This guide has been prepared to assist welding personnel with the preparation of welding procedures required as part of their company certification to CSA Standards W47.1, W47.2 and W186.Descripción completa
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Procedure Welding Consumables
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Welding Consumable Control Procedure
Document No. CO-GN-007 Revision
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WELDING CONSUMABLE CONTROL PROCEDURE
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October 16, 2006
PS
RC/SP
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Rev No
Date
PREPARED BY
REVIEWED BY
APPROVED BY
Page 1 of 10
Document No. CO-GN-007 CO-GN -007
Welding Consumable Control Procedure
Document No. CO-GN-007 Revision
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Contents Sheet
1.0 Purpose
3
2.0 Definitions
3
3. Procedure
3
3.1 General
3
3.2 Stores Receipt
3
3.3 Storage
4
3.4 Traceability
5
3.5 Monitoring
5
3.6 Equipment
5
3.7 Audits
5
4.0 Electrode Flow Control
6
5.0 Documentation
9
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Document No. CO-GN-007
Welding Consumable Control Procedure
Document No. CO-GN-007 Revision
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1.0 Purpose This procedure specifies the manner in which TAC will control all welding consumables during all work campaigns/projects to effectively ensure the quality of the consumable is maintained prior to and during usage.
2.0 Definitions TAC
Thai Alliance Engineering and Construction Co., Ltd.
Consumable
For the purpose of this procedure a consumable is any electrode, wire or flux that is consumed during the welding process. Dedicated person elected by the Warehouse Manager to issue welding consumables.
Storeman
3. Procedure 3.1 General All covered electrodes and fluxes are sensitive to moisture absorption therefore care must be taken during storage and handling to prevent excessive moisture intake. Unacceptable moisture levels may adversely affect welding quality and performance. Where practicable, only one batch of any given size/type of consumable will be in use at any one time. Consumables will be used in order of receipt to minimise storage time. Recognition should be made of expiry dates when issuing consumables in case a later delivery has an earlier expiry date. The person responsible for applying this procedure is the Warehouse Manager monitored by the Quality Control Department. Baking and holding oven temperatures shall be in accordance with the manufacturers’ recommendations for the consumable in use. 3.2 Stores Receipt On delivery of welding consumables the storeman will check the following: •
•
Consumable containers, such as packets, hermetically sealed tins and bags shall be inspected for damage. Certification accompanies consumables upon delivery.
Deliveries without Certification will be quarantined and not issued until receipt of Certification. Batch numbers of delivered consumable are verified as complying with consumable certification. Any damage shall be reported in accordance with the Procedure for Materials Control & Handling. Page 3 of 10
Document No. CO-GN-007
Welding Consumable Control Procedure
Document No. CO-GN-007 Revision
0
Consumables delivered without accompanying certification will be isolated in quarantine and not issued, until the relevant certificate is forwarded by the supplier. Consumables may be issued in special circumstances (i.e. if impacting schedule) only when written confirmation from the supplier confirms the certificate is available and as agreed by the Quality Department. 3.3 Storage 3.3.1 General
It is the responsibility of the Warehouse Manager to ensure that all storage requirements are adhered to at the Erection Yard. It is important that the conditions outlined below are maintained 24 hours a day and 7 days a week. Consumables are to be stored as follows: •
•
•
Unopened containers of consumables are to be stored in warm and dry (ambient) conditions. Properly arranged off the ground and on shelving/pallets that cannot hold moisture. Under cover and protected from any inclement weather.
3.3.2 Low Hydrogen Electrodes
After removal from packaging the welding electrodes shall be stored in a holding oven at between 110°C to 140°C prior to issue. Electrodes, where there is evidence of damage to the packaging, shall be dried in a baking oven at approx. 370°C for a minimum of 1 hour before transferring to the holding oven. A control form shall be completed by the storeman recording the time, type and amount of electrodes baked. After removal from the baking oven the electrodes shall be stored in a holding oven as previously described. In general, electrodes shall only be issued from a holding oven directly for use. Should the electrodes be placed in quivers prior to commencement of shift (ready for welders’ collection), they shall not remain in the quiver for longer than a period of 1/2 hour. Onsite electrodes will be held in heated portable electrode quivers. Any electrodes returned at the end of the shift shall be identified by marking the end with indelible white paint and re-baked as per this procedure. Any electrodes returned after re-issue (with white marking) shall be taken out of circulation. No electrodes will be re-baked more than once. Electrodes vacuum packed during the manufacturing process are intended for use directly from the pack. Any vacuum pack electrodes not used by the end of a shift or during the time recommended by the manufacturer shall be returned to the store for marking (with white paint) and storage in the holding oven. Due to the possibility of over drying (which could directly affect the welding quality or performance), re-issue is permitted only once and baking is not permitted under any circumstances. Page 4 of 10
Document No. CO-GN-007
Welding Consumable Control Procedure
Document No. CO-GN-007 Revision
0
3.3.3 SAW and GTAW Electrodes/Wire
SAW and GTAW electrodes and wire shall be stored as per the manufacturer’s recommendations but generally in a dry area off the floor or ground. 3.3.4 SAW Flux
SAW flux is normally supplied in sealed containers or moisture preventative bags. Provided that they are stored in dry condition off the ground and the containers/bags have not been damaged prior to issue, the flux can be used directly from the container/bag. If the flux is not used directly then the remaining flux must be held in heated holding drums/containers at a temperature of 150°C (+/-25°C). 3.3.5 Inconnel 625 (SMAW)
After removal from their container/package Inconnel 625 consumables shall be baked for a minimum of 2 hours at 200°C. On completion of baking they shall be stored in a holding oven at a temperature of between 120°C and 170°C. 3.4 Traceability The Warehouse Manager will maintain a Welding Consumable Register and continually update the register on an as required basis (as consumables are delivered). When consumables are issued, the storeman shall record type, size and batch no., the welders I.D. no. and the date of issue on the consumable issue form. 3.5 Monitoring Ovens shall be identified as either baking or holding with the required operating temperature posted near the oven. Temperature monitoring sheets shall be posted on each oven and will be completed during monitoring checks by the QC Department or Storeman. Periodical checks shall be carried out on portable quivers to ensure the operating temperature is maintained. Should the quiver be found to be cold the contents will be re-baked or disposed of. 3.6 Equipment All Baking/Holding ovens shall be calibrated to a recognized International standard or in accordance with CO-GN-008 ‘Procedure for Calibration Control’ annually or after repair. 3.7 Audits The QC Inspector shall conduct periodical checks to verify compliance to this procedure and report all findings to the Construction Manager. Page 5 of 10
Document No. CO-GN-007
Welding Consumable Control Procedure
Document No. CO-GN-007 Revision
0
4.0 Electrode Flow Control Procedure I : for Large Amount of Electrode
SMAW ELECTRODE
(1)
Oven 1
(1), (2)
For Backing
Separate Shelf
Oven 2 For Holding
Separate Color Marking
Issue (2) Before (1)
(2)
Portable Oven
(2), (1) Color Marking
Welding (2), (1) (1) Remaining
(2) Color Marking (3)
Reject
Note : (1) is for ’New batch No.’ (2) is for ‘Remaining’ (3) is for ‘Reject’
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Document No. CO-GN-007
Welding Consumable Control Procedure
Document No. CO-GN-007 Revision
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Procedure II : for Small Amount of Electrode
SMAW ELECTRODE
(1) Oven For Backing, Holding (2) Issue (2) Before (1)
Portable Oven Color Marking (2), (1)
Welding (2), (1) (1) Remaining
(2) Color Marking
(3) Reject
Note : (1) is for ’New batch No.’ (2) is for ‘Remaining’ (3) is for ‘Reject’
5.0 Documentation The following standard TAC forms are used in conjunction with this procedure: Welding Consumable Control Sheet Consumable Request Form
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Document No. CO-GN-007
Welding Consumable Control Procedure
Document No. CO-GN-007 Revision
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Welding Consumable Control Sheet Welding Consumable Control Sheet Project : ___________________
