Doc. No.

ASY-ASME-1

Alexandria Shipyard Company Edition 1

Rev. 0

QUALITY CONTROL MANUAL Section 9

Page No. 1 of 6
WELDING CONTROL Date 02-09-2020

9.0 WELDING CONTROL

9.1 All welding, including tack welding, on Code work shall be performed using
qualified Welding Procedure Specifications and Certified welders or welding
operators in accordance with ASME Section IX and the construction Code. No
production welding shall be undertaken until the welding procedures, which
are to be used, have been qualified as per Code.

9.2 Based on existing PQR's, Welding Procedure Specifications shall be prepared

by WE and approved by the TGM. In case, if there are no supporting PQR is
available, WE shall be responsible to qualify the required WPS. The required
test coupons are made under the supervision of WE. Preparation and testing
of the required specimens is performed to ASME Section IX requirements by
an approved testing laboratory & witnessed by Welding Engineer. All
Mechanical tests and NDE results submitted by the laboratory shall be
reviewed by the WE. If acceptable, the Procedure Qualification Record is
prepared and certified by WE. PQR shall address all essential variables for the
welding processes used and when applicable, supplementary essential
variables used in making qualification test welds.

It shall be updated in the "ASME - WPS/PQR Summary Log" and WPS

distributed to CSD & QSD after the approval of TGM.

WPS’s and PQR’s are submitted to the AI for his review and acceptance and
are available for his review at any time.

9.3 The WE shall prepare the "Weld Map (Welding Detail Drawing)" (Exhibit 9.02)
taking into account CSD's advice. Weld Map are offered to the AI for his
review.

9.4 Copies of the qualified Welding Procedure Specifications and Weld Map are
provided by the WE to the CSD for use during production/Assembly. The WPS
shall be made available to the welder/Welding Operator at the welding area.
The welding engineer maintains the original Welding Procedure Specifications,
Procedure Qualification Records, and records of laboratory test results.

9.5 A new Welding Procedure Specification is prepared and qualified whenever an

essential or when applicable supplementary essential variable is changed.
WPS is revised without re-qualification if only non-essential variable is
changed. WPS shall contain all essential and non-essential variables for the
welding processes used and Supplementary essential variables when
applicable.
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9.6 All welders and welding operators to be used in Code welding are qualified to
ASME Section IX and construction Code requirements under the supervision
of the Welding Engineer. The preparation and testing of the required
specimens for welders shall be arranged by the WE. If results are acceptable,
the Welding Engineer prepares and certifies the Record of Welder Performance
Qualification (WPQ) or Welding Operator Performance Qualification (WOPQ).
WPQ/WOPQ shows the essential performance variables actually used for the
test weld and range qualified for production welding. WPQ/WOPQ shall also
be issued to welder based on the performance variables used in making a
successful PQR. Original WPQ/WOPQ are retained by the welding engineer in
his file.

9.7 Use of Individuals For their services as Welders/Welding Operators in ‘ASY

‘ASY may engage individuals by contract or agreement for their services as

welders/Welding operators in shop and the field site (as allowed) by the ASME
Certificate of Authorization under the following conditions:

a) All Code construction shall be the responsibility of ‘ASY’ including

Certification Mark stamping & MDR/MPDR properly executed and
countersigned by the AI.

b) All welding shall be performed in accordance with the ‘ASY’’s WPS in

accordance with the requirements of Section IX.

c) All welders shall be qualified, and their qualifications maintained by

‘ASY’ in accordance with the requirements of Section IX.

d) All welders are under complete and exclusive administrative and

technical supervision of ASY.

e) The CSD or WE have the authority to assign and remove welders at his
sole discretion.

f) Identification symbols of welders are assigned by the Welding Engineer.

g) The arrangement for using such individuals shall have acceptance of

the AIA prior to using them.

h) ‘ASY shall ensure Code compliance of the vessel or pressure part,

including Code certification Mark stamping and providing Data Report
Form properly executed and countersigned by the AI.
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9.8 Copies of "Welder and Welding Operator Work History (Continuity Log)"
(Exhibit 9.04), "Manual Welders and Welding Operators Qualification Log"
(Exhibit 9.05) prepared by Welding engineer shall be provided to the
CSD/Workshop Manager. The original records are maintained in the QA/QC
Department files by QA/QC Document Controller. The Manual Welders and
Welding Operators Qualification Log shall be issued every Three (3) months or
earlier based on the Welder or Welding Operator Work History (Continuity
Log).

9.9 The Performance Qualification of a Welder or Welding Operator shall be

affected when one of the following conditions occurs:

(a) When he has not welded with a process for period of greater than 6
months since the qualified welding process was last used, his
qualifications for that process shall expire: unless, prior to the
expiration of his qualification.

1) A welder who has welded with that process using Manual or

semiautomatic welding under the supervision and control of the
Welding Engineer that shall extend his qualification for an
additional 6 months since the process was last used.

2) A welding operator who has welded with that process using

machine or automatic welding under the supervision and control
of the Welding Engineer that shall extend his qualification for an
additional 6 months since the process was last used.

(b) When there is a specific reason to question his ability to make welds
that meet the specification, the qualifications which support the
welding he is doing shall be revoked. All other qualifications not
questioned remain in effect.

(c) The AI has reason to question a Welder’s ability to make welds that
meet the code requirements.

(d) Whenever there is a change in a Performance essential variable.

9.10 Each qualified welder or welding operator is listed on Welder and Welding
Operator Work History (Continuity Log), maintained by the welding engineer.
Data provided through Radiographic history or by information provided by the
QSD and/or the WE (final visual and dimension report) is used to
record/indicate the date on which the welder or welding operator has welded
using a qualified process and method. The QSD determines the Welder’s
Qualification Validity from Welder and Welding Operator Work History
(Continuity Log) and when a welder’s qualification is expiring, he ensures that
the welder performs either production welding or is re-qualified. Renewal of
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qualification expired as described in 9.9 (a) 1) or 2), 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 variables for which he was previously qualified.
Welders whose qualification has been revoked under 9.9 (b) or (c) above shall
requalify.

9.11 The Welding Supervisor/Site Manager is responsible for assigning welders to

job, verifying that all welders are qualified, and for instructing each welder in
the Welding Procedure Specification to be used. The General Foreman/Field
Construction In-charge shall ensure that the welding including preheating is
being carried out as per the approved WPS. No welding shall be carried out
when the temperature of base metal is lower than -20 Degrees C. When the
metal temperature is between 0 and -20 Degrees C, the surface of all areas
within 75 mm of the joint where the weld is to be made be heated to at least
15 Degrees C. No welding shall be allowed when the surfaces are wet or
covered with ice, or when snow is falling or during periods of high wind unless
the welder and work are properly protected. 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 base material. Temporary attachments to any pressure
retaining part shall be of compatible materials of similar chemical
composition/same P-No.

9.12 Each certified welder/welding operator is issued with a unique letter stamp by
the WE, to identify each weld he makes. This symbol shall not be re-assigned
to another welder/welding operator even after the welder/welding operator
leaves ‘ASY. Each welder/welding operator shall mark his symbol adjacent to
each weld seam he makes and at interval of not more than 3ft. (1000mm).
When conditions prevent the stamping of the welds (i.e. on ferrous materials,
thickness < 6mm and non-ferrous materials thickness < 13.0 mm or when
service conditions prohibit), the welder/welding operator symbol shall be
documented in Weld Map.

9.13 Welding Consumables shall be handled as follows:

9.13.1 All welding consumable materials shall be requisitioned by the WE

and purchased as described in Section 6.0 (Material Control).

9.13.2 All welding materials shall be received as described in Section 6.0

(Material Control).

9.13.3 The Welding Supervisor is responsible for the withdrawal of welding

material from storage using Material Issue Sheet (Exhibit T12).
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9.13.4 Welding material shall be stored in a dry storage space and issued
first-in first-out basis. The welder or welding operator shall use his
electrodes/filler metals as specified by the Welding Procedure
Specification. The issue of these electrodes/filler metals shall be
documented on the "Electrode/Filler Metal Issue Sheet" (Exhibit
9.09). The Electrode/Filler Metal Issue Sheet has space for the
following items: Welder’s Stamp, Job Number, Batch Number,
Electrode/Filler AWS Classification & Diameter, Quantity issued,
Date and Time of issue, returned quantity and signature.

9.13.5 Prior to use all low hydrogen electrodes shall be dried as per
Consumable Manufacturer's requirements. If no recommendations
are available, baking shall be done at 260-350 Degrees C (500-662
Degrees F) for 2 hours minimum and shall be recorded on
"Electrode Baking & Holding Record" (Exhibit 9.10). The
baking/drying step may be deleted if the electrodes are supplied in
the dried condition in a hermetically sealed metal can or Vacuum
packed with a positive indication of seal integrity. Electrodes may
be re-dried only once.

9.13.6 After baking/drying, the electrodes shall be stored continuously in a

holding oven at a temperature recommended by the consumable
manufacturer or at 120 Degrees C (250 Degrees F) minimum and
records are maintained using "Electrode Baking & Holding Record"
(Exhibit 9.10). Electrode baking and holding shall be controlled by
Warehouse Supervisor and monitored by Welding Inspector.

9.13.7 Upon removal from the drying or storage oven or hermetically sealed
containers or Vacuum pack, the electrodes may not be exposed to
the atmosphere for more than 4 hours. The exposure may be
extended to 8 hours if the electrodes are continuously stored in a
portable electrode oven heated to 65 Degrees C (150 Degrees F)
minimum. Electrodes exposed in excess of the permitted time
period may be re-baked only once, identified and issued first.
Electrodes that have become wet or moist bent or flux removed shall
not be used and shall be discarded.

9.13.8 Electrodes exposed to the atmosphere for less than the permitted
time period may be returned to a holding oven maintained at 120
Degrees C (250 Degrees F) minimum. After a minimum holding
period of four hours at 120 Degrees C (250 Degrees F)) minimum
the electrodes may be reissued.

9.14 Production Test Plates:

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9.14.1 Welding of test plates required by the Code, impact test of weld
metal and heat affected zones are prepared in accordance with the
applicable WPS and a procedure prepared by the WE, which
includes Number, identification, type, orientation, location and
dimensions of required specimens, charpy impact temperature and
acceptance criteria.

9.14.2 The Welding Supervisor supervises the welding of the test plates
from which specimens are prepared and tested by an approved
testing laboratory. Test report is reviewed by the WE for acceptance
of results or need for retest.

9.14.3 The Results are submitted to the AI for his review and acceptance.
The AI may witness the tests, if he desires.

9.15 Tack welds shall be performed by certified welders as per the approved WPS.
Either GTAW or SMAW process is used for tack welding. When tack weld
becomes part of final pressure weld, tack welder identification is recorded in
Weld Map or other Inspection Reports.

9.16 Tack welding performed by ‘ASY shall be prepared to assure complete fusion
into the final weld. All tack welds shall be visually examined by Welding
Inspector for cracks and other defects, prior to inclusion into the final
weldment. Defective tacks shall be removed.

9.17 All welding leads, cutting torches and other apparatus shall be kept clean and
free of dirt, grease moisture or any other foreign materials.

9.18 The welding machine current and Voltage shall be checked on a regular basis
by the Welding Supervisor with a calibrated Tong meter.

9.19 AI has the right to call for and witness the tests of Welding Procedures. AI has
the right to call for and witness the welding ability of welders.

9.20 All records referenced in this Section shall be made available to the
Authorized Inspector for his review.