Control of Welding Consumables

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

Page 2 of 6

Reliance 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

1

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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Reliance

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

Page 4 of 6

Reliance 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 vendor’s 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 Confidential © Reliance. All rights reserved

Page 5 of 6

Reliance 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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