Doc No : JEL – QMS - P01
JURONG ENGINEERING LIMITED Rev : B
Quality Management System
Page : 1 of 5
Effective Date : 11-Feb-2016
Title : Welding Consumable 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
Prepared By
QMS Engineer
___________________________ _______________________________ ______________________________
(Name / Signature) _ (Date)
(Designation)
Reviewed By
Head, QMS
___________________________ _______________________________ ______________________________
(Name / Signature) (Designation) (Date)
Approved By
Management Representative
___________________________ ______________________________ ______________________________
(Name / Signature) (Designation) (Date)
Doc No : JEL – QMS – P01
JURONG ENGINEERING LIMITED Rev : B
Quality Management System Page : 2 of 5
Title : Welding Consumable Control Procedure
1. SCOPE:
This procedure covers the requirements of receipt, handling, storage and usage of all welding
consumables for the project. This may be slightly modified to meet Client Requirements or Project
Technical Specifications.
2. REFERENCE:
1. JEL IMS documents
2. ASME Section II – Part C latest edition
3. Client Specifications (if any)
3. RESPONSIBILITY:
3.1 The Material Controller is responsible for
a. Receipt of consumables.
b. Proper unpacking, Storage, Protection and Handling prior issuance to production.
c. Verification of Test Certificate and compare it with consumables.
d. Issue consumables to production based on Material Issue Order.
3.2 The Welding Supervisor is responsible for
a. Receiving of consumables from the warehouse.
b. Storage and handling of the welding consumables within his control.
c. Ensure the baking and holding ovens are working in good condition with calibrated
temperature gauge.
3.3 The Welding Consumable Controller is responsible for
a. Proper storage and Conditioning of the welding consumables.
b. Segregation of all welding consumable by type.
c. Maintain the Baking, holding record and parameters.
d. Issuance of welding consumables to welders.
e. Maintain the consumable issue record.
f. Controlling of unused electrodes returned by welders.
3.4 QC inspector shall perform verification of consumable and records in shop / site.
4. PROCEDURE:
4.1. RECEIVING OF WELDING CONSUMABLES
1. All consumables shall be received at the main store / ware house.
2. After off-loading, the consumables shall be inspected for damage. All damaged consumables will
be quarantined and held for inspection by Quality Controller. If any consumables are in
unacceptable condition, the store keeper shall prepare the “Material / Equipment Exception
Report Overage / Shortage / Damage” (Form No. PJT-QOHSER-04) and send for the
corrective action.
Doc No : JEL – QMS – P01
JURONG ENGINEERING LIMITED Rev : B
Quality Management System Page : 3 of 5
Title : Welding Consumable Control Procedure
3. After inspection, the quantity, batch number, size and type will be checked against the delivery
document including consumable Test Certificate.
4. The material controller shall prepare the Receiving Inspection Report (Form No. MM-QOHSER-
02) indicating the heat no and quantity. A copy of Consumable Test Certificate and the original
RIR shall be reviewed & signed by QC for acceptance.
4.2. STORAGE
1. All consumables are to be stored in dry enclosed area, free from inclement weather and
contaminates in accordance with Manufacturer’s recommendations.
2. . Consumables shall be stored on pallets or shelves and not be stacked excessively high so as
not to damage the packing of the lower layers.
3. They shall be segregated by type, size, batch and stacked properly. Storage system
shall be arranged to facilitate stock movement on first in first out basis.
4. It is the Welding Supervisor’s responsibility that welders obtain the correct consumables as
indicated on the approved Welding Procedure Specification and that they handle, store and
return consumables in accordance with this procedure.
4.3. ISSUE AND CONTROL
4.3.1. SHIELDED METAL ARC WELDING CONSUMABLES (SMAW)
a) All SMAW consumables are to be handled in accordance with the Electrode Control Flow
Chart (Annexure 1).
b) When the package is opened, the electrodes shall be placed in a baking oven for two hours or
as per manufacture’s recommended condition, maintained at the temperature of 300ºC -
350ºC minimum before transferring to the holding oven maintained at a minimum temperature
of 120ºC. The baking shall be recorded in the Electrode Baking Record (Form No.
WCR-01).
c) Welding consumables requisition shall be presented by the qualified welder issued
by welding supervisor / foreman to the Welding Consumable Controller in form of
Welding Consumable Issue Slip (Form No. WCR-02).
d) Welding Consumable Controller shall maintain the Welding Consumable Issue Record
(Form No. PJT-QOHSER-10) and to be checked by the Welding Supervisor duly signed
by him.
e) All returned consumables shall be examined by the Welding Consumable Controller for
damage or contamination. Unserviceable consumables will be scrapped. The electrode shall
be issued only to welders for a period of 4 hours.
Doc No : JEL – QMS – P01
JURONG ENGINEERING LIMITED Rev : B
Quality Management System Page : 4 of 5
Title : Welding Consumable Control Procedure
f) The electrode drawn from the oven shall be placed in an electrically heated quiver at a
minimum temperature of 75ºC before the welder proceeds to his work place.
g) Only calibrated thermometers shall be used to monitor the temperature of the baking and
holding ovens. The calibration status must be clearly identified at the place of working.
h) All returned electrode shall be re-baked. Before re-baking starts, all returned electrode tip
shall be colored, as per the flow chart. First re-baking shall be RED color, second re-baking
shall be YELLOW color, for specific identification of re-baked electrode.
i) The re-baked electrode shall be stored separately in the holding oven and shall be issued first
to production. The returned re-baked electrode, if any, shall not be used again and shall be
discarded.
4.3.2. WIRE, ROD AND FLUX
a) Any wire which is unidentifiable, showing signs of contamination, rust or damage shall not be
used and shall be discarded. All unused wires shall be identified, covered and returned to the
consumable area.
b) Wire feed unit will be protected during inclement weather. Bare and cored wires which
become wet will be discarded.
c) Submerged arc welding fluxes shall be purchased and received in undamaged condition.
Flux from damaged packages shall be discarded or dried at a minimum temperature of
350ºC for two hours before use. Fluxes that have been wet shall not be used and
immediately discarded.
d) Submerged arc welding fluxes may be recycled provided the used flux is free from fused
flux, mill scale or any other foreign matter.
e) Coils when mounted on the feeder unit shall be protected to prevent moisture or rust forming
on the wire. Coils found to be forming rust shall be immediately discarded.
f) The identification of the filler wire shall be maintained and traceable to the liner of the coil
which indicated the diameter, trade name and the batch number.
g) Any wire returned to store shall be examined for damage prior to replacing the wire in
appropriate pallet or rack for re-use. Damage or unidentified wire shall be held for inspection
by the Welding Supervisor.
4.4. MONITORING
1. The Welding Supervisor / Foreman and QC inspector shall monitor the storage and handling of
the welding consumables. The periodic checks shall be conducted by the individuals to assure
compliance to this procedure.
Doc No : JEL – QMS – P01
JURONG ENGINEERING LIMITED Rev : B
Quality Management System Page : 5 of 5
Title : Welding Consumable Control Procedure
2. The storage area shall be designated exclusively for electrode consumables. This area shall
be free of contaminates or from any other intended purposes other than electrode consumable
storage.
3. The Ovens & Quivers shall be checked periodically to assure that they are in proper working
condition and suitable for their intended purpose.
4. House-keeping of the consumable storage area shall be maintained by the Welding
Consumable Controller under the direction of the Welding Supervisor.
5. All the welders must utilize the electrode till the length of 50 mm.
6. The electrode stubs shall be kept into the separate container until the end of the day and
return to the store for storage into the disposal bin.
7. Welders are not allowed to take the consumables directly from the oven.
5. RECORDS
Annexure 1 Electrode Control Flow Chart
MM-QOHSER-02 Receiving Inspection Report
PJT-QOHSER-04 Material / Equipment Exception Report
Overage / Shortage / Damage
PJT-QOHSER-10 Welding Consumable Issue Record
WCR-01 Electrode Baking Record
WCR-02 Welding Consumable Issue Slip
