Marjan Increment Program

Tanajib Gas Plant (TGP) Industrial Support Facilities

WELDING CONSUMABLE CONTROL PROCEDURE

BI/J.O. No.: BI-10-09003-0006 / MTGP13 Period: 29 OCTOBER 2020

Document No. : RTA-ISF-M-GA-1081 Revision No. : 00

WELDING CONSUMABLE
CONTROL PROCEDURE
 Marjan Increment Program
Tanajib Gas Plant (TGP) Industrial Support Facilities
WELDING CONSUMABLE CONTROL PROCEDURE

BI/J.O. No.: BI-10-09003-0006 / MTGP13 Period: 29 OCTOBER 2020

Document No. : RTA-ISF-M-GA-1081 Revision No. : 00

Revision History & Signatories:

1st
29-OCT- submission
00
20 for review &
approval

Shafee Shaik Allan Delsocura Randy Villaruel Bilal Obeidat

Rev
Revision Revision
. Prepared by: Checked by:
Date Description Reviewed by: Approved by:
No. Quality Control Quality Control
Supervisor Manager Project QA Manager Project Manager
 Marjan Increment Program
Tanajib Gas Plant (TGP) Industrial Support Facilities
WELDING CONSUMABLE CONTROL PROCEDURE

BI/J.O. No.: BI-10-09003-0006 / MTGP13 Period: 29 OCTOBER 2020

Document No. : RTA-ISF-M-GA-1081 Revision No. : 00

Table of Contents

1.0 GENERAL……………………………………………………………………………………………………………. 04

2.0 RESPONSIBILITY…………………………………………………………………………………………………. 04

3.0 GENERAL REQUIREMENT………………………………………………………………………………....... 06

4.0 STORAGE, HANDLING & CONDITIONING of WELDING CONSUMABLES………………… 07

Appendix 1 SAIC-W-2010 Receiving Inspection Welding Consumables..…………… 10

Appendix 2 SAIC-W-2032 Control of Welding Consumable………………………………… 13

Appendix 3 SATR-W-2009 Welding Rod oven Calibration/Verification Report…… 17

Appendix 4 SATR-W-2010 Welding Consumables Issuance Report………………...….… 20

Appendix 5 SATR-W-2020 Welding Consumables Receiving Inspection Report…… 22

 Marjan Increment Program
Tanajib Gas Plant (TGP) Industrial Support Facilities
WELDING CONSUMABLE CONTROL PROCEDURE

BI/J.O. No.: BI-10-09003-0006 / MTGP13 Period: 29 OCTOBER 2020

Document No. : RTA-ISF-M-GA-1081 Revision No. : 00

1. GENERAL
1.1. Purpose
 To establish guidelines and define responsibilities for the proper storage, control, issuance
and use of welding electrodes and filler wire (SMAW & GTAW).

1.2. SCOPE
 This procedure applies to all welding consumables proper storage, control, issuance and use
of welding electrodes and filler wires. for production welding for piping and structural (AWS
D1.1) welding activities in according with the project requirements.

1.3. Reference Documents

SAES-W- 011 - Welding Requirements for On-Plot Piping

ASME Sec.II Part C - Welding Rods/Electrodes and Filler Metal

AWS D1.1 - Structural welding codes

ASME SEC IX - Welding and Brazing

ASME B 31.3 - Process piping

SAIC-W-2010 - Receiving Inspection of Welding Consumables

SAIC-W-2032 - Control of welding Consumables

SAIC-W-2009 - Review Procedure –Control of Welding Consumables

SATR-W-2009 - Welding rod oven Calibration/Verification Report

SATR-W-2010 - Welding Consumables Issuance Report

SATR-W-2020 - Welding Consumables Receiving Inspection Report

AWS A 5.32 - Specification for Welding Shielding Gases

2. RESPONSIBILITIES:
1.4. QC Manager
2.1.1. Shall be responsible for the verification and monitoring in the implementation of this
procedure through inspection
 Marjan Increment Program
Tanajib Gas Plant (TGP) Industrial Support Facilities
WELDING CONSUMABLE CONTROL PROCEDURE

BI/J.O. No.: BI-10-09003-0006 / MTGP13 Period: 29 OCTOBER 2020

Document No. : RTA-ISF-M-GA-1081 Revision No. : 00

1.5. QC Supervisor
2.1.2. Shall be responsible for proper implementation of this procedure
2.1.3. Reviews purchase requisitions to ensure correct order specifications.
2.1.4. Supervises Consumable Room personnel and operations.

1.6. QC Welding Inspector:

2.1.5. To be responsible for the implementation of this procedure and to verify that welding
consumables used are approved and controlled.
2.1.6. To perform the receiving inspection of the consumables in accordance with the SATIP and
SAIC.
2.1.7. To check and verify whether welding rods or wire are handled and stored in accordance
with approved procedures.
2.1.8. To verify that portable dry ovens is properly working
2.1.9. Carries out Daily inspection/audit of the consumable room operations according to the
Requirements of this procedure.
2.1.10. Monitors oven and portable quiver temperature on site
2.1.11. Check and ensure calibration of equipment and instrument is still valid.

1.7. Welding Consumable Controller (WCC):

1.7.1. Verify that / lot nos. Of the Consumables received tally with those in the batch/lot
certificate
1.7.2. To receive Electrode Control Slip (ECS) from Welding Foreman for issue welding
consumables.
1.7.3. To request for Receiving Inspection of welding consumables to the QC Inspector.
1.7.4. To segregate and checked returned electrodes and visibly mark the ends to differentiate
between the electrodes requiring for re-drying or re-conditioning.
1.7.5. To restore unused electrodes in baking oven if returned within the time limits. And keeping
record in order to maintain record.
1.7.6. To Responsible for issuance, retrieval, re-conditioning and re-issuance of welding
electrodes, ensure that welding electrodes used are properly controlled and recorded.
1.7.7. To assure of operation for all calibrated dry ovens in accordance with SATIPs and SAICs.
1.7.8. Issue the required electrodes on a first in, first out basis to the work shop.
1.7.9. The damage Consumables will be segregated in the designated quarantine area for return
to the supplier.

1.8. Welding Supervisor/Foreman:

1.8.1. Shall be responsible for receipt, handling, storage and issuance of welding consumable in
accordance with this procedure
1.8.2. To Issue and checked Electrode Control Slip (ECS) forms and advice to maintain the time
limit and expiration to welders.
1.8.3. To be responsible and ensure that welding electrodes used in production welding are
controlled in accordance with this procedure.
 Marjan Increment Program
Tanajib Gas Plant (TGP) Industrial Support Facilities
WELDING CONSUMABLE CONTROL PROCEDURE

BI/J.O. No.: BI-10-09003-0006 / MTGP13 Period: 29 OCTOBER 2020

Document No. : RTA-ISF-M-GA-1081 Revision No. : 00

1.8.4. To return the unused welding consumables to the Welding Consumable Controller. To
verify that the portable ovens are properly working and used by welders

3. GENERAL REQUIREMENT
1.9. Special Consideration for Consumables
1.9.1. Electrodes and Filler Wires shall be purchased in accordance with an ASME Sec.II part C
and approved WPS.
1.9.2. All Welding consumables shall be identified by marking shall be performed as
manufacturer name, size and class.
1.9.3. All filler wires shall be identified with an AWS punch mark on the end shall be identified
with color coding
1.9.4. Welding consumables shall be selected based on their mechanical properties, compatibility
with the materials to be joined, their suitability with the intended service and
consideration of polarity, position and direction of welding.
1.9.5. Welding consumables which are being used outside their rated tensile or impact range
listed in manufacturing specs must be batch tested or have CSD approval.
1.9.6. Control of Welding consumables shall be on accordance with SAIC –W- 2032

1.10. SMAW Electrodes

1.10.1. F-Nos.1 and F-Nos.2 Electrodes shall not be used on the following as per SAES-W-011
(Para 6.6)
1.10.1.1. Material requiring impact test either by code or job specification
1.10.1.2. For pressure retaining welds.
1.10.2. Maximum allowable SMAW Electrode size that can be used as per SAES-W-011para 11.1
1.10.2.1. Low hydrogen electrodes: 5mm=1G/1F position; 4mm = all other position.
1.10.2.2. Non-low hydrogen electrodes 5 mm = all positions.
1.10.3. Sizes larger than those listed above are acceptable only if approved by CSD and only if the
PQR was performed using the electrode size and positions to be used in production. the
approval shall be obtained through the welding procedure review process
1.10.4. In case of non-availability of Welding Rod Oven, vacuum packed electrodes shall he used.
1.10.5. All Electrodes (Low hydrogen electrode) shall be kept in welding rod oven or should use
vacuum packs.

1.11. GTAW Filler Metals

1.11.1. All electrodes and wires shall be stored is sealed containers in dry invironment.Any wires
that have visible rusting or contamination shall not be used and shall be discarded
1.11.2. GTAW Filler Metals (Including those cut or partially used) have either the AWS/ASME
identification or manufacturer unique ID code marked, on each individual rod, by
manufacturer, with slag stencil or stamps.
 Marjan Increment Program
Tanajib Gas Plant (TGP) Industrial Support Facilities
WELDING CONSUMABLE CONTROL PROCEDURE

BI/J.O. No.: BI-10-09003-0006 / MTGP13 Period: 29 OCTOBER 2020

Document No. : RTA-ISF-M-GA-1081 Revision No. : 00

1.12. Shielding Gases

1.12.1. Shielding gases shall conform to requirements of AWS A5.32, Specification for shielding
gases.
1.12.2. Use of other gases and gas mixtures shall be submitted to CSD for approval as per
(SAES-W-011 Para 6.7)
1.12.3. Shielding gases have vendor certificates attesting to the purity of their product for the
gases listed below (refer to attachment 4 of SAIC-W-2032)
1.12.3.1. Argon (Ar): Compressed Gas Association CGA G-11.1 (99%+)

1.13. Instrument and Equipment to be used

1.13.1. Shall be provided with electrode control room for safe keeping and storage of welding
consumables and other related accessories.
1.13.2. Each Electrode control room shall have temperature controlled stabilizing ovens for
welding electrodes.
1.13.3. Stabilizing ovens shall be provided with calibrated thermometer having temperature range
that would cover holding and reconditioning of electrodes.
1.13.4. Oven conditions shall be monitored daily by electrode controller, log book and verification
report using SATR-W-2009 shall be always readily available for inspection/audit by Welding
Inspector.
1.13.5. Portable Quiver shall be issued to each welder for keeping electrodes at moisture-free
condition while at work

4. Storage, Handling & Conditioning of Welding Consumables

1.14. Material Receipt & Storage
1.14.1. Upon receipt of welding materials (ie. bare and covered welding Electrodes and filler wires)
Warehouse keeper shall check that welding Consumables show no sign of damage and that
seals on-hermetically and hermetically sealed containers are unbroken.
1.14.2. Warehouse keeper shall ensure that items conform to P.O requirements and that batch, lot
number, heat number etc material certification received along with the welding material is
verified with batch, lot and heat number are correct
1.14.3. After receiving inspection, the welding materials shall be stored in the warehouse or at the
Electrode Controlled room and being held at an ambient temperature.
1.14.4. Welding Consumables (ie. electrodes and filler material) shall be stored in a clean and dry
place.
1.14.5. Welding Consumables shall be stored indoor under the supervision of the Warehouse
Foreman.
1.14.6. Warehouse Keeper shall store the Welding Consumables on elevated rack according to
type and size.
1.14.7. All unopened containers of welding materials shall be identified by acceptance tag and
stored separately by classification and size
1.14.8. Particular care must be exercised in damp weather to avoid contact with the welding
electrode or holder
 Marjan Increment Program
Tanajib Gas Plant (TGP) Industrial Support Facilities
WELDING CONSUMABLE CONTROL PROCEDURE

BI/J.O. No.: BI-10-09003-0006 / MTGP13 Period: 29 OCTOBER 2020

Document No. : RTA-ISF-M-GA-1081 Revision No. : 00

1.15. Handling of Welding Consumable

1.15.1. After withdrawal of welding Consumables from the warehouse, electrode controller shall
store the unopened and undamaged containers at the Electrode Control Room.
1.15.2. When Containers of low hydrogen Electrodes are opened, they shall be immediately placed
in oven prior to use.
1.15.3. Storage oven shall have continues power supply during work and non-working hours or
days (night and weekend).Storage oven shall have valid calibrated Temperature gauge
when in use
1.15.4. Electrode controller shall ensure the electrode/Welding rods of different material in batch,
lot or heat number or returned electrode/welding rods shall be stored and segregated by
using separate oven or separate marked containers/shelves with in one oven
1.15.5. Where different types and brand of filler wire are to be used for gas tungsten arc
welding .Manufactures color code shall be listed as per type and brand for checking and
reference.

1.16. Electrode allowable atmospheric exposure

1.16.1. Exposure of low hydrogen, Stainless Steel and Non-ferrous electrodes shall not exceed the
following requirement as per SAES-W-011 Attachment I:
1.16.1.1. A5.1 Electrodes: 4 hours maximum open to atmosphere and 8 hours if
continuously kept in portable oven at 650 c
1.16.1.2. A5.5 Electrodes: 2 hours maximum open to atmosphere and 4 hours if
continuously kept in portable oven at 650 c

1.17. Handling and Conditioning of Electrodes

1.17.1. Electrodes belongs to damaged hermetically sealed containers shall undergo drying prior
to its re/issue for welding.
1.17.2. Electrodes shall be re-dried only once and marked or segregated prior to re-issue.
1.17.3. Any electrodes (low hydrogen or non-low hydrogen)and flux that have been wet or moist
shall be discard.

1.18. Drying and re-drying

1.18.1. Drying and re-drying of electrodes shall be performed as follows in accordance with
SAES-W-011 Para 6.2:
1.18.1.1. 2hours minimum at 2600C – 4300C for A5.1 Low-hydrogen electrodes
1.18.1.2. 2hours minimum at 3700C – 4300C for A5.5 Low-hydrogen electrodes
1.18.1.3. 2hours minimum at 1200C – 2500C for Stainless Steel & non-ferrous electrodes

1.19. Storage
1.19.1. Dried Electrodes & electrodes removed directly from its hermetically sealed containers
shall be stored in holding oven for 4 hours at 1200c.

1.20. Re-conditioning
4.7.1 Electrodes exposed to the atmosphere for less than permitted duration shall be re-
 Marjan Increment Program
Tanajib Gas Plant (TGP) Industrial Support Facilities
WELDING CONSUMABLE CONTROL PROCEDURE

BI/J.O. No.: BI-10-09003-0006 / MTGP13 Period: 29 OCTOBER 2020

Document No. : RTA-ISF-M-GA-1081 Revision No. : 00

conditioned or returned to the holding oven for 4 hours at 1200C before re-issue

1.21. Issuance of welding consumables

4.8.1 Welding Foreman shall prepare electrode request from using electrode Control Slip to
document and monitor the welding consumable issue and return for each welder, showing
type, size and quantity of electrodes and filler wires required.
4.8.2 Each welder shall submit the Electrode controller and collect electrodes / welding rods and
placed in pre-heated portable rod oven
4.8.3 Upon receipt of filled-up Electrode Control Slip, Electrode controller shall record/Log the
data using SATR-W-2010 for issued welding consumable and placed it on file for proper
monitoring
4.8.4 Portable rod oven shall be marked individually with welder stamp and welder shall utilize
SATR –W-2009.Portable electrode storage ovens are regularly checked for keeping
temperature at a minimum of 600C
4.8.5 Issuance of more than one (1) Welding consumable type shall be prohibited or issued to a
welder at the same time, i.e., stainless steel and carbon steel electrodes/filler wires.

1.22. Return of Welding Consumables

4.9.1 Upon receipt of returned/unused electrode, Electrode controller shall record the time and
check atmospheric exposure of returned electrodes. Low hydrogen electrode the allowable
exposure limit shall be placed in baking oven for re-drying.
4.9.2 Electrode controller shall check for damaged all returned electrodes, any electrode which
have defect ,such as de-fluxing, wet flux or illegible marking shall be discarded or disposed
properly.
4.9.3 Upon receipt of returned electrodes, Electrode Controller shall fill-up Electrode Control slip
and shall record/log the data using SATR-W-2010 for returned welding Consumable and
placed it on file for proper monitoring, record shall be readily available for Qc
Inspection/Verification.
4.9.4 At the end of the shift, Electrode Controller shall put color coding (High Temperature
resistant paint, Red) for all returned electrode at the electrode exposed tip core wire of the
exposed electrodes prior to re-conditioning. Welder in the subsequent shift shall use this
electrode.
4.9.5 Electrodes that are either exposed to water or breaking flux shall be discarded.
 Marjan Increment Program
Tanajib Gas Plant (TGP) Industrial Support Facilities
WELDING CONSUMABLE CONTROL PROCEDURE

BI/J.O. No.: BI-10-09003-0006 / MTGP13 Period: 29 OCTOBER 2020

Document No. : RTA-ISF-M-GA-1081 Revision No. : 00

Appendix I SAIC-W-2010

Receiving Inspection of Welding Consumables

 Marjan Increment Program
Tanajib Gas Plant (TGP) Industrial Support Facilities
WELDING CONSUMABLE CONTROL PROCEDURE

BI/J.O. No.: BI-10-09003-0006 / MTGP13 Period: 29 OCTOBER 2020

Document No. : RTA-ISF-M-GA-1081 Revision No. : 00

Appendix. II. SAIC-W-2032

Control of Welding Consumable

 Marjan Increment Program
Tanajib Gas Plant (TGP) Industrial Support Facilities
WELDING CONSUMABLE CONTROL PROCEDURE

BI/J.O. No.: BI-10-09003-0006 / MTGP13 Period: 29 OCTOBER 2020

Document No. : RTA-ISF-M-GA-1081 Revision No. : 00

Appendix III SATR-W-2009

Welding Rod oven Calibration/Verification Report

 Marjan Increment Program
Tanajib Gas Plant (TGP) Industrial Support Facilities
WELDING CONSUMABLE CONTROL PROCEDURE

BI/J.O. No.: BI-10-09003-0006 / MTGP13 Period: 29 OCTOBER 2020

Document No. : RTA-ISF-M-GA-1081 Revision No. : 00

Appendix IV SATR-W-2010

Welding Consumables Issuance Report

 Marjan Increment Program
Tanajib Gas Plant (TGP) Industrial Support Facilities
WELDING CONSUMABLE CONTROL PROCEDURE

BI/J.O. No.: BI-10-09003-0006 / MTGP13 Period: 29 OCTOBER 2020

Document No. : RTA-ISF-M-GA-1081 Revision No. : 00

Appendix. V SATR-W-2020

Welding Consumables Receiving Inspection Report

 Marjan Increment Program
Tanajib Gas Plant (TGP) Industrial Support Facilities
WELDING CONSUMABLE CONTROL PROCEDURE

BI/J.O. No.: BI-10-09003-0006 / MTGP13 Period: 29 OCTOBER 2020

Document No. : RTA-ISF-M-GA-1081 Revision No. : 00