WELDING CONSUMABLE

CONTROL PROCEDURE

NWSTEEL TECHNOLOGIES, INC.

1.0 GENERAL

1.1 Purpose

1.1.1 To establish guidelines and define responsibilities for the proper storage, control,
issuance and use of welding electrodes.

1.2 Scope

1.2.1 This procedure applies to all welding consumables proper storage, control, issuance
and use of welding electrodes for production welding for structural (AWS D1.1
Structural Welding Code - Steel) welding activities in according with the project
requirements.

2.1 Reference Document

2.1.1 AWS D1.1_D1.1M-2020 Structural Welding Code - Steel

2.0 RESPONSIBILITIES

2.1 QC Manager

2.1.1 Shall be responsible for the verification and monitoring in the implementation of this
procedure through inspection.

2.2 QC Supervisor

2.2.1 Shall be responsible for proper implementation of this procedure

2.2.2 Reviews purchase requisitions to ensure correct order specifications.
2.2.3 Supervises Consumable Room personnel and operations.

2.3 QC Welding Inspector

2.3.1 To be responsible for the implementation of this procedure and to verify that
welding consumables used are approved and controlled.
2.3.2 To check and verify whether welding electrode are handled and stored in accordance
with approved procedures.
2.3.3 To verify that portable dry ovens is properly working
2.3.4 Carries out Daily inspection/audit of the consumable room operations according to
the Requirements of this procedure.
2.3.5 Monitors oven and portable quiver temperature on site

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 2.3.6 Check and ensure calibration of equipment and instrument is still valid.

2.4 Welding Consumable Controller

2.4.1 To receive Electrode Control Slip from Welding Foreman for issue welding
consumables.
2.4.2 To request for Receiving Inspection of welding consumables to the QC Inspector.
2.4.3 To segregate and checked returned electrodes and visibly mark the ends to
differentiate between the electrodes requiring for re-drying or re-conditioning.
2.4.4 To restore unused electrodes in baking oven if returned within the time limits. And
keeping record in order to maintain record.
2.4.5 To Responsible for issuance, retrieval, re-conditioning and re-issuance of welding
electrodes, ensure that welding electrodes used are properly controlled and
recorded.
2.4.6 To assure of operation for all calibrated dry ovens.
2.4.7 Issue the required electrodes on a first in, first out basis to the work shop.
2.4.8 The damage Consumables will be segregated in the designated quarantine area for
return to the supplier.

2.5 Welding Supervisor/Foreman

2.5.1 Shall be responsible for receipt, handling, storage and issuance of welding
consumable in accordance with this procedure.
2.5.2 To Issue and checked Electrode Control Slip forms and advice to maintain the time
limit and expiration to welders.
2.5.3 To be responsible and ensure that welding electrodes used in production welding are
controlled in accordance with this procedure.

3.0 GENERAL REQUIREMENTS

3.1 Special Consideration for Consumables

3.1.1 Electrodes shall be purchased in accordance with an approved WPS.

3.1.2 All Welding consumables shall be identified by marking shall be performed as
manufacturer name, size and class.
3.1.3 Welding consumables shall be selected based on their mechanical properties,
compatibility with the materials to be joined, their suitability with the intended
service and consideration of polarity, position and direction of welding.

3.2 SMAW Electrode (Low hydrogen electrode)

3.2.1 All Electrodes (Low hydrogen electrode) shall be kept in welding rod oven or should
use vacuum packs.

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 3.3 Instrument and Equipment to be used

3.3.1 Shall be provided with electrode control room for safe keeping and storage of
welding consumables and other related accessories.

3.3.2 Portable Quiver shall be issued to each welder for keeping electrodes at moisture-
free condition while at work.

4.0 Storage, Handling & Conditioning of Welding Consumables

4.1 Material Receipt & Storage

4.1.1 Upon receipt of welding materials, Warehouse keeper shall check that welding
Consumables show no sign of damage and that seals on-hermetically and
hermetically sealed containers are unbroken.
4.1.2 After receiving inspection, the welding materials shall be stored in the warehouse or
at the Electrode Controlled room and being held at an ambient temperature.
4.1.3 Welding Consumables shall be stored in a clean and dry place.
4.1.4 Welding Consumables shall be stored indoor under the supervision of the
Warehouse Foreman.
4.1.5 Warehouse Keeper shall store the Welding Consumables on elevated rack according
to type and size.
4.1.6 All unopened containers of welding materials shall be identified by acceptance tag
and stored separately by classification and size

4.2 Handling of Welding Consumable

4.2.1 After withdrawal of welding Consumables from the warehouse, electrode controller
shall store the unopened and undamaged containers at the Electrode Control Room.
4.2.2 When Containers of low hydrogen Electrodes are opened, they shall be immediately
placed in oven prior to use.
4.2.3 Storage oven shall have continued power supply during work and non-working hours
or days.

4.3 Electrode allowable atmospheric exposure

4.3.1 Exposure of low hydrogen electrodes shall not exceed the following requirement as
per AWS D1.1 Welding Code – Steel:

4.3.1.1 A5.1 Electrodes: 4 hours maximum open to atmosphere and 8 hours

if continuously kept in portable oven at 650 °C

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 4.3.1.2 All electrodes having low-hydrogen coverings conforming to AWS
A5. 1 shall be baked for at least two hours between 500°F and 800°F
[260°C and 430°C]

4.4 Handling and Conditioning of Electrodes

4.4.1 Electrodes belongs to damaged hermetically sealed containers shall undergo drying
prior to its re/issue for welding.
4.4.2 Electrodes shall be re-dried only once and marked or segregated prior to re-issue.
4.4.3 Any electrodes (low hydrogen or non-low hydrogen) and flux that have been wet or
moist shall be discard.

4.5 Storage

4.5.1 Dried Electrodes & electrodes removed directly from its hermetically sealed
containers shall be stored in holding oven for 4 hours at 1200°C.

4.6 Re-conditioning

4.6.1 Electrodes exposed to the atmosphere for less than permitted duration shall be re-
conditioned or returned to the holding oven for 4 hours at 1200°C before re-issue.

4.7 Issuance of welding consumables

4.7.1 Welding Foreman shall prepare electrode request from using electrode Control Slip
to document and monitor the welding consumable issue and return for each welder,
showing type, size and quantity of electrodes.
4.7.2 Portable rod oven shall be marked individually with welder stamp. Portable
electrode storage ovens are regularly checked for keeping temperature at a
minimum of 600°C.

4.8 Return of Welding Consumables

4.8.1 Upon receipt of returned/unused electrode, Electrode controller shall record the
time and check atmospheric exposure of returned electrodes. Low hydrogen
electrode the allowable exposure limit shall be placed in baking oven for re-drying.
4.8.2 Electrode controller shall check for damaged all returned electrodes, any electrode
which have defect such as de-fluxing, wet flux or illegible marking shall be discarded
or disposed properly.
4.8.3 Electrodes that are either exposed to water or breaking flux shall be discarded.

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