Doc No.

: A286-GIGLM-1 004-P J-DOC-QAP-R-0006

~ S(C) Rev : 01
~ GSPL INDIA GASNET LIMITED
Date : 28 .11.2019 Page 1 of8

PROJECT MEHSANA-BATHINDA PIPELINE PROJECT (MBPL), PHASE-II,

SECTION -Ill (HARSOLI - NAWALGARH)

OWNER GSPL INDIA GASNET LIMITED (GIGL)

ENGINEERING ~N~IN~ERS INOlA LIMITFn (FII )

COSULTANT

CONSTUCTION INTERTEK INDIA PVT. LTD. (IIPL)

SUPERVISION

TPIA CERTIFICATION ENGINEERS INTERNATIONAL LIMITED (CEIL)

(EPC) CONTRACTOR JSIW INFRASTRUCTURE PVT LTD

PROCEDURE FOR

For Review
and approval Mahesh P.
For Review NIRAV
00 21 .10.2019
and approval PARMAR Mahesh P.
Prepared by Checked by Reviewed by Approved by
Rev Date Description
JSIW JSIW CEIL IIPL/GIGL
 Doc No. : A286-GIGLM-1 004-P J-DOC-QAP-0006

E GiC)
GSPL INDIA GASNET LIMITED

WELDING CONSUMABLE STORAGE & CONTROL

Rev : 01
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TABLE OF CONTENTS

SR. NO. DESCRIPTION PAGE NO.

1.0. PURPOSE 3

2.0 SCOPE 3

3.0 ~.~RENCES 3

4.0 MATERIALS I
I"

5.0 METHODOLOGY

6.0 QUALITY ASSURANCE & QUALITY CONTROL

I .. I

7.0 HEALTH,SAFETY & ENVIRONMENT 8

8.0 ITP/FORMATS 8

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~ GSPliNDIA GASNET liMITED Date :2 8.11.2019 Page 3 of8

WELDING CONSUMABLE STORAGE & CONTROL

1.0 PURPOSE :
The purpose of this procedure is to identify welding consumables Procurement, handling ,
storing, issuance and treatment of welding consumables in a control manner at site for
ensuring to assure quality of welding process for the MBPL Phase-2 (Section-Ill) Project.

2.0 SCOPE:
This procedure covers the Procurement, storage, inspection and issuance of electrodes as
required for the welding of Line pipes for the permanent installation at Section-Ill, Phase-11
in MBPL Project.

3.0 REFERENCES :
Following documents in totality or in part shall form the reference document:
o Ell Specification No: A286-000-06-041-WSP-01 Rev.9
o A286-000-06-41-WSC-01- WELDING SPECIFICATION CHARTS
o Standard for welding of pipelines and related Facilities-API 1104
o Specification for welding Electrodes and Filler Materials ASME Sec. II Parte.
o Gas Transmission and Distribution Piping System ASME B 31 .8
o Design and Construction Requirements for Cross Country Hydrocarbon Pipelines
OISD-141.

4.0 MATERIALS:
Electrodes/Filler wire
LPG Cylinder/Hand gloves
HALOGEN LIGHT
Mother and portable oven

5.0 METHODOLOGY :
5.1 Procurement Planning
• The JSIW shall provide all the welding consumables necessary for the execution of the
PROJECT such as electrode/filler wire, Hand gloves, LPG Cylinder etc. at his own expense
and these shall bear the approval of the CEIL/IIPL/GIGL. All welding consumables that are
to be used in this project shall not be older than six months from the date of LOA for JSIW.
The JSIW shall submit the details of the brand/make of welding filler materials along with its
successful use in a minimum of 300 km pipeline project earlier to the CEIL/IIPL/GIGL.

• The .electrode shall be suitable for the welding process recommended and the base metal
used. The physical properties of the welds produced by an electrode/ filler wire
mended for the welding of a particular base metal shall not be lower than the
~:::.u;.. values specified for the base metal, unless otherwise specified in lding
ci · ion chart and shall cor ~~p to the physical properties of the cia de/
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WELDING CONSUMABLE STORAGE & CONTROL

filler wire adopted . Where steels with different specified properties are joined the weld
metal yield strength shall match that of the higher strength grade.

• The choice of electrode shall be made after conducting the required tests on the electrode/
filler wire as per relevant standards, and shall be the sole prerogative of the
CEIL/IIPL/GIGL.

• The JSIW shall submit batch test certificate(s) from each electrode/ filler wire
manufacturer(s) furnishing all details of physical and chemical tests carried out by them for
each batch of electrodes to be used. Diffusible Hydrogen test and Mechanical fillet test.

• All electrodes/filler material qualification test records shall be submitted by the JSIW as per
the GIGL approval. The JSIW shall carry batch wise testing of electrodes.

• All electrodes/filler wires and fluxes shall be purchased in sealed containers. Storage and
handling shall be according to manufacturer's recommendation. The humidity of the area
where welding consumables are stored shall be maintained as per the manufacturer's
recommendation. Except the cellulosic coated electrodes, the electrodes removed from the
containers shall be kept in the holding ovens at the temperature recommended by tile
electrodes manufacturers. Baking ovens or storage cabinets with automatic heat controls
and with temperature recorder shall be provided to maintain required temperature for basic
and low hydrogen electrodes and welding flux. Out-of-the oven time of electrodes before
they are consumed shall not exceed the limits recommended by the electrodes
manufacturers. The electrodes shall be handled with care to avoid any damage to the flux
covering. No electrodes shall be left exposed to the atmosphere. Different grades of
electrodes shall be stored separately. Cellulosic electrodes shall be used as per the specific
recommendation made by the manufacturer.

• Manufacturer's recommendation for baking of low hydrogen electrodes shall be followed.

All low hydrogen electrodes shall be used within four hours of issue. If low hydrogen
electrodes are not used within four hours of issue or exposed to atmospheric conditions,
shall be baked again in accordance with the manufacturer's recommendation . Electrodes
are permitted to bake twice ONLY. If these electrodes after the second baking are not used
within four hours, they shall be discarded.

• The electrode used shall be free from rust, oil, grease, lamination, tear, scale and other
foreign matter, which affect the quality of weld.

• Welding Diffusible hydrogen in any of the weld shall be limited to a maximum of 10 ml per
100 g of weld metal irrespective of the type of consumables or welding method . The
method of determination shall be as per AWS A4.3 as indicated in AWS A5 .1 or ISO
3690:2012.
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WELDING CONSUMABLE STORAGE & CONTROL

• The above list shall be tallied against the project construction and delivery schedule in
consultation with the Project Manager, Construction Manager and Planning Engineer (site)
to visu~li;z;e the delivery sched ule of e~ch item . A minimum ord~r l~v~l ~hall b~ ~~t up in
cort8UilHliort with the procurement manager I officer for each item.

.. I or the pipeline Congtruction Work3 , the procurement function is intended to be ca r1·ied out
as following .

lrom site base office - Materials which can be sourced locally.

From head office - Bulk quantities of imported electrodes.

• The Project coordinator and the Planning engineer shall mark, in consultation with the
Project Manager, Construction Manager and the Procurement Manager a tentative quantity
of electrodes to be procured from site I Head office.

• The Procurement Manager at HO shall be responsible for overall procurement function and
control of purchase.

• All welding consumables which are required to be procured and installed permanently for
the project shall be new and specifically purchased for this job from GIGL approved
vendors, duly inspected by CEIL/GIGL.

• The purchase order for the bulk quantity of imported electrodes shall be placed directly to
the manufacturer. The manufacturer subsequent to its clearance from the inspection
agency shall arrange to deliver the consignment to site .

5.2 Documentation
The document~tion will be done ~s per the CEIL IIIPL/GIGL r~quirement$ (if ~ny) . Th~
dispatch /delivery details, packing list etc., will be made as per GIGL requirements.

For each major item, where the involvement of authorities and third parties are involved ,
CEILIIIPL will be consulted on case to case basis to finalize the documentation formats and
the same will be followed .

The manufacturer's batch conformance certificates shall be furnished along with the supply
wherever required.

5.3 Project Procurement Monitoring

The Project Procurement Status Report will be used as the tool to monitor and measure the
status of procurement activity and its overall impact on the project progress.
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WELDING CONSUMABLE STORAGE & CONTROL

5.4 Inspection
The batch test certificates for electrodes shall be reviewed by QAIQC department. The
visual inspection of packed electrodes shall be performed to ensure that correct batch test
certificate , classification and size of electrodes have been received . As per the
requirements of specification , and each batch of electrodes shall be tested as per EIL/GIGL
welding specification chart. The qualification test shall be performed.

On receipt of any project electrode JSIW QC inspector shall verify

1. The materials are procured from GIGL approved vendors only

2. The manufacturer test certificate for each batch is available (Original copy of MTC)
3. The electrode size, AWS class, date of manufacture and brand name shall be Co-
related.
4. The BTC shall also be co-related to ASME II Part-e and relevant SFA No. for
mechanical Properties , chemical composition .
5. Damaged packets of electrodes shall be checked and if observed to be deteriorated
then it will be rejected, and shall be marked with red colour for reject.

The QC inspector shall correlate the material with documents and inspect for physical
damage during the transit. Unaccepted materials shall be stored separately and to be
removed at the earliest.

5.5 Handling and Storage of Electrodes

The electrode packets shall be handled carefully so that there is no damage to flux coating
of electrodes. The electrodes shall be stored as per manufactures recommendations.
Electrode shall be stored separately with respect to size, batch no. and AWS classification.
Damaged and unused electrodes shall be stored separately with respect to size and AWS
classification . Packets of electrode shall be preferably stored in sealed condition only.

All electrodes shall be purchased in sealed containers and stored properly to prevent
deterioration . Electrodes shall be kept in oven , if required, at all conditions as per
manufacturer recommended temperature.

• The welding consumables store may be any suitable closed container.

• The QC manager & P.M . shall be responsible for the correct storage of the welding
consumables.

• Storage and disbursal of welding electrode material shall be controlled through a single
central location/ store personal.
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Unopened containers shall be stored separately according to the AWS/SFA classification

Page 7 of 8

and I or size.

• Bare welding rods shall be stored separately as per AWS/SFA classification and need not
be stored in heated ovens.

• Cellulose type covered electrodes E601 0 & E801 O-P1 shall be stored in a clean, dry area
and shall not be heated.

• Electrodes of different classifications shall be stored separately.

5.6 Issuance of Electrodes

The store in charge shall be issuing the electrodes only after receipt of issue slip signed by
welding engineer. Electrodes shall be issued on concept of "First in First out" (FIFO). There
shall be strict adherence to the concept of FIFO. The store in charge shall be responsible
for demonstration of the implementation of FIFO. Store in charge shall not accept any open
packets of electrodes. However, in case of exceptions he shall seal the electrode packets
by masking tape or other suitable method .

6.0 QUALITY ASSURANCE & QUALITY CONTROL :

Inspection & Test Planning

The quality assurance and quality control for the project procurement will be as per the
various documents as listed above.

Any special requirements of quality control over the vendors, as desired by GIGL, the same
shall be performed on a case to case basis , developing a suitable quality assurance
program in each case.

Audit
Since purchase and site material control being a critical activity, it will be subjected to
Periodic audits by the Internal Audit Wing from HO and internal audits by Site QA/QC In
charge to ensure the conformance of materials to the specifications.

Third Party Inspection

Wherever required, as per the contractual terms and conditions, the third party inspection
by any of the agents appointed by client from time to time, shall be resorted to as a quality
assurance function.
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~ GSPL INDIA GASNET LIMITED Date :28 .11.2019 Page 8 of8

WELDING CONSUMABLE STORAGE & CONTROL

7.0 HEALTH, SAFETY & ENVIRONMENT :

The project procurement plan is to ensure to adhere the safety requirements laid down by
the various regulatory bodies of the Country and the State as well as CEIL/GIGL safety
requirement on products .
No product or a by-product, which does not conform to the HSE requirement of the law of
the land should be promoted and used for the project.
The procurement manager and the procurement officers shall verify, and collect if
necessary, the provisions ensuring the safety during the manufacture and during the
service periods through documentation or by visual inspection to the extent practically
possible.

8.0 ITP/FORMATS :

Records for Electrode Baking : A286-GIGLM-1 004-PJ-FR-01 -QAP-0006

Note: In case of any conflict between the requirements of this procedure. GIGL
Specification shall govern.