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ARABI ENERTECH KSC ASME QUALITY CONTROL MANUAL

Workshop Division

WELDING CONTROL
7.1 SCOPE

7.1.1 All welding work shall be performed using a qualified and approved welding procedure
Specification (WPS) with welders/welding operators qualified &certified in accordance with
the ASME Code Sec. IX and applicable construction Code.

7.2 WELDING CONSUMABLES

7.2.1 Low hydrogen coated electrodes shall be stored and dried according to the consumable
manufacturer’s instructions to minimize absorption of moisture. Electrode class shall be
identified by metallic labels attached to the shelves in the oven. After drying, the
electrodes shall be stored in the holding oven and maintained at holding temperature
according to the consumables manufacturer’s instruction. Record of low hydrogen
electrodes loaded in the baking oven shall be recorded in the Welding Material Issue
Register.
7.2.2 Welding consumables shall be issued to the welder by the Storekeeper against of
“Welding Material Transaction Slip - WMTS” (AE/WSD/F-036) signed by the Welding
Foreman.
7.2.3 Each welder shall have a portable dry oven or quiver to allow him to keep his electrodes.
The portable dry oven or quiver shall be kept in good condition so that dry temperature
range should be maintained minimum 65°C (149°F) to 100°C (212°F). Low hydrogen
electrodes that have become wet or contaminated by foreign material shall be discarded.
7.2.4 “Out of oven time” of electrodes, before they are consumed, shall not exceed 4 hours.
The electrode shall be handled with care to avoid any damage to the flux covering.
7.2.5 At the end of the shift all unused consumables shall be returned to the store and kept in
Holding oven provided that they are undamaged and fully identified.

7.3 WELDING PROCEDURE SPECIFICATION

7.3.1 QC Engineer shall be responsible for preparation and qualification of “Welding


Procedure Specification-WPS” and certification of “Procedure Qualification
Record-PQR” as per ASME code Sec. IX with additional requirements of applicable
construction Code. He prepares Weld Map and assigns WPS to Weld Joints.
7.3.2 WPS shall be qualified by welding and testing the test coupons in accordance with ASME
Sec. IX and the construction Code requirements. QC Engineer shall supervise the welding
of test coupons and record the parameters used in welding of test coupon.
7.3.3 The welded test coupons shall be sent to an approved laboratory for mechanical testing
of the test specimens in accordance with the Code requirements.
7.3.4 On successful completion of the testing, QC Engineer shall enter the details on PQR form
and certify same.
7.3.5 WPS shall be considered qualified, when supported by certified PQR.
7.3.6 Copies of the qualified WPS and approved for the job shall be provided to the Fabrication
Forman for production welding.
7.3.7 A “List of WPS and PQR’’ (AE/WSD/F-020) shall be maintained by QC Engineer.
Applicable WPS and PQR shall be submitted to the AI for his review before start of
welding on Code items.
7.3.8 Whenever an essential variable or when applicable, supplementary essential variable is
changed, a new WPS shall be qualified. All new WPS shall be qualified as per the latest
applicable ASME Code Sec. IX and applicable construction code requirements.

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ARABI ENERTECH KSC ASME QUALITY CONTROL MANUAL
Workshop Division

7.3.9 Whenever a non-essential variable is changed, the WPS shall be issued with new revision.
7.3.10 PQR shall list all essential and when applicable Supplementary Essential variables. WPS
shall list all essential, nonessential and when applicable supplementary essential
variables.
7.3.11 Standard Welding Procedures (Article V of ASME Code Sec IX) are not used in AE.

7.4 WELDER/WELDING OPERATOR QUALIFICATION

7.4.1 All welders/Welding Operators employed on the production welds shall be qualified in
accordance with ASME Sec. IX and construction Code requirements. “Welder
Performance Qualification Record-WPQR” (AE/WSD/F-019) shall be prepared and
certified by the QC Engineer. QC Engineer shall supervise the welding of test coupons
and record the performance variables used.
7.4.2 The test coupons shall be sent to an approved laboratory for mechanical testing or
alternatively radiography examination when allowed by ASME Sec-IX. On successful
completion of tests, QC Engineer shall record the details of qualification on WPQR and
certify same.
7.4.3 Based on the welder qualification records, QC Engineer shall prepare and approve “List
of Qualified Welders” (AE/WSD/F-021) along with WPQ and issue the same to
Fabrication Forman to enable him allocate suitable welder for the welding work. A WPQR
master file and list of qualified welders shall be made available to the AI for review at any
time.
7.4.4 Welders are re-qualified in accordance with paragraph 7.4.1 & 7.4.2 above if:-
a) A performance essential variable changes
b) When he has not welded with a process during a period of 6 months, his
qualification for that process expires; unless, within the 6 month period, prior to
expiration of his qualification.
A welder, who has welded using a manual or semiautomatic welding process,
shall maintain his qualification for manual and semi-automatic welding for that
process for additional six months.
A welding operator, who has welded with a machine or automatic welding
process, shall maintain his qualification for machine and automatic welding for
additional six months for that process.
c) When there is specific reason to question his ability to make welds that meet
specification, the qualifications which support the welding he is doing will be
revoked. All other qualifications not questioned remain in-effect.
d) The AI has reason to question a welder’s ability to make welds that meet the
specification.

7.4.5 Renewal of qualification expired as described in 7.4.4 b), may be made for any process
by welding a single test coupon of either plate or pipe of any material, thickness or
diameter, in any position, and by testing of that coupon as required by Sec IX. A
successful test renews the welder or welding operator’s previous qualification for that
process for those materials, thickness, diameter, position, and other variable for which he
was previously qualified.
7.4.6 No individual shall be allowed to weld (including tack welding) if he is not qualified.

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ARABI ENERTECH KSC ASME QUALITY CONTROL MANUAL
Workshop Division

7.5 WELDER IDENTITY AND CONTINUITY

7.5.1 All qualified welders shall be given a unique identification number and issued a welder ID
card. QC Engineer shall be responsible for allocation of identification numbers and
keeping their records. This ID cards should show the range for which they are qualified.
During work they must always carry card with them. In case a welder leaves AE, his
identification number shall not be re-issued to any other welder.
7.5.2 Record of welders used for each weld shall be kept in “Weld Summary Record”
(AE/WSD/F-038), by QC Engineer. Fit up & welding record shall be principal document
to identify the welder who welded a particular seam.
7.5.3 In addition to the fit up & welding record, welders shall mark or stamp their identification
number near the weld seam at an interval not more than 3 feet (1 meter.) (When
stamping on the part is permitted.)
7.5.4 Welder continuity is maintained by endorsing each “Welder Continuity Record”
(AE/WSD/F-019A) periodically not exceeding a period of 6 months. Endorsement shall
be made by QC Engineer based on the continued satisfactory performance of the welder
for each process he is qualified for.

7.6 PRODUCTION WELDING CONTROL

7.6.0 As specified on the Weld Map, the fabrication Forman shall arrange for welding of various
seams using WPS stated on the Weld Map. After selecting suitable welder using the List
of Qualified Welder & WPQ, he shall explain to the welder the applicable requirements of
the WPS and then allow welding work to proceed.
7.6.1 Welding shall be carried out by qualified welders in accordance with approved WPS.
7.6.2 Tack welds used to secure the alignment shall either be removed completely when they
have served their purpose or their stopping and starting ends shall be properly prepared
by grinding or other suitable means so that they may be satisfactorily incorporated in the
final weld.
7.6.3 All tacking shall be done by qualified welders using qualified and approved WPS. Tacks
shall be visually examined by the QC Engineer for visual defects during the fit-up
inspection. If found defective, tacks shall be removed.
7.6.4 On completion of each run, craters, welding irregularities, slag etc. shall be removed.
Wire brushes used for cleaning stainless steel joints shall have stainless steel wires and
grinding wheels used for grinding stainless steel shall be of suitable type. Separate
grinding wheels and wire brushes should be used for carbon steel and stainless steels.
7.6.5 While the welding is in progress, care should be taken to avoid any kind of movements of
the components, shocks, vibrations and stresses to prevent occurrence of weld cracks.
Care shall also be taken to protect the welding activities from adverse weather conditions
like wind, rain, dust etc.
7.6.6 The Fabrication Forman shall ensure that the welding including pre-heat is being carried
out as per the approved WPS. All weld surfaces shall be cleaned and kept free of any
spatter, scales, slag and oxidation. Any lugs or temporary attachments welded for
alignment shall be removed in such a manner to avoid damage to the material.
7.6.7 All weld edge preparation, fit ups and surface after back chip and final welding shall be
examined by QC Engineer and record of this inspection shall be kept on Fit up & Welding
Record. He shall be responsible for offering to the AI for clearance on fit up & welding
record as per his designated inspection points.
7.6.8 All welds shall be visually inspected by QC Engineer to ensure that they are free from
unacceptable defects and welds meet Code requirements.

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ARABI ENERTECH KSC ASME QUALITY CONTROL MANUAL
Workshop Division

7.6.9 Weld repair shall be carried out using a qualified and approved WPS. Unacceptable weld
discontinuities shall be completely removed by chipping, grinding, gouging, or other
methods (suitable for the type of material being repaired) to clean, sound metal and
excavated area shall be examined and weld repaired.
7.6.10 For production weld test plates the requirements shall be indicated on the drawings with
details specified on ITP (regarding the seams for which test plates are required). QC
Engineer shall be responsible to ensure Code compliance for while welding and testing of
production test plates.

7.7 REVIEW BY AUTHORISED INSPECTION

7.7.1 Records of all WPS, PQR, WPQR with other relevant production welding documents shall
be made available to the AI for his review
7.7.2 AI may ask for re-qualification of any procedure or welder for cause at any time.

7.8 USE OF INDIVIDUALS FOR THEIR SERVICES AS WELDERS

7.8.1 Some times at field sites or in the shop depending on the work load, it may become
necessary to use individual welders/welding operators, who are not regularly employed
by company, for their services as welders or welding operators by contract or
agreement. In such cases,
7.8.2 Arabi Enertech shall be responsible for all Code construction including welds made by
such welders.
7.8.3 All such welders shall be qualified by Arabi Enertech QC Engineer in accordance with the
requirements of this Section. All welding shall be performed as per the Arabi Enertech
WPS.
7.8.4 Arabi Enertech QC Engineer shall be responsible for the complete and exclusive
administrative and technical supervision of such welders. He shall have authority to
assign or remove any welder at his direction without involvement of any other
organization.
7.8.5 Welders not in employment of Arabi Enertech when used shall be given a unique
identification number as detailed in paragraph 7.5. These numbers shall be of different
series than that used for AE welders.
7.8.6 QC Engineer (for shop) and Site QC Engineer (for field sites) shall be responsible to keep
all records and present them to the AI for review.
7.8.7 Arabi Enertech is responsible for the Code compliance of the vessel or part, including
Certification Mark stamping and providing MDR/MPDR with the acceptance of the AI.
7.8.8 Workshop Manager shall ensure that the program is acceptable to the AIA.

Section: 7 Revision: 1 Issue: 3 Date: 12/12/2013 Page 4 of 4