QUALITY CONTROL PROCEDURE

QCP-M101

WELDING

01 QCP-REV-01 PKV 15/01/14 ACK 15/01/14 SJ 15/01/14

00 QCP-00 S.N 12/20/10 SR 12/20/03 PK 12/20/10
Rev. Description Prepared by Date Checked by Date Approved by Date
QA/QC Manager
Issued by: AAI Co. Ltd.

1.0 PURPOSE

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 This procedure is intended to describe the minimum requirements for general welding.

2.0 SCOPE
This is applicable to all welding works. Requirements specific to piping, pressure vessels,
tanks and structural steel welding are incorporated in the relevant procedures.

3.0 REFERENCES

INDUSTRY CODES AND STANDARDS

ASME SEC IX - Welding & Brazing Qualifications.
AWS D 1.1 - Structural Welding Code
ASME SEC V - Nondestructive Testing

SATORP ENGINEERING SPECIFICATIONS

JERES-W-011 REV 04 - Welding Requirements for On-plot piping

JERES-W-L-105 - Piping line class & Material Specification

4.0 MATERIALS
4.1 All welding rods and filler wire shall conform to ASME Section II or approved welding
procedure specifications.

5.0 PROCEDURE
5.1 WPS & PQR

5.1.1 Welding procedure specifications shall be prepared and qualified in accordance with
appropriate national/international standards ASME SEC IX and client specifications.
5.1.2Welding Procedure Specification (WPS) and Procedure Qualification Record (PQR)
shall be submitted for client approval, if required.
5.1.3 For specific applications, client-supplied procedures may be used.
5.1.4 Welding procedure requirements shall be strictly followed for both tack and
permanent welding.
5.1.5 Welding procedure specifications shall be made available at construction sites for
reference.

5.2 Welder Qualification

5.2.1 All welders shall be qualified by third party in accordance with the appropriate
national/ international standards.

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 5.2.2 If required, welders shall be qualified in accordance with the client procedures and
instructions.
5.2.3 Performance qualification record of welders shall be submitted for client review, if
required.
5.2.4 Welder cards shall be available with welders at all times at the work location for
review.

5.3 Equipment’s

5.3.1 Welding machines will be inspected to verify the condition of welding cable, terminal
legs and electrode holder.

5.3.2 Storage ovens shall have calibrated temperature gauge to continuously monitor the
temperature.

5.3.3 Portable ovens will be provided to welders for storing non-low hydrogen electrodes.

5.4 Preparation
5.4.1 Wind shields or tents shall be provided when the wind is strong enough to affect arc
stability or shielding gas coverage.

5.4.2 Welding shall not be done when surfaces are wet or exposed to rain.
5.4.3 Contamination from the environment, such as wind-blown sand, shall be prevented
by the use of adequate shielding.
5.4.4 Prior to welding, oil, moisture, rust, scale, sand, paint or other foreign matters shall be
removed from the weld surface and at least one inch of adjacent base metal.
5.4.5 Flame-cut surfaces shall be power brushed or ground prior to welding.
5.4.6 Thermal-cut surfaces of stainless steel and non-ferrous materials shall be ground to
bright (unoxidized) metal prior to welding.

5.5 Storage & Conditioning Of Smaw Electrodes & Gtaw Wire

5.5.1 Low hydrogen electrodes conforming to AWS A 5.1. (Carbon Steel)

Drying
Prior to use, all electrodes shall be dried to 260-430 0C for two hours minimum. The
drying step may be deleted if the electrodes are supplied in the dried condition in a
hermetically sealed metal can with a positive indication of seal integrity. Electrodes
may be re-dried once only.
Storage
After drying electrodes shall be stored continuously in ovens at 120 0C minimum.
Exposure

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 Upon removal from the drying or storage oven or hermetically sealed containers, the
electrodes may not be exposed to atmosphere for more than four hours. The exposure
may be extended to eight hours if the electrodes are continuously stored in a portable
electrode oven heated to 65 0C minimum. Electrodes exposed to the atmosphere for
less than the permitted time period may be reconditioned. Electrodes exposed in
excess of the permitted period must be re-dried. Electrodes that have become wet or
moist shall not be used and shall be discarded.
Re-conditioning
Electrodes exposed to the atmosphere for less than the permitted time period may be
returned to a holding oven maintained at 120 0C minimum. After a minimum holding
period of four hours at 120 0C minimum the electrodes may be reissued.

5.5.2 Low hydrogen electrodes conforming to AWS A 5.5. (Low alloy steel)
Drying
Prior to use, all electrodes shall be dried to 370-430 0C for two hours minimum. For
E70XX and E80XX electrodes, the drying step may be deleted if the electrodes are
supplied in the dried condition in a hermetically sealed metal can with a positive
indication of seal integrity. Electrodes may be re-dried once only.
Storage
After drying electrodes shall be stored continuously in ovens at 120 0C minimum.
Exposure
Upon removal from the drying or storage oven or hermetically sealed containers,
the electrodes may not be exposed to atmosphere for more than two hours for
E70XX or E80XX electrodes and 30 minutes for any higher strength electrodes.
The exposure may be extended to four hours and one hour respectively if the
electrodes are continuously stored in a portable electrode oven heated to 65 0C
minimum. E70XX and E80XX electrodes exposed to the atmosphere for less than
the permitted time period may be reconditioned. E70XX and E80XX electrodes
exposed in excess of the permitted period must be re-dried. Higher strength
electrodes (above 80XX) must be re-dried after any atmospheric exposure.
Electrodes that have become wet or moist shall not be used and shall be discarded.
Re-conditioning
E70XX and E80XX electrodes exposed to the atmosphere for less than the
permitted time period may be returned to a holding oven maintained at 120 0C
minimum. After a minimum holding period of four hours at 120 0C minimum the
electrodes may be reissued.

5.5.3 Stainless steel and non-ferrous electrodes.

Drying
Prior to use, all electrodes shall be dried to 120-250 0C for two hours minimum. The
drying step may be deleted if the electrodes are supplied in the dried condition in a
hermetically sealed metal can with a positive indication of seal integrity. Electrodes
may be re-dried once only.
Storage
After drying electrodes shall be stored continuously in ovens at 120 0C minimum.
Exposure

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 Upon removal from the drying or storage oven or hermetically sealed containers,
the electrodes may not be exposed to atmosphere for more than four hours. The
exposure may be extended to eight hours if the electrodes are continuously stored in
a portable electrode oven heated to 65 0C minimum. Electrodes exposed to the
atmosphere for less than the permitted time period may be reconditioned.
Electrodes exposed in excess of the permitted period must be re-dried. Electrodes
that have become wet or moist shall not be used and shall be discarded.
Re-conditioning
Electrodes exposed to the atmosphere for less than the permitted time period may
be returned to a holding oven maintained at 120 0C minimum. After a minimum
holding period of four hours at 120 0C minimum the electrodes may be reissued.
5.5.4 Non- Low Hydrogen Electrodes to A 5.1 or A5.5.
The electrodes shall be stored in a dry environment. Any electrode that has become
moist or wet shall not be used and shall be discarded.
5.5.5 GTAW Filler wire.
All wires shall be stored in sealed containers in a dry environment. Any wires that
have visible rusting or contamination shall not be used.

6.0 INSPECTION &TESTING:

6.1 Visual inspection and tests (radiography, penetrant testing, magnetic particle, hardness,
etc.) shall be performed by third party agency in accordance with the fabrication
code and client specifications.

7.0 ASSOCIATED DOCUMENTS:

7.1 Welding Procedure Specifications & Procedure Qualification Record

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