TRHT Egcb QC Ap 017 - A

PROJECT: TINRHERT FIELD DEVELOPMENT PROJECT-EPC1
DOCUMENT: QUALITY CONTROL PROCEDURE

WELDING CONSUMABLE CONTROL
DOCUMENT NO: 08572-TRHT-EGCB-QC-AP-017
Contents
1.0 PURPOSE ........................................................................................................................................................... 5
2.0 SCOPE................................................................................................................................................................. 5
3.0 PROJECT OVERVIEW ..................................................................................................................................... 5
4.0 REFERENCE DOCUMENTS ........................................................................................................................... 6
5.0 TERMINOLOGY ................................................................................................................................................. 7
6.0 RESPONSIBILITIES .......................................................................................................................................... 7
7.0 PROCEDURE ..................................................................................................................................................... 8
7.1 Approval of welding consumables ............................................................................................................... 8
7.2 Packaging of low hydrogen SMAW electrodes.......................................................................................... 8
7.3 Purchase of Consumables ............................................................................................................................ 8
7.4 Receipt of Bulk Storage of Consumables ................................................................................................... 8
7.5 Identification & Color coding of welding consumables ............................................................................. 9
7.6 Storage of Welding Consumables ............................................................................................................... 9
7.7 Issue to Site Consumable store ................................................................................................................... 9
7.8 Site Consumable Store................................................................................................................................ 10
7.9 Thermal Treatment of Consumables ......................................................................................................... 10
7.10 Gas (Shielding & Purging) .......................................................................................................................... 11
7.11 Issue of Welding Consumables.................................................................................................................. 11
7.12 SMAW Electrodes (Standard Packaging)................................................................................................. 12
7.13 SMAW Electrodes Vacuum Packaged...................................................................................................... 12
7.14 Inspection and Test Status ......................................................................................................................... 12
7.15 Test and Measuring Equipment ................................................................................................................. 12
7.16 Safety ............................................................................................................................................................. 13
8.0 APPENDICES ................................................................................................................................................... 13
Page 3 of 16

Notes:
This document shall be applied to Construction/Inspection & Test activities carried out at TINRHERT Field Development
(EPC1) project.
This document is based on widely used international codes, standards and good engineering practice that is applied in
Oil & Gas Projects and is intended to highlight the minimum tests and inspections that ensure quality requirements are
fulfilled within the scope of the document.
This document is generated to provide guidelines to TINRHERT Field Development (EPC1) project teams including
their GCB’s during preparation of project specific QCPs and shall be customized to meet specific requirements based
on applicable project specifications and/or other statutory and regulatory requirements. It may also be utilized at
bidding/proposals stage.
In case of any conflict between this document and the Project specification, drawings and applicable codes, the project
specification shall take precedence over this QCP.
When filling RFI/ITR, do not leave any blanks. If an item/activity is not applicable, denote as N/A.
Use of Blanco, Tipp-ex etc. on RFI/ITR is forbidden.
Page 4 of 16

1.0 PURPOSE
The purpose of this procedure is to describe a method of controlling welding consumables for the
permanent work of the project described below.
2.0 SCOPE
2.1 This Quality Control Procedure defines the Quality Control activities and the system to be applied
for controlling WELDING CONSUMABLE CONTROL used by GCB and their Subcontractor(s)
personnel at Project site.
2.2 This document identifies all WELDING CONSUMABLE CONTROL that is subject to control and all
applicable information regarding calibration or functional tests, calibration methods and intervals.
3.0 PROJECT OVERVIEW

3.1 SONATRACH has decided to develop the TINRHERT fields with its own resources. These
fields are in south-eastern Algeria within the Wilaya of Illizi. The geographic position of these
fields is indicated on the map below
Page 5 of 16

3.2 Contractor (GCB) Scope of Work / Services in brief: Scope of activities are briefly described below
Erection of Structural steel works interconnecting pipe racks, platform, ladder, walkways, Shelters etc.
• A network for the collection consisting of flow line and trunklines with a length of 376
km for the connection and the production of the thirty-six (36) wells.
• The cathodic protection temporary and definitive of the network collection of thirty-
six (36) wells
• The cathodic protection definitive collection network for the 50 wells of the EPC
Project3
• The surface installations to wells, and the manifolds these works concern including
the following
4.0 REFERENCE DOCUMENTS

116Z-TRHT-AP-A-0000005 Project Execution Plan requirements for EPC
116Z-TRHT-AS-QC-0000001 Supplier QAQC Requirements
116Z-TRHT-AS-QC-0000002 EPC QA QC Requirements
116Z-TRHT-AP-A-0000001 Document Identification & Numbering Procedure
08572-TRHT-AQ-QC-00-OO-207 Coordination with Algerian Regulatory Authority
08572-TRHT-SP-PI-00-OO-207 Technical Specification for Marking & Color Coding
08572-TRHT-AP-GN-00-OO-202 Document control procedure
08572-TRHT-AQ-QC-00-OO-214 Right First Time Procedure
08572-TRHT-SP-PL-18-OO-221 Pipeline Material Specification
08572-TRHT-SP-PI-00-OO-204 Piping Material Specification
08572-TRHT-AQ-QC-00-OO-211 Piping Fabrication Specification
08572-TRHT-AQ-QC-00-OO-209 Welding Specification
08572-TRHT-AQ-QC-00-OO-212 Pipeline Welding Specification
08572-TRHT-GCB-GN-AP-004 Material Identification & Traceability Procedure
08572-TRHT-GCB-GN-AP-001 QCP-Closed Loop RFI and Inspection Control
Procedure
08572-TRHT-AQ-QC-00-OO-213 QCP-Quality Observation, Daily Surveillance and
Quality Walkthrough at Site
08572-TRHT-SP-PL-18-OO-223 Specification for Pipeline Construction
08572-TRHT-AQ-QC-00-OO-201 Project Non-Conformity Procedure
08572-TRHT-AQ-QC-00-OO-213 Quality Control Procedure-Observation, Daily
Surveillance & Quality Walkthrough
Page 6 of 16

5.0 TERMINOLOGY
Company Sonatrach
PMT Petrofac International UAE LLc
Contractor GCB
CA Contracting Authority
Project Tinrhert Field Development Project – EPC 1
QC : Quality Control
CRA : Corrosion Resistant alloy
WCRC : Welding Consumable Receipt certificate
WPS : Welding Procedure Specification
PQR : Procedure Qualification Record
QMS : Quality Management System
Customer : Main Contractors, PMCs, End users
NCR : Non-Conformity Report
SMAW Shielded Metal Arc Welding
GTAW Gas Tungsten Arc Welding
CS Carbon Steel
LTCS Low temperature Carbon Steel
SS Stainless Steel
DSS Duplex Stainless Steel
6.0 RESPONSIBILITIES
6.1 Welding Engineer
6.1.1. Reviews purchase requisitions to ensure correct consumables are purchased against
approved WPS.
6.1.2. Reviews consumable batch certificates against purchase requisition prior to release to
stock. Assesses disposition where packaging damage is observed
6.1.3. Establishes re-order levels to ensure there are no shortages during construction.
6.1.4. Supervises welding audits by welding inspector, reviews audit records for unacceptable
trends.
6.1.5. Supervises consumable room personnel and operations.
6.1.6. Compiles welding consumable conditioning instructions.
6.1.7. Develops welding consumable colour coding system.
6.2 Welding Consumable Store man
6.2.1. Maintains effective control and storage of welding consumables as per manufacturer’s
instruction and as specified in this procedure.
Page 7 of 16

6.2.2. Requisitions consumables from central store.

6.2.3. Carries out baking & drying of welding electrodes as per manufacturer’s
recommendation and or specific project instructions issued identified on the packet and
maintains the Consumable Treatment Record (Appendix 6.1).
6.2.4. Issues consumables against the Consumable request Form (Appendix 6.3)
6.2.5. Receives and handles returned electrodes.
6.2.6. Labelling of segments of ovens with the type and size of consumables.
6.3 Welding Foreman

6.3.1 Monitors handling of welding consumables on site in line with the requirements of this
procedure.
6.3.2 Prepares Weld consumable request Form as required by approved WPS.
6.3.3 Ensures that all unused electrodes are returned to the consumable store at the end of
every shift.
6.3.4 Ensures that welders correctly use the electrode quivers and other equipment and
protect them from damage/deterioration.
6.4 Welding Inspector
6.4.1 Carries out daily inspection/audit of the consumable room operations according to the
requirements of this procedure and completes Consumable Store surveillance Form
(Appendix 8.2).
6.4.2 Monitors portable quiver(s) temperatures on site and checks calibration status.
7.0 PROCEDURE
7.1 Approval of welding consumables
7.1.1. The Welding engineer, in accordance with approved WPS’s and PQR’s, shall approve
welding consumables for use on the project.
7.1.2. The Welding Engineer, in accordance with project requirements, shall determine batch-
testing requirements for consumables.
7.2 Packaging of low hydrogen SMAW electrodes
7.2.1. Low hydrogen SMAW electrodes stored in Manufacturer supplied standard packing i.e.
cardboard packs with polythene shrink-wrapping. Alternatively, in specially designed
vacuum packaging (VacPac).
7.2.2. GTAW wire stored in Manufacturer supplied standard packing, i.e. cupboard packs with
polythene shrink wrapping.
7.3 Purchase of Consumables
7.3.1 The Welding Engineer, with respect to classification, brand and testing certification
requirements shall review purchase orders and retain all consumable certification for
future reference.
7.4 Receipt of Bulk Storage of Consumables
7.4.1. Incoming consumables shall be unloaded to an area segregated from other certified
welding consumable stock. The storekeeper shall receive deliveries of welding
consumables after verifying brand, AWS classification, size, quantity and packaging as
specified on the lot/batch certificate provided by the manufacturer. Any damage to
Page 8 of 16

packaging shall be reported to the Welding Engineer to assess the effect of any
damage and advice on disposition
7.4.2. Welding engineer shall review consumable certificate, to determine conformance with
order specification and shall endorse/reject the certificate accordingly.
7.4.3. Upon receipt of endorsed certificate, the storekeeper shall release the consumables
for entry to certified stock and transfer to bulk storage.
7.5 Identification & Color coding of welding consumables
7.5.1 All consumables shall be manufacture identified with brand name and AWS
classification on each Electrode or Filler wire.
7.5.2 In addition, all consumables shall be colour coded in order to visually identify even
during storage in Owens with below mentioned Colour codes.
MATERIAL GRADE CONSUMABLE TYPE IDENTIFICATION COLOR

CS - Cellulosic E 6010 Brown
Low alloy steel -
8010 - P1 Yellow
Cellulosic
Low alloy steel – Low
8018 GH4R Blue
Hydrogen
SS 316 ER 316L, E 316L-16 Green
DSS ER 2594, E2209-15 Red
Dissimilar CS TO SS,
ER 309LMo, E309LMo-17 Orange
SS to DSS, CS to DSS
7.5.3
7.5.4 For Electrodes Color code shall be applied on rear end of the electrode across the
electrode cross section.
7.5.5 For Filler wires colour shall be applied on the Flat surface where, manufacturer’s
marking exists.
7.5.6 Type of colors used shall be Sulphur, Zinc & Halogen free.
7.5.7 Colour code Chart shall be stuck on walls of Stores and at various construction notice
boards for the easy identification of type of consumables.
7.6 Storage of Welding Consumables
7.6.1 Bulk storage of welding consumables shall be in a designated area, which is specific
for that purpose. The area shall be dry and protected from the elements as per the
manufacturer’s recommendations. The consumables shall be segregated by type (e.g.
SMAW electrodes, GTAW wire) brand, AWS classification, size and batch/lot number.
Consumables shall be stored on wooden pallets / racks and not directly on the floor.
7.7 Issue to Site Consumable store
7.7.1 Welding consumables shall be issued to site consumable store, as production
consumption requires on a first in first out (FIFO) basis whenever practical. A copy of
the endorsed consumable test certificate shall be sent to the site consumable store
with each issue of consumables.
Page 9 of 16

7.8 Site Consumable Store

7.8.1 The site consumable store atmosphere shall be subject to the following 24 hours
controls:
• Temperature:
• 15°C - 25°C (Max. Relative Humidity 50%)
• Above 25°C (Max. Relative Humidity 40%)
7.8.2 Atmospheric conditions shall be checked by the Welding Inspector on a daily basis
using a calibrated thermometer and hygrometer and reported on the Consumable Store
Audit Log (Appendix 8.2)
7.8.3 The consumables shall be segregated by type (e.g. SMAW electrodes and GTAW wire)
brand, AWS classification, size and batch/lot number. Consumables shall be stored on
wooden pallets and not directly on the floor. Consumables shall be maintained in
original packaging until treatment or issue.
7.8.4 It is recommended to cut 100 – 150mm from the wire tip of the spool, i.e., to remove
the portion of the wire where moisture absorption would have taken place between
shifts, thereby preventing porosities.
7.9 Thermal Treatment of Consumables

7.9.1 SMAW Covered Electrodes – Standard Packaging
• Cellulosic electrodes (E6010 / E8010-P1) should not be dried unless until
recommended by the manufacturer, drying these electrodes will remove the
necessary moisture required for optimal performance of these electrodes.
Electrodes with signs of extreme moisture pickup (e.g. damp electrodes or
evidence of water or condensation on the electrodes) should be discarded.
• All Low Hydrogen type basic coated welding electrodes shall be either dried or
baked as per the manufacturers’ recommendation and or specific project
instructions sheet which is based on manufacturers’ recommendation. The
Welding Engineer shall establish thermal treatment requirements based on the
manufacturers recommendation and shall supply thermal treatment instruction to
the consumable Storekeeper stating temp/time cycle for baking and holding
ovens.
• Baking and holding ovens shall be uniquely numbered and the Welding Inspector,
using a calibrated digital thermometer, shall check temperatures daily.
• During baking electrodes shall be stacked to permit adequate heat distribution
and avoid damage to the flux coating, maximum four layers. Carbon Steels & CRA
Welding Electrodes shall be baked in separate ovens with the contents clearly
marked on the door. Baking of electrodes of the same type but different
classification in the same oven shall be avoided
• Baking shall be the responsibility of the Storekeeper and baking activities shall be
logged on the Welding Consumable Treatment Log (Appendix 8.1)
• On completion of the baking cycle the electrodes shall be transferred to a holding
oven. Carbon Steels & CRA Welding Electrodes shall be held in separate ovens
with the contents clearly marked on the door. There shall be no restriction for
stacking in holding ovens. Holding of electrodes of the same type but different
classification in the same oven shall be avoided.
Page 10 of 16

7.9.2 Re-baking of Low Hydrogen type SMAW Electrodes

• At the end of every shift the Welding Foreman shall ensure that any unused
electrodes are returned to the consumable store to an area segregated for this
purpose. Returned SMAW electrodes shall be re-baked only once. On receiving
returned electrodes the Storekeeper shall check the electrodes and discard those
showing signs of coating damage. He shall mark the end of the electrode for re-
baking with high temperature black dye prior to re-baking. Any returned electrodes
marked with black dye at the end shall be discarded and shall not be used for
production welding (These electrodes may be used for welder training).
7.9.3 Electrode thermal treatment cycles prior to issue
MATERIAL CONSUMABLE BAKING / REDRYING

HOLDING TEMP
GRADE TYPE TEMP
No Holding allowed in oven or
CS E 6010 No Baking allowed
quiver
LTCS E7018-1 250 to 3500C for 2 Hours 120 to 1500C Indefinite (2 times)
Low alloy steel E 8018 GH4R 300 to 3500C for 2 Hours 120 to 1500C Indefinite (2 times)
No Holding allowed in oven or
LTCS E 8010 p1 No Baking Allowed
quiver
SS 316 E 316L-16 250 to 3000C for 2 Hours 120 to 1500C Indefinite (2 times)
DSS E2209-15 260 to 2800C for 2 Hours 120 to 1500C Indefinite (2 times)
Dissimilar CS
TO SS, SS to E309LMo-17 250 to 3000C for 2 Hours 120 to 1500C Indefinite (2 times)
DSS, CS to DSS
7.10 Gas (Shielding & Purging)

7.10.1 Shielding & Purging gas (when required) used for welding shall be of the welding grade,
composition and purity as specified on the relevant WPS. Approved suppliers shall
issue shielding & purging gas with the appropriate conformance certificates for each
lot. Storage shall be as per the manufacturer’s recommendation.
7.10.2 The following provides guidance for the most commonly used welding gas, Argon
• Argon purity minimum 99.9% as required by WPS.
• The Oxygen content of the back purge shall not exceed 0.2% or 2000 ppm for
stainless steel and 0.05% for duplex stainless steel.
• Shielding gas requirements used for auto GMAW welding as per approved WPS.
7.11 Issue of Welding Consumables
7.11.1 Welding consumables shall be issued against Weld consumable request Form
(Appendix 8.3) raised by the Welding Foreman.
7.11.2 Wires found to be rusted shall not be used.
Page 11 of 16

7.11.3 Damaged wire spools shall not be issued. The lot/batch number shall be checked
during the receipt of used wire spool. If identification for lot/batch number does not exist
on wire spool then actions to be taken to identified wire spool. Corrective and
preventive shall be identified and implemented to avoid causes.
7.12 SMAW Electrodes (Standard Packaging)
7.12.1 SMAW electrodes shall be issued from the holding oven into preheated portable
quivers, which shall maintain a temperature from 700C to 1000C.
7.12.2 Quiver temperature shall be monitored by the Welding Inspector on a daily basis as
part of daily welding surveillance. Portable quivers shall be individually numbered.
7.12.3 Electrode issue quantity shall as a maximum be sufficient for one working shift of up to
12 hours.
7.12.4 Quivers shall be returned to the consumable store at the end of every shift and logged
on the Quiver Control Sheet.
7.13 SMAW Electrodes Vacuum Packaged
7.13.1 Vacuum packaged electrodes do not require baking and do not need to be held in
portable quivers. They can be issued and used direct from the packaging, the date and
the Consumable Storekeeper shall mark time of issue on the package. After a
prescribed period exposed to the atmosphere, specified by the manufacturer (usually
twelve hours), vacuum packed electrodes shall be returned to the consumable store
for re-baking as described above.
7.14 Inspection and Test Status
7.14.1 All quality records and logs identified in this procedure shall be generated and
maintained.
7.15 Test and Measuring Equipment
7.15.1 Baking and holding ovens and potable heated quivers for use with SMAW consumables
shall be designed for that purpose. All items shall be checked and calibrated
periodically as per the manufacturers’ recommendations and project requirements.
7.15.2 All calibration certificates shall be retained and filed in Quality Department with a copy
held in the consumable store and kept for future reference.
7.15.3 Temperature measuring devices on heating equipment above shall be indicators only.
Checks shall be by proprietary temperature sensitive crayon or by calibrated digital
thermometer on a regular basis when in use.
7.15.4 Measurement of atmospheric conditions shall be by the thermometer and hygrometers
Page 12 of 16

7.16 Safety
7.16.1 All operations shall be conducted in line with the requirements of Construction Safety
Procedures.
7.16.2 Necessary personnel safety equipment shall be provided and worn.
8.0 APPENDICES
8.1 Consumable Thermal treatment Form
8.2 Consumable storage Surveillance Form
8.3 Consumable Request Form
Page 13 of 16

Appendix 8.1 - Consumable Thermal treatment Form
Baking Holding
Electro Dia Batc Qt Tim Welding Welding
S No Time Tem Time Time
de Type mm h No y e Supervis Supervisor
In p In out
Out or Sign Sign
RETURNED
ELECTRODES
GCB QC PIUL QC Company QC

NAME
SIGN
DATE
Page 14 of 16

Appendix 8.2 - Consumable Storage Surveillance Form
Report No : Date / Time:
Consumable Store Location :
Item Activity Comments

Check Welding Consumable treatment
1
record
2 Check Welding Consumable Request card
3 Check consumable store audit log
4 Check colour coding for welding electrodes
5 Check storage & Handling of consumables
Check Calibration status of baking ovens,

6 holding ovens, temperature humidity meter
and thermocouple / Thermometer
Check quivers are pre-heated, if required to

7
70 Deg C (min) before issuing electrodes
Check returned electrodes are segregated

8
and color coded
9 Check Quiver control sheet
Check vacuum packs are issued with date

10
and time of issue
RECORD OF ACCEPTANCE PREP BY CHECKED BY APPROVED BY
NAME
POSITION
DATE
SIGNATURE
Page 15 of 16

Appendix 8.3 – Consumable Request Form
Plant/Unit: Project No.:
Rev. No.: System/Sub-system No.:

Welder’s Name:
…………………………………………………….. WELDING CONSUMABLES ISSUANCE
Welder’s ID:
Brand ǿ Issued
………………………………………………………….. AWS No. Lot No.
Name (mm) (kg.)
WPS No. : ……………………………
Quiver: No…………………..……T
(0C)……………………………
Area:
…………………………………………………………………….
Shop No.: Issued by store
Received by
…………………………………………………………… keeper
Requested by Welding Foreman: Name: Name:
Name Signature Date Signature: Signature:
Date: Date:
Welder’s Name:
WELDING CONSUMABLES ISSUANCE
……………………………………………………..
Welder’s ID:
Brand ǿ Issued
………………………………………………………….. AWS No. Lot No.
Name (mm) (kg.)
WPS No. : ……………………………
Quiver:
No…………………..……T(0C)……………………………
Area:
…………………………………………………………………….
Shop No.: Issued by store
Received by
…………………………………………………………… keeper
Date: Date:
Page 16 of 16

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PROJECT: TINRHERT FIELD DEVELOPMENT PROJECT-EPC1

DOCUMENT: QUALITY CONTROL PROCEDURE

DOCUMENT: QUALITY CONTROL PROCEDURE

Use of Blanco, Tipp-ex etc. on RFI/ITR is forbidden.

DOCUMENT: QUALITY CONTROL PROCEDURE

3.0 PROJECT OVERVIEW

DOCUMENT: QUALITY CONTROL PROCEDURE

4.0 REFERENCE DOCUMENTS

DOCUMENT: QUALITY CONTROL PROCEDURE

DOCUMENT: QUALITY CONTROL PROCEDURE

6.2.2. Requisitions consumables from central store.

6.3 Welding Foreman

DOCUMENT: QUALITY CONTROL PROCEDURE

MATERIAL GRADE CONSUMABLE TYPE IDENTIFICATION COLOR

DOCUMENT: QUALITY CONTROL PROCEDURE

7.8 Site Consumable Store

7.9 Thermal Treatment of Consumables

DOCUMENT: QUALITY CONTROL PROCEDURE

7.9.2 Re-baking of Low Hydrogen type SMAW Electrodes

7.9.3 Electrode thermal treatment cycles prior to issue

MATERIAL CONSUMABLE BAKING / REDRYING

7.10 Gas (Shielding & Purging)

DOCUMENT: QUALITY CONTROL PROCEDURE

DOCUMENT: QUALITY CONTROL PROCEDURE

DOCUMENT: QUALITY CONTROL PROCEDURE

Appendix 8.1 - Consumable Thermal treatment Form

GCB QC PIUL QC Company QC

DOCUMENT: QUALITY CONTROL PROCEDURE

Appendix 8.2 - Consumable Storage Surveillance Form

Report No : Date / Time:

Consumable Store Location :

Item Activity Comments

2 Check Welding Consumable Request card

3 Check consumable store audit log

4 Check colour coding for welding electrodes

5 Check storage & Handling of consumables

Check Calibration status of baking ovens,

Check quivers are pre-heated, if required to

Check returned electrodes are segregated

9 Check Quiver control sheet

Check vacuum packs are issued with date

DOCUMENT: QUALITY CONTROL PROCEDURE

Appendix 8.3 – Consumable Request Form

Plant/Unit: Project No.:

Rev. No.: System/Sub-system No.:

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