SPARKLE CLEANTECH PVT. LTD.

QC PROCEDURE

Document Title
WELDING CONSUMABLE CONTROL,
STORAGE AND ISSUANCE PROCEDURE

Document No
SCTPL-Q-P-001

A1 22.03.2019 Issued for RK ASP ASP

Implementation
Rev Date Purpose of Issue Prepared by Checked by Approved By
 REF : SCTPL-Q-P-001
Welding Consumable
REV. No. : A1
SPARKLE CLEAN TECH PVT LTD Control, Storage and REV. Date : 22.03.2019
Always moving forward… Issuance Procedure

INDEX

Sr. No Description

1.0 SCOPE

2.0 REFERENCE DOCUMENTS

3.0 RESPONSIBILITIES

4.0 GENERAL REQUIREMENTS

5.0 WELDING CONSUMABLE CONTROL PROCEDURE

6.0 ATTACHMENT

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Welding Consumable
REV. No. : A1
SPARKLE CLEAN TECH PVT LTD Control, Storage and REV. Date : 22.03.2019
Always moving forward… Issuance Procedure
1.0 SCOPE:
1.1 The purpose of this procedure is to ensure that all welding consumables are received, stored,
conditioned, issued and used in an effective and controlled manner.
1.2 This procedure describes the Welding Electrodes, bare filler wire and SAW Fluxes that how
the requirements will be strictly implemented and complied by Welding and Fabrication
team, same will be monitored by QC Welding Inspectors directly.
1.3 This procedure applies to all projects and all Sparkle fabrication shop and construction sites.

2.0 REFERENCE DOCUMENT:

2.1 ISO 9001-2008
2.2 ASME Sec IX. Ed. 2017
2.3 ASME Sec. II Part C
2.4 ASME Sec VIII Div.1 Ed. 2017
2.4 ASME Sec VIII Div.2 Ed. 2017
2.5 ASME B31.3 Ed. 2017
2.6 API 650 Ed.2013
2.7 API 620 Ed. 2013

3.0 RESPONSIBILITIES
3.1 Fabrication Shop Manager
Will ensure that the shop team associated with the requirements of this procedure i.e.
welding consumable stores and QC department are provided with the necessary facilities
and co-operation from all Welding and Fabrication personnel -Welding Supervisors and
foreman for satisfactory implementation this procedure to customer requirements and
continually monitor the effectiveness.
3.2 Welding Supervisor/Superintendent/Foreman
Implements and continually ensure the requirement of compliance to this procedure by
store, welding team and by all Welders to Customer Specifications, ITP, approved WPS and
manufacturer recommendations.
3.3 Welding Consumables Controller
Responsible for the receipt, verification for identification/classification, quantity, batch
certificates, inspection by QC Welding inspector, storage, conditioning and issue of all
consumables from the welding store.
No welding consumable to be issued without inspection and acceptance by Welding
Inspector and consequent instructions [Note: sometimes client inspection may be required
before acceptance].

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 REF : SCTPL-Q-P-001
Welding Consumable
REV. No. : A1
SPARKLE CLEAN TECH PVT LTD Control, Storage and REV. Date : 22.03.2019
Always moving forward… Issuance Procedure
Ensures that only the consumables which are traceable and approved are received into
stores and issued on DOM [date of manufacture] basis. He maintains records of Copies of
batch certificates, Oven calibration records and Consumable receipt, baking, conditioning
and issue register. He will demonstrate same during periodical surveillance by QC
department and customer representative.
3.4 Welding Inspector
Monitors daily welding activities and verifies compliance to the receipt, issue, control and
use of the correct welding consumables.
3.5 Material Controller
Ensure that all welding consumable received comply with purchase order requirements and
that the certification for the items received is forwarded to the QC supervisor for review,
inspection and approval, retention, maintains log of all consumable receipts.

4.0 GENERAL REQUIREMENTS

4.1 Electrodes, Filler Wires and Fluxes shall be purchased in accordance with ASME Sect. II Part C
as per approved WPS and from M/s Client approved manufacturer only(if mentioned in
project requirement) with Batch/lot certificates with inspection clause EN 10204 -3.1.
4.2 Welding consumable includes SMAW electrodes, and GTAW, GMAW, FCAW filler wires, all
welding consumables shall have been identified by marking. Manufacturer's name, size and
AWS class at the time of receipt.
4.3 All filler wires shall be identified with an AWS punch mark on the end by manufacturer and in
addition same will be identified with color coding also at shop as explained in this procedure.
4.4 Unlisted welding consumable other than ASME Sect. II Part C shall obtain Client approval
through the welding procedure review process. Other consumables shall be used with the
approval of Client and, depending upon the process and application proposed and may
require testing in addition to that specified in ASME IX.
4.5 Shielding Gases GTAW and GMAW shall conform to the requirements of Project and
applicable WPS.
4.6 Control of welding consumables shall be in accordance with this procedure.
4.7 Instrument & Equipment to be used in welding consumable control room for storage, baking,
holding and other temperature measuring shall valid calibration certificates.
4.8 Each Welding consumable control room shall have temperature controlled baking, holding
ovens for welding electrodes conditioning as required.
4.9 Portable quiver shall be issued to each welder for keeping electrodes at moisture-free
condition while at work. The temperature and working condition of quivers shall be
externally monitored by using calibrated temperature measuring instruments.
4.10 The following Equipment's and Instruments shall be calibrated at the maximum of
cycle of twelve (12) months or stringent requirement of contract Schedule and after
maintenance. The valid certificates or Validity stickers shall be displayed

1. Electrode Baking Oven

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REV. No. : A1
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2. Electrode Holding Oven
3. Flux Holding Oven
4. Thermo Hygrometer
5. Portable oven (quiver)
4.11 In case multiple contracts are handled at shop at a time, the consumable storage area,
Holding oven, receipt and issue system shall be separate against to contract number. Not to
be mixed up.
4.12 Alloy steel, Stainless steel, DSS and SDSS welding electrodes stored, baked, kept in holding
oven shall separately, individually be carried out, not to be mixed up with other carbon steel
electrodes. Mixing up will be subject to rejection of entire consumables.

5.0 WELDING CONSUMABLE CONTROL PROCEDURE

5.1 Receipt and Storage
No welding consumables will be allowed into stores for stacking/storage and issue until subject
consumables are verified and accepted in all respect by QC Supervisor/QC inspector.
All Electrodes, filler wires, and fluxes and its brand shall conform to approved applicable WPS. QC
will endorse his acceptance after verification against to requirement on BTC and Material receipt
record [MRR/MRIR]. All signed BTC and Receipt record will be retained at welding consumable
stores and copies with QC department which is traceable on demand.
The Baking and Holding ovens used for conditioning welding consumables shall have temperature
indicators that are maintained in a current valid calibration.
5.2 Storage and Stacking at stores
All welding consumables shall be stored and stacked in racks, off the floor on pallets, in such a way
to prevent any physical damage or contamination Consumables for use on various grades and types
of material shall be clearly segregated by AWS classification [type] and size on stacking shelves
clearly identifying its grade and size so as to control the possibility of error during issue.
Separate baking, holding ovens shall be used for immediate conditioning according AWS material
classification example: carbon steel and stain less steel to avoid metallurgical contamination
5.3 Temperature/Humidity
The temperature and humidity of the store shall be, such as to maintain a suitable atmosphere to
prevent deterioration or contamination of the electrodes and filler wires/fluxes. Manufactures
recommendations and storage instructions shall be followed.
Calibrated valid temperature and humidity measuring instruments shall be provided in welding
consumable stores to ensure the same.
5.4 Stock Rotation and issue
All flux coated welding consumable shall be issued/used on a DOM [Date of manufacture] basis by
details provided in packs and BTC. Filler wires either DOM or "First-IN Fist -OUT" basis or DOM basis.

5.5 Baking, Holding and issue of Electrodes

Other than low hydrogen electrodes requires to be dried as per requirements of manufacturer
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REV. No. : A1
SPARKLE CLEAN TECH PVT LTD Control, Storage and REV. Date : 22.03.2019
Always moving forward… Issuance Procedure
recommendations. The manufacturer's requirement shall be made available with Welding stores
All packaged low hydrogen flux coated electrodes shall be conditioned in accordance with this
procedure, clients specifications and manufacturers Recommendations prior to issue for use.
Baking Temperature shall be as per manufacturer’s recommendations in baking oven. Controlled
baking with record/register of AWS class, Batch#, size, date, time of loading into baking oven and
baking duration and time of transfer to holding oven shall be maintained as per attached format.

5.6 Drying and Re-drying

Drying and Re-drying of electrodes shall be performed in accordance with manufacturer
recommendations.
Storage baked electrodes & electrodes removed directly from its hermetically sealed containers
shall be stored in holding ovens kept at temperature in accordance with manufacturer
recommendations.
5.7 Issuing of consumables
Welders requiring consumables, shall identify their requirements to their direct supervisor who will
issue sign a Consumable request slip after verification against WPS in use only sufficient consumable
to issue a welder production for a maximum of four hours at will be requested at given time the
issued slip will be provided to the welder are designated assistant so as to with draw from the
welder store.
The consumable control personnel will only issue the consumable to the welder or designated on
presentation of a fully completed welding consumable request register duly sign by the welding
foremen/supervisor.
The welding store person will make entry on the welding consumable contribution Form shall
following details
1. Contract
2. Project
3. Plant area location of project
4. Welder name symbol
5. Issued and returned quantities
6. Size, type and batch numbers
7. Signature of receipt
5.8 Re-conditioning
Electrodes exposed to the atmosphere for less than the permitted duration shall be re-conditioned
or returned to the holding oven as per manufacturer’s recommendations before re-issued.
The temperature of holding oven shall be maintained continuously at 120°C,
Electrodes supplied in hermitically sealed metal containers may be first issued without conditioning
with limitation that same to be issued directly to portable welder quivers after opening; however
remaining electrode shall be kept in holding oven at 120°C
Limited electrodes shall be issued from the holding oven to Portable Welder's quivers which are
preheated to 70oC to 80°C, against authorized "Welding Consumable Request Register Filled", same
shall have welder name and welder ID number.
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Welding Consumable
REV. No. : A1
SPARKLE CLEAN TECH PVT LTD Control, Storage and REV. Date : 22.03.2019
Always moving forward… Issuance Procedure
No electrodes shall be issued without authorized Welding Consumable Request Register Signature
which is duly signed by Welding Supervisor/ Foreman.
The Welder requiring consumables identify their requirement to their direct supervisor, who will
issue and sign a Welding Electrode Request register after verification with WPS in use. The limitation
to authorize based on shift production maximum four hours.
The Welding store persons shall maintain complete details in register about of date, time, welder
name, ID number, AWS class, size, quantity and batch
Issued as well quantity returned will be checked by QC as well as Client representative
Low hydrogen type electrodes for carbon steel applications that remain unused at end of shift or
working hours shall be returned to consumable stores in the same electrode quivers and
temperature. Then returned electrodes will be examined if damaged one will be scrapped, if there is
no damage will be separated and used only for miscellaneous non-permanent works.
"Electrodes can be baked only one time or as specified by manufacturer recommendations".
5.9 Filler wires/ Fluxes
Same welding Consumable request slip system to be followed for Filler wires and fluxes also.
All filler wire shall be taken from storage container ensuring that each rod is clearly identifiable to
type and grade [AWS], if no, requires to be scrapped
Filler wire for alloy material shall be purchased individually stamped marked with material ID/AWS
class
If there is no stamping or ID on filer wires then end colour coding may be followed subject. A
separate work instruction requires to be developed for various filler wires applicable in the project
and its colour.
Filler wires for SAW, GMAW, FCAW or STT will be retained on their original spools case. Only spools
with proper Batch number identification and AWS class will be issued
Bare Filler Metal Color Coding Table 1
Classification Color Coding
ER7OS-6 Blue
ER70S-G Red
ER80S Orange
ER90S Yellow
ER308 Blue
ER308L Yellow
ER309 Black
ER309L Beige
ER316 Orange
ER316L Brown
ER321 Red
ER347 Copper
ERNiCr-3 Green

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REV. No. : A1
SPARKLE CLEAN TECH PVT LTD Control, Storage and REV. Date : 22.03.2019
Always moving forward… Issuance Procedure
6.0 ATTACHMENT
WELDING CONSUMABLE RECEIVING LOG
WELDING CONSUMABLE BAKING REGISTE
WELDING CONSUMABLE ISSUANCE RECORD

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 WELDING CONSUMABLE RECEIVING LOG
Manufacturer & Product
Date Size Dia X Batch No / PMI Report No. Production
Type SFA No Description Lot No QC Sign
Received Length Heat No (Alloy) Issue Date
(UNIT PACKAGE TYPE & WEIGHT)
 WELDING CONSUMABLE BAKING REGISTER
Electrode Electrode Batch Electrode Size Baking Time Baking Holding Material
DATE Qty.
Brand / SFA No. / Lot No (mm) Start End Temperature Temperature Controller Sign
 WELDING CONSUMABLE ISSUANCE RECORD
HEAT NO /
DATE WELDER ID SFA NO MAKE SIZE QTY ISSUED ISSUE TIME ISSUER SIGN QTY RETURNED RETURN TIME QC Sign
BATCH NO