless a s'eci+ic reBdryingcycle 1as been agreed by t1e Contractor res'onsible engineer..B Returned%0AWelectrodest1at 1a"e're"iouslybeensubing-dryingcycles s1all be scra''ed. %'ooled 9elding consumables s1all be returned to t1e store u'on com'letion o+ t1e ed and maintained regularly +or 9ear and tear. Waste 0anagement 'rocedure s1all be strictly +ollo9ed to >ee' t1e ing and 1olding o"ens-3ui"ers s1all be used +or $o9 1ydrogen lectrodes ats1o'-site +acilities. %1ielding Gas cylinders must be in 'ro'er 9or>ing conditions.1ing register CDocument No. 0F-FB7,2D. Welding Consumable Return register CDocument No. 0F-FB7))D. %A# 5andboo> +or storage ; 5andling recommendations +or Consumables. Treatment Welding Consumables CFigureB&D.DOC80NT T!T$: Quality Control Procedure For Welding ConsumablesControlDOC. NO. PAG :;of9OR!G!NATOR No.Re" A Date : DOC80NT T!T$: Quality Control Procedure For Welding ConsumablesControlDOC. NO. PAG :9of9OR!G!NATOR No.Re" A Date :