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WELDING CONTROL PROCEDURE

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LIST OR REVISIONs
Rev. Date Comment Prepared By Reviewed By Approved By
0 01-01-2019 For Implementation Ahmed El-Sharkawy Ahmed Safwat
1 01-03-2019 Change in the procedure number Ahmed El-Sharkawy Ahmed Safwat

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INDEX
No. DESCRIPTION PAGE
1 OBJECTIVES 4
2 SCOPE 4
3 REFERENCE 4
4 DEFINITIONS 4
5 RESPONSIBILITIES 4
6 PROCEDURE 4
7 RECORDS 6
8 ATTACHMENTS 7

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1. OBJECTIVES
The purpose of this procedure is to monitor the welding application, welder qualification and welding procedures as per
governing code, standard and project specifications.

2. SCOPE
This procedure is prepared in order to cover qualification of welders, welding operators and WPSs according to the
project specification, covered by the relevant reference code such AWS D1.1, EN code, API and ASME Code Section IX

3. REFERENCE
3.1. ISO 9001:2015
3.2. AWS D1.1 – Steel Structural Welding Code
3.3. EN 1090 - Technical Requirements of the execution of the steel structure
3.4. EN ISO 9606 Qualification testing of welders — Fusion welding.
3.5. EN ISO 15609 Specification and qualification of welding procedures for metallic materials; General rules.
3.6. EN ISO 15607 Specification and qualification of welding procedures for metallic materials; Welding procedure
specification.
3.7. EN ISO 15614 Specification and qualification of welding procedures for metallic materials; Welding procedure
test.
3.8. ASME IX – ASME Boilers and Pressure Vessel Codes for Welding and Brazing Qualifications
3.9. API 1104 – American Petroleum Institute for Welding of pipelines and related facilities

4. DEFINITION
QCM Quality Control Manager
WE Welding Engineer
WPS Welding Procedure Qualification
PQR Procedure Qualification Record
WPQR Welder Performance Qualification Record
Company ASF
Authorized inspector Any third-party inspection agency

5. RESPONSIBILITIES
5.1. WELDING ENGINEER
5.1.1. The WE responsible for the preparation and qualification of WPSs identifying all essential, non-essential and
when required supplementary essential variables required by the applicable Code of construction,
5.1.2. The WE shall sign the WPS record based on form no. ASF-QC-WCP-003 after its successful qualification. The
WPS shall refer to supporting PQR record form based on form no. ASF-QC-WCP-002
5.1.3. The WE shall arrange the qualification of each WPS, witness the welding of the test coupon and record the
welding variables used for each qualification and fill PQR as run sheet on form no. ASF-QC-ARS-001 for each
PQR.
5.1.4. The WE shall maintain the original copies of WPS and PQR and laboratory test reports in the job file.
5.1.5. The WE responsible to make copy of all qualified WPSs on form no. ASF-QC-WCP-005, for the job undertaken
and provided to the Welding Foreman who instructs the welders who responsible to the production welds.
5.1.6. The WE responsible for training, qualification, certification and assignment of welders and assure that their
qualification is running properly, Evaluate their competency and precision through performance in the
welder’s log record on form no. ASF-QC-WCP-007.

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6. PROCEDURE
6.1. WELDING PROCEDURE QUALIFICATION
6.1.1. WPS are prepared by the WE and approved by the QCM and shall include all welding variables required for
the welding process by the governing code plus any additional variables required by the applicable
construction Code and the intended range of production welding. The required qualification tests are
prepared under the supervision of the WE. Examine and testing welding samples at authorized laboratory;
WE is responsible to review the laboratory test reports. If acceptable he prepares and certifies, by signature
and date, the PQR record based on form no. ASF-QC-WCP-002. The PQR shall include at least all essential
variables used in welding of test coupon.
6.1.2. Copies of the qualified WPS and PQR are provided to the Production Manager and Production Engineer for
the purpose of application in the production welding.
6.1.3. Welding Map on form no. ASF-QC-WCP-008 will be prepared by the WE and approved by the QCM, which
specifies the WPS for each individual welded joint. The Welding Map is submitted to the Production Manager
and the Production Engineer for implementation
6.1.4. WPS may be revised whenever there is a change in a non-essential variable. Whenever there is a change in an
essential or supplementary essential variable, a new WPS and PQR is required

6.2. QUALIFICATION OF WELDERS

6.2.1. All Welders at shop or site shall be qualified according to reference code/construction code of the job, under
the supervision of the WE. Welders are either qualified by mechanical testing or by volumetric NDE
examination (RT or UT). Testing welding samples is performed by an approved testing laboratory. When
volumetric examination (RT or UT) is used in lieu of mechanical test, it shall be performed by qualified NDE
level II operator and report is reviewed by WE, and if the NDE reports are acceptable; WE prepare and certify
Welder Performance Qualification Record (WPQR) on form no. ASF-QC-WCP-004. The WPQR documents
contain the essential variables which actually used in welding test in addition to the qualified ranges
6.2.2. A WPQR is also issued for Welder who have welded a test coupon to qualify a WPS, based on the performance
essential variables used, and provided the test results meet the Code requirements.
6.2.3. send copy of qualified welders list to production department; The original WPQR record are retained in the
Welding Engineer's file.
6.2.4. The WE issue Qualified Welders List according to the relevant form no. ASF-QC-WCP-006, which approved by
QCM.

6.3. REQUALIFICATION OF WELDERS

Welders requalification is required according to clause 6.1 to clause 6.3.
6.3.1. change in WPQR essential variables.
6.3.2. Welder who not practice welding for six months or more after qualification.
6.3.3. When there is a specific reason to test his ability to get a sound
6.3.4. The welding Inspector has reason to test Welders’ ability to get a sound weld

6.4. RENEWAL OF QUALIFICATION

6.4.1. Renewal of welders’ certification by welding a single test coupon of either plate or pipe, of any material,
thickness or diameter, in any position, by inspection the test coupon as required by governing code; A
successful test renewal his previous qualification or by checking last UT or RT report of the welders
6.4.2. Welders whose qualifications have been revoked for any reason under 6.2 shall be re-qualified in the same
process of the initial qualification.
6.4.3. Welding engineer is responsible to update the qualified welders list according to applied code; and approved
by QCM

6.5. PRELONGATION OF WELDER’S QUALIFICATION.

6.5.1. the welding engineer is responsible to record all welder’s activity based on form number ASF-QC-WCP-007 for
the monthly evaluation.

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6.5.2.When welders’ certificates are expired The WE is responsible to determine the continuity or
requalification is required for each welder based on his record in welder log and last UT or RT report.

6.6. PRODUCTION WELDING

6.6.1. The production engineer verifies that all production welders are qualified to get a sound welding foreman is
responsible to select welders from the qualified welders list, as well as welders using the applicable WPS,
both documents are prepared by the WE and approved by the QCM.
6.6.2. Each qualified welder shall have a unique stamp; each weld made by a welder shall be identified by stamping
adjacent to the weld and in case stamping is not possible, the identification is recorded on the welding map.
when a welder leaves the company; his stamp will not be reissued for other again.
6.6.3. Any tack welds made by qualified Welders using the qualified WPS designated on the Welding Map, if left tacking
in place, the ends of each tack weld shall be ground to ensure complete fusion; After that each tack weld is
visually examined by the QC Inspector, and if there are any defective, it shall be completely removed.

6.7. WELDING MATERIAL

6.7.1. All welding material shall be received by the WE, who is responsible to verify that marking on the package and
filler metal and randomly checks its quality according to form no. ASF-QC-MRI-003
6.7.2. Welding material is stocked in dry storage space and issued to welding Forman by the Storekeeper using issue
request.
6.7.3. Low hydrogen electrodes are received and stored in hermetically sealed containers, when opened, the
electrodes are placed in heated oven maintained at the temperature recommended by the manufacturer, before
issue to Welders.
6.7.4. 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.
6.7.5. examine remaining coated low hydrogen welding electrodes with welders before it back to storage in the holding
furnace; if there are Damaged or unidentified electrodes will not use for Code work.

6.8. PRODUCTION TEST PLATES

6.8.1. Welded test plates for impact tests of base metal, weld metal and heat affected zones. The production test
plates are prepared in accordance with a procedure prepared by the WE, 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.
6.8.2. The QC engineer supervises the welding of the test plates using during the test specimens from which specimens
are prepared and tested by a qualified testing laboratory whose test report is reviewed by the WE for acceptance
of results or need for retest. test results are submitted to the authorized inspector for his review. the authorized
inspector may witness the tests if he desires.

6.9. WELDERS NOT EMPLOYED BY THE COMPANY.

6.9.1. the company can use welders from outsource to do some specific jobs, the WE is responsible to ensure from
their qualification according to the job code.
6.9.2. All the welding shall according to a qualified WPS.
6.9.3. All Welders shall be qualified and the qualification or requalification record must be retained according to as in
the above from clause 6.2 to clause 6.5.
6.9.4. The QCM and the WE have the authority to exclude Welders based on their discretion.
6.9.5. The welding engineer submit the WPQR and welder’s list to the authorized inspector for review and approval
before starting code welding.

7. RECORDS
All data related to the welding material, qualified procedures and welder’s qualification certification shall be retained in
the WE job file.

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8. ATTACHMENT
8.1. Procedure Qualification Record – form no. ASF-QC-WCP-002
8.2. Welding Procedure Specification – form no. ASF-QC-WCP-003
8.3. Welder Performance Qualification Record – form no. ASF-QC-WCP-004
8.4. Welding procedure Specification List – form no. ASF-QC-WCP-005
8.5. Qualified Welders List – form no. ASF-QC-WCP-006
8.6. Welders Log – form no. ASF-QC-WCP-007
8.7. Welding Map – form no. ASF-QC-WCP-008
8.8. Welding Receiving Material Inspection Report – form no. ASF-QC-MRI-003
8.9. PQR As run sheet – form no. ASF-QC-ARS-001

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