WELDING CONTROL

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7.0 WELDING CONTROL

7.1 SCOPE
This section covers the control of welding materials, process and personnel
accordance with ASME Section II and Section IX and Code Section used for
construction

7.2 GENERAL

7.1.1 Every welder or welding operator shall be qualified in accordance with the
Requirements of ASME Section IX with additional requirements of the applicable
Code Section to which work is performed

7.2.2 Every welder or welding operator is assigned with an individual employ number;
every joint welded by them shall be marked adjacent to the weld with their individual
number at 0.9 meter apart or recorded in weld traceability record (Exhibit 13). For
ferrous material less than 6mm thick and non-ferrous materials less than 12mm thick
stamping is not permitted.

7.2.3 The welding supervisor is responsible for instructing and supervising the welders
and welding operators.

3.8 WELDING PROCEDURE SPECIFICATION (WPS) AND PROCEDURE

QUALIFICATION RECORD (PQR)

7.3.1 The welding Engineer prepares WPS which include essential, non-essential
and supplementary essential variables when required for the process by ASME
code section IX, with reference to construction Code and the intended range of
production welding. The required test weld is conducted under his supervision.
Preparation and testing of the required test specimens is performed by the testing
Laboratory to meet section IX, whose report of the test result is reviewed by
Welding engineer. If acceptable, he shall prepare, sign and date the PQR
Recordings of the actual variables used in making the qualification test weld.

7.3.2 The Welding Engineer shall date and certify the PQR (Exhibit 22) and made
Available to the Authorized Inspector for his review and acceptance

7.3.3 The relevant WPS shall be posted for the particular project on the notice board at
the shop and field site for welder’s reference. The QA/QC Manager maintains
the WPS/PQR file.
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7.3.4 The WPS are revised whenever there is a change in a non-essential variable.
Whenever an essential or supplementary essential is changed, a new WPS is
Written, supported by newly qualified PQR

7.3.5 The A.I. may request to qualify the WPS at any time when he has reason to
question the WPS for making sound welds.

4.8 WELDERS/ WELDING OPERATORS QUALIFICATION

7.4.1 All welders and welding operators shall be qualified to ASME Section IX and
the Code sections used for fabrication. The welding engineer shall witness the
required test. The Welding Engineer shall certify the welder and welding operator
qualification record. The results of these tests shall be duly recorded.

7.4.2 The original copy of the performance records of the welders and welding operators
shall be documented, dated and certified by the Welding Engineer.

7.4.3 Copies of the welder and welding operator record are put on the Notice Board for
reference.

7.4.4 WPQ/ WPOQ are available for review and acceptance by the A.I. who may
request to re-qualify at any time if he has doubts in the welder’s and welding
operator’s ability to weld.

7.5 REQUALIFICATION OF WELDERS & WELDING OPERATORS

Welder and welding operator are qualified per section 7.4 where

a) A performance essential variable changes

b) A welder and welding operator has not welded with a process for 6 months;
His qualification for that process shall expire.
c) The A.I. has reason to question a welder’s ability to make sound welds that
meet the specification.

7.6 MAINTANCE OF WELDING & WELDING OPERATOR QUALIFICATION

7.6.1 Welding Engineer shall have complete and exclusive administration and
supervision of all in-house and sub-contracted welders and the right to assign
and remove any welder at his direction.

7.6.2 The Welding Engineer shall determine from the welder log when welder
qualification is expiring to ensure that he performs production welding or is
properly requalified.
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7.7 PRODUCTION WELDING

7.7.1 The Welding Engineer shall be responsible for verifying that all production welders
are qualified for the performance essential variables listed in the WPS.

7.7.2 The welding supervisor shall be responsible for assigning, instructing &
supervising the welder in the correct use of WPS listed in the drawing for each
weld.

7.7.3 Each welder shall identify each weld he makes by recording in the welders data
record or stamp his number adjacent to and at intervals of less than 0.9 meter on
each weld joint.

7.7.4 The QC Inspector shall keep a record of the welds made by the welder on the fit
up and Visual Inspection report (Exhibit X). This record shall be made available to
the A.I. upon his request. When radiography is a requirement in the weld joint, the
welder’s identification shall be indicated on the radiographs with other identification
required by code.

5.8 WELDING CONSUMABLES

1.8.2 Welding consumables shall be ordered through the store department.

2.8.2 All the welding consumable shall be received as described in section 4 of this
Manual.

7.8.1 The Store keeper shall be responsible for the welding consumables to maintain a
minimum stock level.

7.9 STORAGE AND ISSUE OF WELDING CONSUMABLES

7.9.1 All welding consumables shall be stored in a dry storage space.

7.9.2 Low hydrogen coated electrodes shall be received, checked for damaged
packaging and stored. When opened, the electrodes shall be placed in a backing
oven at the temperature recommended by manufacturer. After which the
electrodes shall be transferred to the holding oven and maintained at a
temperature of 150ºC or as recommended by the Manufacturer. Backing & holding
temperature can be changed in according to manufacturer’s recommendation.
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7.9.3 Low hydrogen electrodes shall be issued for a four-hour period or only in quantity sufficient
to complete the weld. At the end of four-hour period, all unused electrodes shall be
returned to the store for rebaking as per manufacturer’s recommendation prior to reuse.

7.9.4 The welder shall draw the required consumables from the stores as per consumable request
slip endorsed by the welding supervisor.

7.9.5 The Store keeper shall record and maintain control in issuing all welding consumables in
the log book.

7.9.6 The Welding Supervisor / foreman shall monitor and control all consumables drawing by
the Welders or welding operators.

7.9.7 The welder shall proceed to the work place. He shall check welding parameters as specified
in the WPS before welding.

7.9.8 The Welding Engineer verify log of the oven temperature on a monthly basis.

7.10 FLUX

7.10.1 Upon receipt, all bagged flux shall be examined for damage to its protective
Packaging and stored in a dry area.

7.10.2 When opened, the flux shall be stored in a heated flux oven maintained at 150ºC
± 25ºC

7.10.3 The Store Keeper shall issue a minimum satisfactory amount of flux from the flux
oven.

7.10.4 The flux to be recycled shall be cleaned of molten flux or slag by filtering through
a sieve and any other foreign matter shall be removed.

7.10.5 The welding Engineer on a monthly basis shall verify the log of the flux oven
temperature.

7.11 SUBMERGED ARC WELDING WIRE

7.11.1 Submerged arc welding consumable shall be examined for damages to its
protective packaging upon receipt.

7.11.2 Coils when mounted on the wire feed unit shall be protected to prevent moisture
or rust forming on the wire.

7.11.3 Coils found with rust shall be discarded.

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7.11.4 Identification of the submerged arc filler wire shall be maintained and issued only
with the flux recommended by manufacturer.

7.12 TACK WELDS

7.12.1 All tack welds whether left in place or completely removed shall be performed by
Qualified welders in accordance with a qualified WPS designated in the drawing.

7.12.2 If left in place, the end of each tack weld ids ground to ensure complete fusion
In to the final weld , and should be welded by a qualified as describe in
paragraph 7.4.

7.12.3 Each tack weld shall be visually examined for defects, and if found to be
Defective shall be completely removed.

7.13 SUBCONTRACTOR WELDERS

7.13.1 When the Welders and welding operators are not in he employment of MTQ the
Following condition shall be met.

a) MTQ shall be responsible for Code compliance of the completed pressure

Vessels or parts, including Code symbol stamping and providing data report
forms properly executed and signed by A.I.

b) All welding shall be performed in accordance with MTQ qualified WPS as per
ASME Section IX.

c) All subcontractor welders shall be qualified in accordance to paragraph of

7.4

d) MTQ’s Welding Engineer shall have the responsibility and authority as

follows

 A complete & exclusive administrative and technical supervision of all

Welders and welding operators

 Authority to assign and remove welders at his discretion without

Involvement of any other organization

 Assignment of welder identification symbols

 To obtain acceptance by the A.I

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