Section 15 — Inspection
QA/QC Procedures for Welding Consumables
IPE Engineering Practice IPE-EP-15-5-7
Document number: IPE-EP-15-5-7 · Section: 15 — Inspection
SCOPE
- This document provides instructions for the receiving inspection and control of welding consumables.
- These instructions shall be applicable for all electrodes and filler metal.
- A revision bar indicates all changes made to this Revision.
2.0 REFERENCES
The latest edition of the following standards and publications are referred to herein.
STANDARDS AND PUBLICATIONS
| IPE Engineering Practices |
|---|
| EP 15–5–1 QA/QC Procedures for Commodity Purchases |
| ANSI/AWS |
| A5.01 Filler Metal Procurement Guidelines |
DEFINITIONS
- Certified Material Test Report (CMTR) – A document, or documents, on which are recorded the results of tests, examinations, repairs, or treatments required by the Material Specification. Supplementary or special requirements, in addition to the requirements of the Material Specification, as required by the Purchase Order shall also be included on the CMTR. The specification of the material being represented including the year of issue, and the material heat number shall also be included on the CMTR. All such documents shall identify the applicable Material Specification and shall be identified to the material represented.
- GMAW – Gas Metal Arc Welding process that utilizes bare or flux cored electrode wire coils of various diameters as a consumable electrode.
- GTAW – Gas Tungsten Arc Welding process which utilizes a non–consumable tungsten electrode and lengths of bare or flux coated wire of various diameters as filler metal.
- Manufacturer – The recipient of a direct or indirect purchase order for materials and/or equipment. In this context, a direct order is one issued to a Manufacturer by a Contractor or the Owner. An indirect order is one issued to a Manufacturer by a vendor (recipient of a direct order) for materials, fabricated components, or subassemblies.
- Lot – A group of items with the same heat number.
- Owner – Inflection Point Engineering, LLC
- Receiving Inspection – A receiving inspection shall be that inspection necessary to ensure that the dimensions, physical integrity, chemical composition, and mechanical properties of representative samples of commodity items are in conformance with those detailed by the applicable quality specifications. A receiving inspection shall require performance of specified examinations and tests of an inspection lot of the commodity, and review of documentation and reports that accompany the item(s).
- SMAW – Shielded Metal Arc Welding process that utilizes flux coated consumable electrodes of different diameters as a filler metal.
PROCEDURE
- Sealed metal containers of SMAW welding consumables shall be examined to ensure container integrity. Label identification shall be compared with the requirements of the Purchase Order to ensure the proper material was received.
- Containers of GTAW filler metal shall be opened to verify by sampling that each length of wire is tagged with the proper alloy identification. The container shall then be taped shut and marked to indicate that it has been checked. Each container label shall be checked against the requirements of the Purchase Order to ensure the proper material was received.
- Labels of coiled GMAW filler metal containers shall be checked against the requirements of the Purchase Order to ensure the proper material was received. The container shall be marked to indicate that it has been checked.
5.0 DOCUMENTATION
Inspection of each container of welding filler metal shall be documented using the Receiving Inspection Checklist Form Table 1 or an equivalent method which includes all of the elements of the Inspection Checklist.
6.0 TABLES
TABLE 1
RECEIVING INSPECTION CHECKLIST FOR WELDING CONSUMABLES
| DATE | DATE | DATE | CHECKED BY | CHECKED BY | CHECKED BY |
|---|---|---|---|---|---|
| MANUFACTURER | MANUFACTURER | MANUFACTURER | PURCHASE ORDER NO. | PURCHASE ORDER NO. | PURCHASE ORDER NO. |
| ELECTRODE/FILLER ROD TYPE | ELECTRODE/FILLER ROD TYPE | ELECTRODE/FILLER ROD TYPE | DIAMETER | DIAMETER | DIAMETER |
| HEAT/LOT NUMBERS | HEAT/LOT NUMBERS | HEAT/LOT NUMBERS | HEAT/LOT NUMBERS | HEAT/LOT NUMBERS | HEAT/LOT NUMBERS |
| INSPECTION CHECKLIST | INSPECTION CHECKLIST | INSPECTION CHECKLIST | INSPECTION CHECKLIST | INSPECTION CHECKLIST | INSPECTION CHECKLIST |
| 1) | SEALED METAL CONTAINER VERIFIED | SEALED METAL CONTAINER VERIFIED | SEALED METAL CONTAINER VERIFIED | YES | NO |
| 2) | GTAW WIRE LENGTHS PROPERLY TAGGED | GTAW WIRE LENGTHS PROPERLY TAGGED | GTAW WIRE LENGTHS PROPERLY TAGGED | YES | NO |
| 3) | EACH CONTAINER LABEL VERIFIED AGAINST P.O. REQUIREMENTS | EACH CONTAINER LABEL VERIFIED AGAINST P.O. REQUIREMENTS | EACH CONTAINER LABEL VERIFIED AGAINST P.O. REQUIREMENTS | YES | NO |
| APPROVED FOR STOCK | APPROVED FOR STOCK | APPROVED FOR STOCK | APPROVED FOR STOCK | ||
| HOLD FOR DISCREPANCIES | HOLD FOR DISCREPANCIES | HOLD FOR DISCREPANCIES | HOLD FOR DISCREPANCIES | ||
| DISCREPANCIES RESOLVED | DISCREPANCIES RESOLVED | DISCREPANCIES RESOLVED | DISCREPANCIES RESOLVED | ||
| COMMENTS/DISCREPANCIES NOTED: | COMMENTS/DISCREPANCIES NOTED: | COMMENTS/DISCREPANCIES NOTED: | COMMENTS/DISCREPANCIES NOTED: | COMMENTS/DISCREPANCIES NOTED: | COMMENTS/DISCREPANCIES NOTED: |
| SIGNED | SIGNED | SIGNED | DATE | DATE | DATE |
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