WELDING CONSUMABLES CONTROL

PROCEDURE

Prepared By Approved By Reviewed & Accepted By

Welding Engineer QCE Client / AI
Name

Sign

Date
 REVISION RECORD SHEET

Rev. No. Date Procedure Clause No Description of Revision Remarks

Revised-To indicate test

pressure, attachment of
Clause 5.4.1,5.4.3 pressure gauge to vessel
1 03.06.2014
and 5.7.2 and pressure to be
maintained during visual
inspection.

Revised Para 3.0 Indicate

2 25.04.2017 Clause 3.0
Code Edition

3 25.01.2018 Clause 3.0 Revised Code Edition

Clause 5.1.1, 5.3.1, Revised Procurement, Storage

5.3.2, 5.5.3, 5.5.1 and & Handling and Issue of
5.5.2 Electrodes/ Filler Matels

Clause 5.4, 5.9 and

Deleted
5.10

S.No CONTENTS Page

: No
1.0 PURPOSE 4
2.0 SCOPE 4
3.0 REFERENCES 4
4.0 ABBREVIATIONS 4
5.0 PROCEDURE 4
5.1 Procurement 4
5.2 Receiving Inspection 5
5.3 Storage & Handling 5
5.4 Electrodes 6
5.5 Issue of Electrodes/Filler Metals 6
5.6 Returned Electrodes/Filler Metals 6
5.7 Responsibility 7
5.8 Calibration 7
6.0 ATTACHMENTS 7
1.0 PURPOSE
The purpose of this procedure is to specify the minimum requirements for the
control of filler metals (welding consumables) while procuring, receipt, storage,
baking, holding and issuance.

2.0 SCOPE
This procedure is concerned for Control of Welding Consumable as applicable to
the Fabrication of Pressure Equipments/Parts as per ASME Code requirements.

3.0 REFERENCES
3.1 ASME Section VIII, Div.I of 2019
3.2 ASME Section II Part A, C and Section V of Edition 2019
3.3 Customer/ Project Specification
3.4 QCM - Quality Control Manual, (Latest Revision)

4.0 ABBREVIATIONS
BOM - Bill of Material
TDC - Technical Delivery Condition
QCM - Quality Control Manual - ASME
MRIR - Material Receiving Inspection Report

5.0 PROCEDURE
5.1 Procurement

5.1.1 Production Engineer shall prepares Material Requisition (QCM/F/06) for the
welding consumables mentioning the brand name, ASME/AWS specification, size,
quantity and requirement of batch certificates and sent to Purchase Manager for
verification of stock availability. Updated MR will be sent for MD approval for
further procurement.
5.1.2 Approved Material Requisition will be forwarded to QCI for preparation of TDC
(QCM/WC/001) for the requested welding consumables.
5.1.3 Welding Engineer prepares TDC for each type of Welding Consumables, and
forward to QCE for his approval. QCE approves TDC and forward to Purchase
Manager along with MR.

5.1.4 Purchase Order will be prepared by Purchase Manager based on quantity

requested which will reference the applicable TDC number and revision number.
5.1.5 Purchase order will be approved by MD.
5.2 Receiving Inspection

5.2.1 On receipt of a consignment of Welding Consumables, Store In-charge shall carry

out checking for any damage and quantity verification for each type of Welding
Consumables. Store In-charge will offer to QCI for inspection in accordance with
PO & TDC. The following checks are made by QCI to ensure it meets PO & TDC
requirements.
5.2.1.1 Inspection for any visible signs of transit damage that could affect the
performance of welding materials (i.e., container’s tightness & protective packing
etc.)
5.2.1.2 Filler metal test certificates shall be reviewed in accordance to the relevant TDC
requirement and also the traceability as detailed in clause 5.4.
5.2.2 Upon acceptance of inspection, MRIR (QCM/F/08) shall be signed off by QCI and
reviewed by QCE, and issued to stores In-charge for taking in to stock/issuance.
5.2.3 The consumables for which the certificates are missing / inaccurate or damaged
ones shall be isolated and kept in a separate area with “Hold” tag.
5.2.4 In case of transferring consumables from one job to another, separate Material
Receiving Inspection Report (QCM/F/08) shall be prepared and inspected for
suitability by QCI.

5.3 Storage & Handling

5.3.1 Store In-charge is responsible for proper storage and careful handling of accepted
electrodes to avoid damage to them and to the containers in which they are
packed.

5.3.2 Electrodes and filler wires shall be stored in accordance with the manufacturer’s
instruction available with Stores In-charge. Consumables shall remain in their
original containers, which shall be marked with the manufacturer’s name,
consumable trade name and the batch number.

5.3.3 Consumable that shows signs of damage or deterioration, e.g. Cracked or flaked
coatings, rusty or dirty wires, damaged or flaked copper coatings shall be
disposed off. All welding consumables shall be traceable until their usage.

5.3.4 Low hydrogen electrodes which are received in hermitically sealed containers shall
be loaded to the baking oven once the seal is opened

5.4 Electrodes:

5.4.1 Basic coated low hydrogen type electrodes after removal from
containers/pockets shall be baked in calibrated ovens in accordance with
manufacturer’s instruction. Records of Baking of electrodes are maintained in
Electrode and Flux Baking Register (PSVPL/WC/001/F02). Oven shall be heated
to required temperature prior to placing the electrodes.

5.4.2 After baking to the baking temperature for required duration as per
manufacturer recommendation in the Baking oven, the electrodes shall be
transferred to the holding oven kept at 110 - 140⁰C.

5.4.3 The Baking ovens and Holding ovens shall have automatic heat controls &
baking ovens shall have a temperature read out display. .
5.4.4 While loading in the baking/holding oven, the different classifications of
electrodes shall be segregated in separate shelves/ trays to avoid mixing.

5.4.5 Electrodes shall be issued to the welders in electrically heated quivers. The returned
electrodes shall be treated as mentioned in clause 5.8

5.5 Issue of Electrodes/Filler Metals

5.5.1 Issue of electrodes and filler metals are controlled by Store In-charge against the
request Production Engineer in the Welding Consumable Slip
(PSVPL/WC/001/F03) maximum 20nos of electrodes or 2kgs of filler wire shall be
issued to welders at a time.

5.5.2 Electrodes shall be subjected to one initial baking only. To control this, the unused
electrodes that are returned shall be kept in a separate tray identified in the
holding oven and issued first on subsequent day to the welders.

5.6 Returned Electrodes/Filler Metals

5.6.1 Welders /welding operators shall return the balance electrodes/filler wires (if any,
after use /at the end of shift) to the Stores In-charge.
5.6.2 If the electrode originally requires any baking/drying, it shall be kept in the
holding oven. The unused returned electrodes shall be used for other applications
than ASME Code Jobs. All returned undamaged electrodes shall be kept in
separate tray or box with traceability in holding oven

5.6.3 If the returned electrode/filler wire is found to be damaged or if the electrode is so

wet, it shall be discarded from use.

5.7 Responsibility

5.7.1 Production Engineer is responsible for implementation of Welding Consumable

Control, once filler metals have been issued by Store In-charge.
5.7.2 Store In-charge shall be responsible for baking of electrodes and records to be
Maintained in Electrode Backing Inspection Report (PSVPL/WC/001/F02).
5.7.3 Welding Engineer shall prepare the Technical Delivery Condition (TDC) for filler
metals (PSVPL/WC/001/F01). This shall be reviewed and approved by QCE.
5.7.4 Store In-charge shall be responsible for verification of Filler metal upon receipt,
QCI shall be responsible for receiving inspection & acceptance.
5.7.5 QC Inspector shall be responsible for verification of electrode baking records on
Daily basis

5.8 Calibration
5.8.1 Only calibrated ovens used for baking/holding of electrodes shall have
temperature measurement devices calibrated once in a year or whenever
malfunctioning/repair noticed.
5.8.2 All ovens shall have stickers affixed with details of equipment, date of calibration
and calibration due date, and it should have clear visibility.

6.0 ATTACHMENTS

6.1 PSVPL/WC/001/F01 - Technical Delivery Condition for Welding Consumables

6.2 PSVPL /WC/001/F02- Electrode / Flux Baking Register
6.6 PSVPL /WC/001/F03-Welding Consumable Requisition Slip