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1.1. GENERAL :

All welding on Code work is performed using Welding Procedure Specification

(WPS) (Exhibit No. 07-01) by Welders qualified in accordance with the ASME Code
Section IX and the applicable construction Code Section.

1.2. WELDING PROCEDURE SPECIFICATION :

1.2.1. WPS’s are prepared by the Welding Engineer reviewed by Welding Manager
and shall include all welding variables required for the welding process by
ASME Code sec. IX and the intended range of production welding. The
required test welds are made under the supervision of the Welding Engineer.
Preparation and testing of the required test specimens are performed by an
approved testing laboratory whose report of test results is reviewed by the
Welding Inspector. If acceptable Welding Engineer prepares and Welding
Manager certifies, by signature and date, the Procedure Qualification Record
(PQR) (Exhibit No. 07-02). The PQR shall include all essential actual
variables used in making the qualification test welds and the actual test
results.
1.2.2. Copies of the qualified WPS’s are provided to the Production Manager.
1.2.3. WPS’s shall be revised whenever there is a change in a non-essential
variable without requalification. Whenever there is a change in an essential
or supplementary essential variable, a new WPS will be prepared and
qualified.
1.2.4. WPS’s and PQR’s are submitted to the Authorized Inspector for his review.
The Authorized Inspector may call for and witness the tests for welding
procedures.
1.2.5. The Welding Engineer shall prepare a Qualified WPS list (Exhibit No. 07-03)
1.2.6. Existing PQRs shall be verified by Welding Engineer for meeting governing of
Edition of construction Code before use.

1.3. QUALIFICATION OF WELDERS:

1.3.1. All Welders to be used for Code welding at shop or site are qualified to
ASME Code Sec. IX and the applicable construction Code section, under the
supervision of the Welding Engineer. Preparation and testing of the required
specimens or radiography of the test weld, is performed by an approved
testing laboratory. Their report is reviewed by the Welding Engineer, and if
acceptable, he prepares and certifies the Welder Performance Qualification
Record (WPQ) (Exhibit No. 07-04). The WPQ documents the performance
essential variables actually used for the test welds and ranges qualified for
production welding.
1.3.2. A WPQ is also issued for any Welder who have welded a test coupon to
qualify a WPS, based on the performance essential variables used, and
provided the mechanical test results and visual examination meets the Code
requirements.
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1.3.3. Copies of the WPQ are sent to the Production Manager for their respective
Welders. The original WPQ’s are retained on file maintained by the Welding
Engineer.

1.4. REQUALIFICATION OF WELDERS:

1.4.1. Welders are re-qualified in accordance with paragraph 7.3. Above if:
a) A performance essential variable changes.
b) A Welder has not welded with a process during a period of six months or
more.
Within the six months period, prior to his expiration of qualification:
1. A Welder who welds using manual or semiautomatic will maintain his
manual or semiautomatic welding with that process.
2. The welding operator has welded with that process using machine or
Automatic welding
c) When there is a specific reason to question his ability to make welds that
meet specification, the qualifications which support the welding he is
doing will be revoked. All other qualifications not questioned remain in
effect.
d) The Authorized Inspector may ask for witnessing the ability of a welder.

1.5. Renewal of Qualification:

1.5.1. Renewal of qualification expired under 7.4.1.b may be made for any process
by welding a single test coupon of either plate or pipe, of any material,
thickness or diameter, in any position, and by testing that coupon as required
by Section IX. A successful test renews the Welder or Welding Operator his
previous qualification.
1.5.2. Welders whose qualifications have been revoked under 7.4.1. (c) Or (d), shall
re-qualify

1.6. MAINTENANCE OF WELDER’S QUALIFICATION:

1.6.1. Each qualified Welder who performs welding is listed on Qualified Welder List
(Exhibit 07-05) maintained by the Welding Engineer.
The welding foreman prepares the Welder’s Log (Exhibit 07-06) on monthly
basis.
1.6.2. The Welding Engineer determines from the Welder’s Log (Exhibit 07-06)
when the Welder’s qualification will expire, so as to ensure he performs
production welding, or is re-qualified.

1.7. PRODUCTION WELDING:

7.7.1 Before welding, the QC inspector shall examine the fit up and prepare
Dimensional Check Report (Exhibit 07-07).
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7.7.2 Welding Map (Exhibit 07-08) will be prepared by the Welding Engineer and
approved by the Quality Control Manager, which specifies the WPS for each
individual welded joint. The Welding Map is submitted to the Production
Manager for use by the Welding Foreman.
7.7.3 The Production Manager verifies that all production Welders are qualified for
the performance essential variables to be used, and the Welding Foreman is
responsible for instructing the Welders in the correct use of the WPSs listed
on the Welding Map (Exhibit 07-08) for each weld.
7.7.4 Each qualified Welder is issued a unique welder identification No. stamp by
Welding Engineer, for identification of welders of production welds and
tacking, Welding Engineer shall record welder identifying stamp number on a
copy of the Welding Map (Exhibit 07-08) and then transfer the numbers to
the original Welding Map at the final documentation and this method shall be
the basic recording method. To assist the Welding Inspector in this record
keeping the Welding Foremen may mark the Welder identification adjacent
to each weld at intervals not exceeding 1 meter (3 feet). When a Welder
leaves the company, his stamp will not be reissued. When service conditions
prohibit hard stamping, and shall not be done on ferrous materials under 6
mm (¼”) thick and non-ferrous materials under 13 mm (½”) thick.
7.7.5 Copies of the qualified WPS’s are provided to the Production Manager who
will assure that the WPS’s are available to the welders in work area.
7.7.6 After welding the Q C Inspector shall inspect the completed weld and
prepare welding joint Visual Inspection Report (Exhibit 07-09).

1.8. TACK WELDS :

Tack welds, shall be made by Qualified Welders using qualified WPS, and shall be
examined for any defects prior to welding and any defect found shall be removed
completely before welding.

1.9. WELDING MATERIAL:

1.9.1. All welding material is purchased and received as described in (MATERIAL

CONTROL) Section 4 of this Manual.
The welding Engineer shall prepare the TDC for Filler Wires (Exhibit No. 04-
09).
A Welding Material Requisition (Exhibit No. 04-07) is to be used for
requesting the welding consumables and the Welding Consumables PO
(Exhibit No. 04-08).
The welding Engineer shall inspect the welding consumables and review the
certificates, and issue the Welding Consumables Receiving Report (Exhibit
No. 04-10).
1.9.2. Welding material is stocked in dry storage space and issued to Welders by
the Storekeeper (Electrodes) as specified on the designated WPS’s and
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against a Welder Material Request /Release Note (Exhibit No. 07-10)

prepared by the Welding Engineer.
1.9.3. Low hydrogen electrodes are received and stored in sealed containers.
When opened, the electrodes are placed in oven maintained at the
temperature recommended by their manufacturer as per Drying Log (Exhibit
No. 07-11), then the electrodes shall either transferred to the holding oven or
the temperature reduced to the holding temperature as per the manufacture
recommendations before issue to Welders.
1.9.4. Coated low hydrogen electrodes are issued only in a quantity sufficient to
complete the welds during the shift and maintained by the Welder in the
portable oven at the recommended temperature.
1.9.5. Unconsumed coated low hydrogen electrodes returned for workshop shall
not use for Code work.

1.10. PRODUCTION TEST PLATES:

1.10.1. Welded test plates for impact tests of base metal, weld metal and heat
affected zones, production test plates are prepared in accordance with a
procedure prepared by the Welding Engineer, which includes Number,
identification, type, orientation, location and dimensions of required
specimens, required preheat temperature, PWHT conditions, minimum
design metal temperature and charpy impact test temperatures.
1.10.2. The Production Manager supervise the welding of the test plates from
which specimens are prepared and tested by approved testing laboratory
whose test report is reviewed by the Welding Engineer for acceptance of
results or need for retest.
1.10.3. Test results are submitted to the Authorized Inspector for his review and
acceptance. The Authorized Inspector may witness the tests if he desires.

1.11. USE OF INDIVIDUAL WELDERS NOT EMPLOYED BY THE COMPANY:

1.1.1. Individual Welders not employed by the company may be used to perform
Code welding, at the shop or field site controlled by the shop, provided all
of the following conditions have been met before such Welders are
assigned to Code work:
1.1.1.1. All Code construction is the sole responsibility of the Company
including Code symbol stamping and providing Manufacturer’s
Data Report forms properly executed and countersigned by the
Authorized Inspector.
1.1.1.2. All Code welding is performed using WPS’s written and qualified
as in 7.2. above.
1.1.1.3. All such Welders have been qualified as in 7.3. & 7.4. above
and their qualifications maintained as in 7.6. above.
1.1.1.4. The Quality Control Inspector or Quality Control Site Inspector
as applicable has complete and exclusive administrative and
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technical supervision of all such Welders, including assignment

of welder No. as in para 7.7.2 above.
1.1.1.5. The Quality Control Manager has the authority to remove
Welders at his discretion.
1.1.1.6. Evidence that this program has been accepted by the
Manufacturer’s Authorized Inspection Agency which provides
the inspection service.
1.1.1.7. The Welding Engineer shall submit WPQ forms and Welder’s
List to the Authorized Inspector for his review and acceptance
for such Welders before they perform Code welding.

1.12. WELDING RECORDS:

All records mentioned in this Section are available for review by the Authorized
Inspector and are retained in the job file maintained by the Q C Inspector.

1.13. Related Exhibits

1. Welding Procedure Specification (WPS) (Exhibit No. 07-01)
2. Procedure Qualification Record (PQR) (Exhibit No. 07-02).
3. Qualified WPS list (Exhibit No. 07-03)
4. Welder Performance Qualification Record (WPQ) (Exhibit No. 07-04)
5. Qualified Welder List (Exhibit 07-05)
6. Welder’s Log (Exhibit 07-06).
7. Dimensional Check Report (Exhibit 07-07).
8. Welding Map (Exhibit 07-08)
9. Visual Inspection Report (Exhibit 07-09)
10. Material Request /Release Note (Exhibit No. 07-10)
11. Drying Log (Exhibit No. 07-11)
12. Welding Material Requisition (Exhibit No. 04-07)
13. Welding Consumables PO (Exhibit No. 04-08)
14. TDC for Filler Wires (Exhibit No. 04-09)
15. Welding Consumables Receiving Report (Exhibit No. 04-10)