Doc.

Title : PROCEDURE FOR WELDING CONSUMABLE CONTROL

Q A T A R Doc. No: : GAM-PRO-QAC-GTL-038 Rev. D Date 21.04.08

TABLE OF CONTENTS

1. SCOPE ________________________________________________________________________5
2. PURPOSE _____________________________________________________________________5
3. HSSE _________________________________________________________________________5
4. REFERENCES _________________________________________________________________5
5. DEFINITIONS _________________________________________________________________6
6. SAFETY _______________________________________________________________________6
7. RESPONSIBILITIES ____________________________________________________________7
7.1. Welding Engineer __________________________________________________________________7
7.2. Welding Inspector__________________________________________________________________7
7.3. Welding foreman __________________________________________________________________7
7.4. Consumable Store-Man _____________________________________________________________7
8. EQUIPMENT___________________________________________________________________8
9. PROCEDURE __________________________________________________________________8
9.1. GENERAL _______________________________________________________________________8
10. RECEIPT AND BULK STORAGE OF CONSUMABLES _____________________________9
11. ISSUE OF WELDING CONSUMABLES _________________________________________13
12. QUALITY ASSURANCE_______________________________________________________13
13. ATTACHMENTS_____________________________________________________________14

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 Doc. Title : PROCEDURE FOR WELDING CONSUMABLE CONTROL

Q A T A R Doc. No: : GAM-PRO-QAC-GTL-038 Rev. D Date 21.04.08

1. SCOPE
The scope of this procedure is to present the controls adopted by GAMA-QATAR for
storage, handling, identification, conditioning and issue of welding consumables to be
applied in the C2 ASU PEARL GTL PROJECT.

2. PURPOSE
The purpose of this procedure is to define the requirements for consumable handling and
assign corresponding responsibilities.

3. HSSE
All works shall be in compliance with the State of Qatar laws and regulations, Ras Laffan
Industrial City and International standards, codes, LINDE ENGINEERING AG and QSGTL
and/or its PMC requirements and instructions.

In addition all employees and GAMA subcontractor employees on site will have through
LINDE ENGINEERING AG Site Safety Induction and GAMA Qatar Safety induction for site
safety, health, environmental and security prior to work activities. Other training courses will
be attended as required by LINDE ENGINEERING AG or QSGTL and/or its PMC as
required.

4. REFERENCES
ASME Section IX: Welding & Brazing Qualification

ASME Section II: Part C- Specification for Welding Rods, Electrodes

And Filler Metals

T-13.377.441: Quality control requirements for welding

T-13.377.438: Specification for Traceability, Alloy verification and material

substitution

T.4.096.687: Welding Consumable control

DEP 31.38.01.31 GEN: Shop and field fabrication of piping

DEP 30.10.60.18-Welding of metal (Amendments/supplements to API RP 582)

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 Doc. Title : PROCEDURE FOR WELDING CONSUMABLE CONTROL

Q A T A R Doc. No: : GAM-PRO-QAC-GTL-038 Rev. D Date 21.04.08

5. DEFINITIONS

Company : QSGTL or its PMC

Contractor : LINDE ENGINEERING AG

Sub Contractor : GAMA QATAR

Contract : QSGTL Pearl Plant - C2 ASU Project

ITP : Inspection and Test Plan

QCP : Quality Control Procedure

QCR : Quality Control Record

WPS : Welding Procedure Specification

PQR : Procedure Qualification Record

WPQT : Welding Procedure Qualification Test

NDT : Non Destructive Testing

WQT : Welding Qualification Test

SMAW : Shielded Metal Arc Welding

SAW : Submerged Arc Welding

GTAW : Gas Tungsten Arc Welding

GMAW : Gas Metal Arc Welding

6. SAFETY

• All Operations shall be conducted in line with the requirements of the

construction Safety Procedures.
• Necessary personnel protective equipment will be provided and worn.

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 Doc. Title : PROCEDURE FOR WELDING CONSUMABLE CONTROL

Q A T A R Doc. No: : GAM-PRO-QAC-GTL-038 Rev. D Date 21.04.08

7. RESPONSIBILITIES
Responsibilities of project personnel relative to this procedure are described below:
7.1. WELDING ENGINEER
• Prepares the welding procedures and requirements for consumables as per the approved
welding procedures.
• Reviews purchase requisitions to ensure correct order specifications.
• Reviews welding consumable batch certificates accordance with ISO10474 3.1B
specification.
• Establishes re-order levels for welding consumables in line with project requirement.
• Supervises Consumable Room personnel and operations.
• Compiles Welding Consumables Identification Tables.
• Compiles Welding Consumables Conditioning Instructions.
• Has a responsibility for welding consumables control up the time of issue.
7.2. WELDING INSPECTOR
• Carries out Daily inspection/audit of the consumable room operations according to the
requirements of this procedure.
• Monitors, oven, hoppers and portable quiver(s) temperature on site and check calibration
status is valid.
• Monitors implementation of this procedure.
• Carries out weekly documented surveillance of consumables usage on site (check list)
7.3. WELDING FOREMAN

• Monitors handling of welding consumables on site in line with this procedure.

• Prepares Welding Consumables Request Card per WPS requirement.
• Ensure that all unused electrodes have been returned to the Consumables Store at the end
of the shift/day.

7.4. CONSUMABLE STORE-MAN

• Maintains effective general storage of consumables in the site storage room.
• Requisitions consumables from main stores.
• Carries out electrode conditioning per conditioning instructions and maintains
• Welding Consumables Treatment Record.
• Preheats portable quivers for issue of SMAW electrodes.
• Issues consumables against GAM-QCR-QAC-GTL-060
• Receives and handles returned consumables per procedure requirements and marks the
returned electrodes for re-baking or dispose-off previously re-baked electrodes. All the
returned electrodes shall be colour coded white at grip end or electrodes for re-bake and
reported in GAM-QCR-QAC-GTL-060

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 Doc. Title : PROCEDURE FOR WELDING CONSUMABLE CONTROL

Q A T A R Doc. No: : GAM-PRO-QAC-GTL-038 Rev. D Date 21.04.08

8. EQUIPMENT

• Baking and holding ovens and portable heated quivers for use with SMAW consumables
will be designed for that purpose. All these items shall be checked and calibrated
periodically in accordance with T-4-250-915.

• All calibration certificates shall be retained and filed for future reference and kept at the
QA/QC department.

• Temperature measuring devices on heating equipment above shall be indicator only.

Checks shall be by proprietary temperature sensitive crayon or by calibrated digital
thermometer on frequent basis (when in use).

• Measurement of atmospheric conditions shall be by thermometers and hygrometers.

9. PROCEDURE

9.1. GENERAL

• Approval of welding consumables

Welding consumables for use on this project (in the permanent works) shall be
approved by the Contractor through the approval of WPS' & PQR’s.

The Welding Engineer shall determine batch-testing requirements for welding

consumables per project specifications. These requirements shall be incorporated into
the purchase orders.

• Packaging of Low-hydrogen SMAW electrodes & SAW Flux

Low-hydrogen SMAW electrodes shall be supplied in standard packaging or,

alternatively, extra low moisture conditioned in specially designed vacuum packaging
(Vac Pac).
SAW flux, shall be supplied in polythene lined bags (If applicable).

• Purchase

Purchase orders shall be reviewed by the Welding Engineer to ensure correct and
adequate specification with respect to approved brand, and testing/certification
requirements. All certification shall be retained and filed for reference. All certification to
be submitted to Linde for approval before using.

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 Doc. Title : PROCEDURE FOR WELDING CONSUMABLE CONTROL

Q A T A R Doc. No: : GAM-PRO-QAC-GTL-038 Rev. D Date 21.04.08

• Identification of Welding Consumables

In order to permit effective surveillance & checking, individual consumables shall be

visually identifiable against brand/AWS class, which shall be marked on the electrodes
by the manufacturer or on site.

The Welding Engineer shall establish the consumable identification system, which shall
be documented and distributed to all relevant personnel.

10. RECEIPT AND BULK STORAGE OF CONSUMABLES

• Receipt

Incoming welding consumables shall be unloaded to an area segregated from other

certified stock. The Storekeeper shall receive deliveries of welding consumables
checking brand, AWS class, size, quantity and packing is as per the purchase order and
delivery document, and that certification is provided. Packaging shall be examined for
damage, which shall be reported to the Welding Engineer to determine the effect of
damage and advise disposition.

The consumable certification shall be reviewed by the Welding Engineer to determine

conformance with order specification and he shall endorse the certificate accordingly.
Return of the certificate to the Store man shall release the consumable for entry to stock
and transfer to bulk storage area in the warehouse.

Stacking of electrodes shall be carried out as per manufacture(s) recommendations.

Tagging of the electrodes is not required as electrodes are clearly marked by the
manufacturer(s) and they are separated in the consumable store based on their trade
name, AWS number and size.

• Bulk Storage of Welding Consumables

Bulk storage of welding consumables shall be in a designated area, which shall only be
used for storing welding consumables. The area shall be dry and protected according to
the manufacturer's recommendations.

The consumables shall be segregated by type (e.g. SMAW electrode, SAW flux, SAW
wire (If applicable), GTAW wire etc.), AWS class, brand, size, and batch number and
shall be maintained in original shipping bundles/pallets.

Consumables shall be stacked with adequate Dunnage at stacking heights per

manufacturer's recommendations and shall be tagged for ease of identification.
Consumables shall not be stored directly on the floor.

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 Doc. Title : PROCEDURE FOR WELDING CONSUMABLE CONTROL

Q A T A R Doc. No: : GAM-PRO-QAC-GTL-038 Rev. D Date 21.04.08

• ISSUE TO THE SITE CONSUMABLE ROOMS

The Consumable Room Store man shall issue welding consumables to the site
Consumable Rooms against a Stores Requisition prepared. The form to be checked and
signed by Gama Qatar Welding Engineer

Consumables shall be issued on a First-in/First-out (FIFO) basis whenever practical.

• SITE CONSUMABLE ROOM

The consumable room atmosphere shall be subject to control within the following
criteria:

5-15° C < 60%

15-25° C < 50%
Above 25° C < 40% Relative humidity

The QC Inspector on a daily basis, using a thermometer and hygrometer and reported
on the GAM-QCR-QAC-GTL-061, shall check consumable room atmospheric
conditions.
The consumables shall be segregated by AWS class (e.g. SMAW electrode, SAW flux,
SAW wire, GTAW wire etc.), brand, and size - batch and shall be maintained in original
packaging until split for conditioning or issue.

• METHOD OF MARKING BAKED, UN BAKED & RE-BAKED CONSUMABLES

Colour code for marking of baked and Un baked consumables will be as per
manufacturer’s standard colour chart .All returned consumables should be marked with
white at the grip end of electrodes before re-bake.

• CONDITIONING OF SMAW & ALUMINIUM WELDING CONSUMABLES

Conditioning thermal treatment of welding consumables shall be according to the

manufacturer's recommendations.

The Welding Engineer shall establish conditioning requirements based on

manufacturer's recommendations and supply conditioning instructions to the
Consumable Store-man stating temperature/time cycle for baking and holding via the
Welding Consumables Conditioning Table.

Baking and holding ovens shall be uniquely numbered and temperatures shall be
checked daily by the QCI, reporting on the GAM-QCR-QAC-GTL-062. Temperature
checks shall be by calibrated digital thermometer.

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 Doc. Title : PROCEDURE FOR WELDING CONSUMABLE CONTROL

Q A T A R Doc. No: : GAM-PRO-QAC-GTL-038 Rev. D Date 21.04.08

• LOW-HYDROGEN SMAW ELECTRODES

Extra-low moisture type electrodes supplied in 'Vac-Pac' does not require baking before
first use (only returned electrodes require baking) or the baking shall be according to the
manufacturers’ recommendation.

Electrodes supplied in standard packaging shall be baked as per Manufacturer's

instructions and as specified in the attached "Welding consumables conditioning
treatment table".

During baking, electrodes may be stacked to permit adequate heat distribution and to
avoid damage. There shall be no restriction for stacking in holding ovens. Contents of
the oven shall be clearly marked on the oven door.

Baking shall be the responsibility of the Consumable Store man and activities shall be
logged in the GAM-QCR-QAC-GTL-063, which shall record:

• Date
• Brand
• AWS class
• Batch number
• Size
• Quantity
• Oven number
• Treatment temperature
• Time when electrodes reach soak temperature
• Time of removal from baking oven.

In baking oven Temperature 300°C/Mfg Recommendations, on completion of the baking

cycle, the electrodes shall be transferred to a holding oven at temperature of 150°C/Mfg
Recommendations. Austenitic Stainless steel SMAW consumables shall be held in
separate ovens, segregated, identified properly, and the contents shall be displayed on
the oven door.

Vacuum-packed electrodes do not require baking prior to use.

Returned SMAW low hydrogen electrodes may be re baked once only. On receiving
returned electrodes, the Store man shall check the electrodes, discarding any showing
coating damage. He shall mark the bare end of the electrode with high temperature dye
prior to re-baking. Further returned electrodes displaying the dye indicator shall be
discarded and remove from the consumable room. Returned consumables shall be
recorded.
Returned electrodes being held for re-baking shall be placed in a storage location
segregated for this purpose.

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 Doc. Title : PROCEDURE FOR WELDING CONSUMABLE CONTROL

Q A T A R Doc. No: : GAM-PRO-QAC-GTL-038 Rev. D Date 21.04.08

• AUSTENITIC SMAW ELECTRODES

Control of baking and holding requirements shall be In Baking oven Temperature 300°C
& Holding oven Temperature 120°C to 150°C or Manufacturer's recommendation shall
be strictly followed and as specified in "Welding consumables conditioning treatment
table".
Consumables shall be stored in segregated area/shelving within the consumables
Store/issue room.

• SAW FLUX (IF APPLICABLE)

Basic and semi-basic SAW Flux shall be pre-treated in a heated flux holding oven
according to the Welding Engineer's instructions and the flux shall be transferred to
machine hoppers as required.

At the end of each shift any unused flux shall be removed from the SAW machine
hopper and returned to the heated flux holding oven.

Flux shall not be used direct from the bag.

Used SAW fluxes, may be re-circulated up to 3 cycles through the closed system. After
this the flux should be mixed with twice its volume of new flux prior to further use.

SAW Flux handling controls shall be in accordance with manufacturer's

recommendation.

• WELDING GASES

Gases used for weld protection purposes shall be of the welding grade composition
having purity, as defined on the relevant WPS's.

Protective gasses must be issued with appropriate conformance certificates and must
be stored as per vendor's recommendations.

The following provides guidance for the most commonly used gasses in welding:

Composition Table:

Composition Percent by value

Minimum Maximum
Oxygen N/A 0.005
Hydrogen N/A 0.005
Nitrogen N/A 0.005
Argon 99.9 100

Argon shall not contain more than 0.02 mm of vapour water per litre of gas measured at
21.1°C at 1 atm absolute, or have a dew point of -53.8°C or colder.
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 Doc. Title : PROCEDURE FOR WELDING CONSUMABLE CONTROL

Q A T A R Doc. No: : GAM-PRO-QAC-GTL-038 Rev. D Date 21.04.08

11. ISSUE OF WELDING CONSUMABLES

Welding consumables shall be issued against the GAM-QCR-QAC-GTL-060 minimum

the following information is required
• Date
• Area
• Welder’s Name
• Stamp No
• Issued QTY
• Type/Size
• Batch No
• Returned QTY
• Initials/Signature consumable store man
• Initials/Signature welder

• SAW & GTAW Wires

SAW & GTAW wires shall be issued in original packaging.

• SMAW Electrodes (General)

SMAW electrodes (Except Vac Pac) shall be issued into pre-heated portable quivers,
which shall maintain a temperature of 70° C minimum.

Quiver temperature shall be monitored by QCI on a daily basis as an element of the

daily welding audit. Portable quivers shall be individually numbered for identification.

Electrode issue quantities shall, as a maximum, be sufficient for one working shift.
Electrodes may be retained in quivers up to 5 hours maximum.

Quivers shall be returned to the consumable room at the end each session.

12. QUALITY ASSURANCE

A Quality Assurance System shall be operated conforming to related standards.
Controls and checks shall be established and documented.

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 Doc. Title : PROCEDURE FOR WELDING CONSUMABLE CONTROL

Q A T A R Doc. No: : GAM-PRO-QAC-GTL-038 Rev. D Date 21.04.08

13. ATTACHMENTS
• GAM-QCR-QAC-GTL-060

• GAM-QCR-QAC-GTL-061

• GAM-QCR-QAC-GTL-062

• GAM-QCR-QAC-GTL-063

• GAM-QCR-QAC-GTL-082

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 C2 ASU PEARL GTL PROJECT
RAS LAFFAN INDUSTRIAL CITY

Q A T A R WELDING ELECTRODE ISSUE REGISTER

Subcontract Ref.: Report No.

Item Description: Inspection Date:

Item Location / Area: Test Code No.:

Subsystem: ITP No.:

Ref. DWG / Documents:

Used Measuring and test equipment ref. (if applicable):

RETURN SIGNATURE OF
WELDING SIZE SIGNATURE
ISSUE WELDER NAME BATCH NO AREA ELECTRODE CONSUMABLE
DATE ELECTRODES IN MM WELDER NO OF WELDER
QUANTITY (WHITE PAINT) STORE MAN
AWS CLASS Ø

ORGANIZATIONS DATE NAME SIGNATURE

THIRD PARTY REP.

Accepted By

GAMA REP.

LINDE REP.

QSGTL REP.
GAM-QCR-QAC-GTL-060
 C2 ASU PEARL GTL PROJECT
RAS LAFFAN INDUSTRIAL CITY

QATAR WELDING CONSUMABLE STORE

ROOM CHECK LIST
Subcontract Ref.: Report No.
Inspection
Item Description:
Date:
Item Location / Area: Test Code No.:

Subsystem: ITP No.:

Ref. DWG /
Documents:
Used Measuring and test equipment ref. (if applicable):

SIGNATURE
S.NO DATE INSTRUMENT ID HOURS
TEMPERATURE HUMIDITY

ORGANIZATIONS DATE NAME SIGNATURE

THIRD PARTY REP.

Accepted By

GAMA REP.

LINDE REP.

QSGTL REP.
GAM-QCR-QAC-GTL-061
 C2 ASU PEARL GTL PROJECT
RAS LAFFAN INDUSTRIAL CITY

QATAR WELDING CONSUMABLE HOLDING

REGISTER
Subcontract Ref.: Report No.
Inspection
Item Description:
Date:
Item Location / Area: Test Code No.:

Subsystem: ITP No.:

Ref. DWG /
Documents:
Used Measuring and test equipment ref. (if applicable):

WELDING HOLDING
SIZE IN OVEN NUMBER BATCH NO SIGNATURE
DATE ELECTRODES QUANTITY HOURS TEMPERATURE
MM Ø
AWS CLASS

ORGANIZATIONS DATE NAME SIGNATURE

THIRD PARTY REP.

Accepted By

GAMA REP.

LINDE REP.

QSGTL REP.
GAM-QCR-QAC-GTL-062
 C2 ASU PEARL GTL PROJECT
RAS LAFFAN INDUSTRIAL CITY

QATAR WELDING CONSUMABLE BAKING

REGISTER
Subcontract Ref.: Report No.
Inspection
Item Description:
Date:
Item Location / Area: Test Code No.:

Subsystem: ITP No.:

Ref. DWG /
Documents:
Used Measuring and test equipment ref. (if applicable):

WELDING BAKING
SIZE IN OVEN NUMBER BATCH NO SIGNATURE
DATE ELECTRODES QUANTITY HOURS TEMPERATURE
MM Ø
AWS CLASS

ORGANIZATIONS DATE NAME SIGNATURE

THIRD PARTY REP.

Accepted By

GAMA REP.

LINDE REP.

QSGTL REP.
GAM-QCR-QAC-GTL-063
 C2 ASU PEARL GTL PROJECT
RAS LAFFAN INDUSTRIAL CITY
Q A T A R
WELDING CONSUMABLE REQUEST CARD
Item Description: Report No:
Iso.No : Date:
Area :

SR.NO BATCH NO AWS CLASS DIA - mm QTY REQUESTED QTY ISSUED

DESCRIPTION DATE NAME SIGNATURE

REQUESTED BY

ISSUED BY

CHECKED BY
GAM-QCR-QAC-GTL-082