Doc No :

Rev :
Quality Management System Page : 1 of 4

Effective Date :

Title : Welding Control Procedure

Rev. Description of Change Clause

A Initial Release for implementation. N.A.

B Overall review & fine tuning of the procedure to suit present condition. General

C Welding orientation to welders added as shown and inclusion of 3.1 e, 4

Welding Process Flow Chart.

Prepared By

QMS Engineer
_________________________ _______________________________ ______________________________
(Name / Signature) (Designation) (Date)

Reviewed By

Head, QMS
_________________________ _______________________________ ______________________________
(Name / Signature) (Designation) (Date)

Approved By

Management Representative
_________________________ ______________________________ ______________________________
(Name / Signature) (Designation) (Date)
 Doc No :
Rev :
Quality Management System Page : 2 of 4

Effective Date :

Title : Welding Control Procedure

1.
1. SCOPE:

This procedure specifies and details the methods for controlling the welding activities and conditions
for the pre-fabrication, pre-assembly and Mechanical erection activity for the project. This procedure
shall provide guidance to Welding and QA/QC personnel in the execution of their duties.

2. REFERENCE DOCUMENTS:

The following documents shall be referred to in conjunction with this procedure.

a) Approved Welding Procedure Specification and Procedure Qualification Record (WPS & PQR)
b) Client Technical Specification (if required)
c) Welder Performance Qualification Certificates (WPQ)
d) ASME Sec IX
e) AWS D1.1
f) ASME Sec. II Part C

3. PROCEDURE:

3.1. Welding Control

a) QA/QC Engineer shall be responsible for preparation of Welding Procedure Specification

(WPS) and Procedure Qualification Record (PQR), which will be sent to Fabrication
Engineer/Site Engineer for review and implementation. QA/QC Engineer shall be
responsible for carrying out procedure qualification tests and performance qualification tests
for welders and welding operators. Welding Supervisor shall assist QC Engineer to carry
out the tests. QC Engineer shall prepare and certify Welder Performance Qualifications
(WPQ) / Welding Operator Performance Qualifications (WOPQ) records. The qualification
of WPS shall be done as per ASME Sec IX - Welding, Brazing and Fusing Qualifications or
AWS D1.1 – Structural Welding Code-Steel or as per Client Specification.

b) Approved WPS applicable for the items shall be checked for availability. Supporting
Procedure Qualification Record (PQR) shall be qualified according to the welding
parameters specified in the project specifications. The PQR shall be subjected to applicable
NDT and Mechanical Destructive Test to satisfy the acceptance criteria such as ASME B
31.1, AWS D1.1, etc.

c) Welding Consumable Control Procedure (Doc. No. JEL-QMS-P01) which includes the
welding consumables storage, baking and issue, shall be prepared by QA/QC Engineer
based on the recommendation of the welding material manufacturer and approved by the
QA/QC Manager / Head.

d) QA/QC Engineer shall supply the approved WPS and List of Qualified Welders/Welding
Operators and WPQ / WOPQ to the Welding Supervisor for instructing the welders and
ensuring the compliance of parameters given in WPS and applicable Drawings. Welding
Supervisor shall display the relevant WPS/PQR (latest revision) at site/workshop. This has
to be periodically ensured by the QA/QC personnel.
 Doc No :
Rev :
Quality Management System Page : 3 of 4

Effective Date :

Title : Welding Control Procedure

e) Before starting welding works, the welders shall be given welding orientation by
welding supervisor and or QA/QC Engineer on approved WPS / PQR, control of
welding consumables, client specific requirements, site / shop regulations, etc. and
the record shall be maintained. Entire welding process shall be carried out as per the
Welding Process Flow Chart (Appendix A).
f) Welding Supervisor / foreman (including sub-contractor) shall instruct the welders during
the tool box meeting and allocate the job with respect to the relevant WPS.

g) Also the Welding Supervisor / Foreman shall examine the weld joints before welding to
ensure the cleanliness in and adjacent to the weld joint. He shall verify the WPS to ensure
that the recommended parameters like preheat, consumables and welder's qualifications
etc. are adhered to during welding.

h) Welding Engineer / Supervisor shall ensure that the welding equipment, welding
consumable storage cabinets / flasks / portable oven / quiver and baking / drying ovens are
in good condition for use.

i) Interruption of welding. Once welding has commenced, the normal field practice is to
completely fill the joint without interruption to welding. However, if an interruption in
welding is required, then it is essential that the deposited weld thickness is equal to the
lesser of 10 mm or 25% of the joint thickness. The partially filled weldment must be
immediately covered with thermal insulation blankets and the weld allowed to cool slowly.
The partially completed weldment in P No. 15E (SA 335 Gr. P91) material shall receive
an intermediate PWHT before resumption of welding. Before welding is resumed, the
weld surface shall be visually examined for cracks and the weldment heated to the
preheat temperature specified in the applicable WPS.

j) Welding Supervisor shall prepare Welding Record, which shall contain welder's number, the
detail of job, joint number and WPS employed.

3.2. Monitoring of Welding

a) Welding Supervisor shall ensure that only qualified welders are assigned for the respective
welding process and position. Welders / Welding Operators shall be identified with
“Welder / Welding Operator Identification Badge. Tack welders shall be qualified, if
necessary. Correctness of WPS used for the items welded shall be checked.

b) Upon completion of each weld joint, the Welding Supervisor shall ensure that the welder’s
number shall be marked on the pipe spool and entered on Welding Record for each joint
welded. QC shall maintain the welder continuity record based on the Welding Record.

c) Welding Supervisor shall strictly monitor the entire welding process and control it. QA/QC
personnel shall also take responsibility to monitor and random check the activities carried
out by the welders.

d) All welders’ mobility and joint welding especially Low Alloy Steel shall be monitored
frequently for WPS requiring pre-heat and PWHT.

e) For structure and other casing welding and fillet welds, monitoring shall be on random
basis only.
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Rev :
Quality Management System Page : 4 of 4

Effective Date :

Title : Welding Control Procedure

3.3. Welders Performance

Welders shall be monitored as per the followings:

 Welders utilized mainly for fillet welding and non-radiographic works activity shall be
visually checked by QA/QC Inspectors.

 Welders utilized for welding joints with radiography shall not exceed rejection rate of
2.75%. Otherwise the welders concerned will be subjected for re-training, re-
qualification or down-graded to fillet welding. Welders’ Performance are monitored
on monthly basis and recorded in the Welders’ Performance Record (PJT-QOHSER-
22).

4. RECORDS:

PJT-QOHSER-11 Welding Procedure Specifications (WPS)

PJT-QOHSER-12 Procedure Qualification Records (PQR)
PJT-QOHSER-13 Welder Performance Qualifications (WPQ)
PJT-QOHSER-14 List of Qualified Welders