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Reliance

Procedure for
Control of Welding Consumables

EPCMD-2-QM00-JEP-ME-027

01

14.04.2014

00

19.04.2013

Rev

Date

Revised and
re-issued for
Implementation
Issued for
Implementation
Revision

SRB

TD

SNS

TD

KSS / EMK

SNS

Prepared By

Checked By

Approved By

Reliance
Contents
1. Purpose .. 3
2. Scope ............ 3
3. Reference .......... 3
4. Abbreviations and Terms 3
5. Responsibilities .. 4
6. Methodology . 4

EPCMD-2-QM00-JEP-ME-027, Rev 01
Confidential Reliance. All rights reserved

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1.

Purpose
The purpose of this procedure is to have effective control of welding consumables for
timely availability as well as to meet quality requirements of the weldment.

2.

Scope
The scope of this procedure covers estimation of welding consumables, raising PR for
procurement action, checking welding consumables at CMC stores on receipt, approval
of

welding consumables

for

issue and issue

of welding consumables to the

contractor(s). This procedure is applicable for all construction activities carried out at
Jamnagar.

3.

Reference

4.
1

ASME Sec.II Part ( C) latest edition

EPCMD-2-QM00-JEP-ME-029 :Reconciliation of
Associated Consumables for Piping & Structure.

EPCMD-2-QM00-JEP-ME-021 : Procedure for approval of welding electrodes,


filler wires & fluxes manufacturers

EPCMD-2QM00 TCR ME013 :Technical supply conditions of welding electrodes,


filler wires and fluxes

Welding

Consumables

&

Abbreviations and Terms

CMC

Construction Material Center

CS

Carbon steel

Contractor

Construction contractors of Reliance

DCC

Document Control Center

FCAW

Flux Cored Arc Welding

GTAW

Gas Tungsten Arc Welding

GMAW

Gas Metal Arc Welding

LAS

Low Alloy Steel

LTCS

Low temperature carbon steel

MIN

Material Issue Note

PR

Purchase Requisition

P.O.

Purchase Order

QMD

Quality Management Department

EPCMD-2-QM00-JEP-ME-027, Rev 01
Confidential Reliance. All rights reserved

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5.

SS

Stainless Steel

SAW

Submerged Arc Welding.

SMAW

Shielded Metal Arc Welding

TC

Batch Test Certificate

WTG

Welding Technology Group, under QMD

Welding consumables- Welding electrodes, filler wires & flux used in GTAW, SMAW,
FCAW, GMAW, SAW processes

Responsibilities

Sr.
No.

1
Activity

Responsibility

01

Provide scope of work

Projects

02

Scope of welding automation

Area Construction
Manager

03

Estimate welding consumable, check stock level and Raise PR

WTG-QMD

04

Raise P.O.

Procurement

05

Receipt of welding consumables, check quantity and corelation with P.O.

CMC

06

Verify condition of welding consumables received in line with


technical supply conditions

QMD at CMC

07

TC verification and PMI (as applicable)

WTG-QMD

08

Taking welding consumables in stock and storage of welding


consumables in protected condition

CMC

09

Recommendation for issue of welding consumables from CMC

Construction manager
and QMD-Field

10

Approval for issue of welding consumables from CMC

WTG

11

Issue of MIN

Material coordinator

12

Issue of welding consumables from stores

CMC

Construction Managers/Engineer in Charges is responsible for implementing this


procedure in their area.

HOD, QMD is responsible for maintaining this procedure.

DCC is the custodian of this procedure.

EPCMD-2-QM00-JEP-ME-027, Rev 01
Confidential Reliance. All rights reserved

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6.

Methodology

6.1

Estimation of welding consumables, PR raising & verification of TCs :

1
6.1.1 WTG estimates welding consumables on receipt of Job scope, scope of welding
automation and EPCMD-2-QM00-JEP-ME-029 Reconciliation of Welding Consumables &
Associated Consumables for Piping & Structure. After checking the existing stock
level, WTG raises PR for meeting additional quantity requirements, if any.
6.1.2 After PR approval, WTG approaches Purchase department with reference to approved
PR, latest revision of Procedure for approval of welding electrodes, filler wires & fluxes
manufacturers (EPCMD-2-QM00-JEP-ME-021) and Technical supply conditions of
welding electrodes, filler wires and fluxes (EPCMD-2QM00 TCR ME013) to facilitate
procurement in time. Procurement group is raising PO accordingly.
6.1.3 After receipt of welding consumables at CMC stores, CMC verifies item, quantity and
co-relates with the P.O. Also AWS class, brand name, manufacturer, size, batch
number and condition of welding consumables is checked by QMD at CMC in line with
TC and technical supply conditions. In case co-relation is not established/ condition
does not fulfill requirements, matter is highlighted to WTG as well as procurement.
6.1.4 For CS and LTCS welding consumables, TCs are reviewed by WTG for checking
technical correctness. Whereas for LAS/SS/non ferrous welding consumables, over and
above TC review, PMI is carried out on every batch for positive identification of the
material. When TC as well as PMI results meet the requirement, CMC is informed to
take the material into stock. Wherever result does not comply with the requirements,
the same is rejected immediately and highlighted to procurement group. The supply
having discrepancy is kept under quarantine and such welding consumables are not
issued. Over and above, whenever there is reason to raise doubt against vendors
supply, any additional test is carried out, depending on type of consumable.

6.2

Storage of welding consumables :


Following guidelines have been given to CMC which can be reinforced from time to time
for effective storage:

6.2.1 Welding consumables must be stored in their original packing in a dry place adequately
protected from the effects of weather and in accordance with the manufacturer's
recommendations. For all consumables, the usage principle valid is: First-In FirstOut.
6.2.2 Welding consumables will be stored as per classification, size, batch number and
brand name with proper identification tags to facilitate retrieval.
6.2.3 When stored, SMAW electrodes will be stacked as shipped or as per the specific
manufacturer's recommendations.
6.2.4 Filler wire used must be properly stored to avoid damage and rust. They should be kept
in their original bundle or package.
6.2.5 Flux supply is made normally in bags with polyethylene inner lining and should be
stored as supplied.
EPCMD-2-QM00-JEP-ME-027, Rev 01
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6.3

Issue of welding consumables from CMC :


Following is the present approach for issuance of welding consumables:

6.3.1 Material withdrawal request is prepared by contractor & recommended by Construction


Manager for issuing the quantity. The welding consumable required is verified by field
QMD and approved by WTG.
6.3.2 Based on the approved request, MIN is issued by respective material coordinator.
Based on approved MIN, CMC issues the welding consumables.

7.
1

Discrepancy Handling
Any non conformance related to welding consumables at field is reported to WTG for
necessary action.

EPCMD-2-QM00-JEP-ME-027, Rev 01
Confidential Reliance. All rights reserved

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