Welding SMAW On Site Procedure

Content List

Document Title 1
Content List 2
1. Objectivity 3
1.1 Purposed 3
1.2 Objectivities 3
2. Scope 3
3. Reference 3
4. Responsibility 3
5. Procedure of welding control 4
5.1 Welding Procedure Qualification SMAW 4
5.2 Qualification of Welder SMAW 4
5.3 Re Qualification of Welder SMAW 5
5.4 Supervision of welder Qualification 5
5.5 Production Welding SMAW 5
5.6 Material Welding SMAW 5
5.7 Field Portable dryer 5
5.8 Equipment Welding Machine 5
5.9 Joint Preparation 7
5.10 Table Inspection welding 7
5.11 NDT Nonconforming 7
6. General Flow of Welding control material 8
7. General Flow of Welding control on site 9
8. Related Documents 10

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 Welding SMAW On Site Procedure

1. OBJECTIVITY
1.1 PURPOSED
Welding control procedure is made as standard all welding production process.
Welder operator on site must be qualified according AWS D1.1 structural welding
code steel.

1.2 OBJECTIVITY
Ascertaining of quality an substance as according to criteria standard which have
been specified by company.

2. SCOPE
All supporting document in this procedure on welding on site for steel structure Station
MRT Block M:
● Welding Procedure Specification (WPS) - SMAW
● Procedure Qualification Record (PQR) - SMAW
● Welder performance qualification record (WPQR) - SMAW

3. REFERENCE
3.1 AWS D1.1

4. RESPONSIBILITY
QC Inspector will observe of the welder qualification periodically and make the Welder Log
(welder document)

5. PROCEDURE
5.1 Welding Procedure Specification SMAW (Shield Metal Arc Welding)
5.1.1 QC inspector, welding Inspector prepares qualification of Welder
Procedure Specification (WPS), Procedure Qualification Record (PQR), and
Welder Performance Qualification Record (WPQ) to be submitted to
production department then used by welder.
5.1.2 QC Inspector , welding inspector should always do supervision toward
implementation of Welding Procedure Specification (WPS) and Procedures
Qualification Record (PQR).
5.1.3 Welding Procedure Specification (WPS) made by QC Inspector, welding
inspector as one of requirement on standardization code. Inside, there are
many things that should be done before production process runs,
including :

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 Welding SMAW On Site Procedure

• Weld Test that supervised and witnessed by QC Inspector , WI as

design and witnesses from client if necessary
• All variables used should be recorded on PQR.
5.1.4 Weld test result must be tested by an appointed independent laboratory
5.1.5 The test result shall be reviewed and reported by QC Inspector , WI then
QC will prepare and publish the PQR

5.2 Qualification of Welder SMAW

5.2.1 All that relates to the quality from welder and welding code under
observation by production supervisor and witnessed by QC.
5.2.2 QC will prepare and guarantee the quality that the personnel of welder is
accepted according to standard and will be written in Welder Performance
Qualification Record (WPQ).
5.2.3 QC will publish the number identification which is mentioning in WPQ.
.
5.3 Re-Qualification Of Welder (SMAW)
5.3.1 Re-qualification of welders shall be conducted if the below condition was
found:
1. Existence of change performance of welder
2. A charge in performance variable essential
3. A welder not welded in the specified process for six months or more,
the qualification for that process shall expire

5.4 Supervision of Welder (SMAW)

5.4.1 All qualifications of welder will be recorded in the document (Welder Log)
5.4.2 Welder Log includes the date and the process in which welder be
qualified.
5.4.3 QC inspectors shall check once in 3 months for each welder
5.4.4 QC will determine the welder's expired time and shall be re-qualified.

5.5 Material Welding SMAW

5.6.1 Welding material should be stored in a dry place and issued by the store
keeper at the request of the welder in accordance with WPS.
Filler metal / Electrode specification :
AWS Specification : A5.5
AWS Classification : E 7016, E 7018
Diameter : 3.2, 4.0

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 Welding SMAW On Site Procedure

5.6.2 If the store receives low hydrogen electrode, the process of storage
should be as per recommendation of manufacturer before submitted to
welder.
5.6.3 Each welder should be minimize its use would be required to store, the
electrodes are not used and returned back to the store to be kept in the
ware house.
5.6.4 Warehouse keeper on site shall examine the conditions of return of the
electrode should be clean and identified. The damaged electrodes and no
identification must be removed

5.6 Production Welding on Site

5.5.1 QC Inspector is responsible for selecting welder production which is
qualified based on Welder Log and Welder Performance Qualification
Record (WPQ)
5.5.2 supervisor erection is responsible for giving instructions to the welder to
follow the parameters in the Welding Procedure Specification (WPS)
5.5.3 Each welder must be put a mark on their welding result in accordance
with their ID which is made by QC as the basis for welding result
inspection in both visual and NDT testing (PENETRANT TEST)
5.5.4 If any Tack Weld for the prop of straightness, it can be eliminated after
welding process end and have to cross checking visually if there is any
defect / imperfection that happened.

5.7 Field Portable Dryer

Each welder shall have at least one portable dryer. Welders stamp number shall
be clearly marked on his portable dryer. One portable dryer shall be limit to one
type of welding electrode. During welding work, the portable dryer shall be kept
warm at temperature range 40-140 degree C.
The welding material controller shall carry out control of drying, re-drying and
warming.
The drying oven and warming oven shall be clearly marked to show the type of
electrodes contained.

5.8 Equipment for Welding Machine

The equipment for the shielded metal arc welding process consists of a power
source, welding cable, electrode holder, and work clamp or attachment. Figure
below

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 Welding SMAW On Site Procedure

5.9 Joint Preparation

5.9.1 Joint Pipe to Pipe with use two alternative
a. First method with use Not backing

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b. 2nd with use backing

Legend
CJP Complete Joint Penetration ( AWS D1.1 )
FPBW Full Penetration Butt Weld (Client Spec – General Notes 3STO-STR-1002-TB1)

5.9.2 Joint End Plate to End Plate

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5.9.3 Joint End Plate to End Plate with under Gap 45mm include

5.9.4 Joint End Plate to End Plate with above Gap 45mm

5.9.5 Sequence Welding Process

First welding process is joint pipe to pipe

2nd welding process is joint end plate to end plate

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 Welding SMAW On Site Procedure

First welding process vertical up no 1 is a half diameter pipe

2nd welding process vertical up no 2 is a half diameter pipe

5.10 Table Inspection and test for welding ( Steel Roofing )

Welding Percentage of welding inspection

No Welding Type
Category Visual PT MT UT
1 Butt Joint CJP Pipe to pipe 100% 100 % NA NA
2 Butt Joint PJP End plate to End plate 100% 10 % NA NA
3 Butt Joint PJP Pipe To End Plate 100% 10 % NA NA

Note to table 5.11

a. Inspection welds shall include ends as a minimum for partially inspection welds balance
of weld length to be inspection on partially inspected welds shall be applied at random
location along the weld
b. PT inspection as follow NDE Mapping
5.10 NDT Non-conforming Level
If non-conformity is found on one segment when NDT runs, so NDT should be
done refer to table of inspection and test for welding
For material which non-conformity result on NDT test, it can directly do rework.
Give & put repair sticker tagging on material which non-conformity result in NDT
test.

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6. General Flow for Control Material Welding

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7. General Flow for Welding control on site

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 Welding SMAW On Site Procedure

8. Related Documents
Form 6.2-08 : Welding Qualification Test
Form 7.5-05 : Procedure Qualification Record
Form 7.5-04 : Welding Procedure Specification
Form 8.2-06 : Liquid Penetran Examination Report

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