BP BERAU LTD 1.0. Purpose.
This procedure describes the system of receipt, storage, handling and treatment of welding consumable in all fabrication area of the workshop and the yard (Open Area).
2.0. Reference.
2.1. ASME Section II Part C. 2.2. EEMUA Publication No. 158 paragraph 5.3.2. 5.3.2. 2.3. AWS D1.1 – D1.1 – 2004 2004 2.4. ESAB Six Edition - Consumables for Manual and Automatic Welding. 2.5. GS 118-4
3.0. Responsibility.
3.1. Contractor welding engineer is responsible to issue procurement requirement, warehousing requirement, reviewing the manufacturing test certificate, specifying additional handling and reconditioning requirements. 3.2. The warehouse supervisor is responsible for withdrawal, handling and storage of consumables. He is also responsible to monitor who check the temperature of oven. 3.3. The store keeper is responsible to issue welding welding rod, electrode and flux to the welder or the welding operator. He is also responsible for scrapping damaged consumables. 3.4. The welding inspector is responsible for the periodic inspection or audit of stored materials.
4.0. Warehousing.
4.1. All welding consumable will be received at the warehouse. 4.2. Then, the warehouse supervisor will issue the Consumables Receiving Inspection Report (CRIR) which indicate batch / lot number, brand name, manufacturer, delivery date, dimension and quantity ( See appendix-1 ) The welding engineer will check the batch certificate against specification and the CRIR. The welding engineer will sign the certificate and CRIR for approval. A copy of
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BP BERAU LTD approved CRIR will be sent to warehouse for releasing the consignment, the original certificate and CRIR will be kept by the welding engineer. 4.3. All additional and issuance of welding consumable from storage will be carried out on a rotation basic to ensure to correct stock rotation. 4.4. All welding consumable shall be stored in their original sealed container packing. Each packet of welding consumable shall be stored on the pallets or shelves. The welding consumable shall not be stacked excessively high (do not stack more than eleven layers of electrodes ) so as will damage the packaging of the lower layers. 4.5. Unopened packets of electrode shall be stored under warm and dry conditions. These conditions shall be maintained, 24 hours a day 7 days a week, to avoid promoting pick up of the moisture which permeates through the packaging and be absorbed into the flux coating. Upon receipt the main stock of consumables shall kept and maintained in a close and dry environment with a minimum of temperature 20 oC and a relative humidity equal to or less than 60%.
5.0. Baking, Oven and Drying for Low Hydrogen Electrode.
5.1. Low Hydrogen Electrode AWS A5.1 (E 7016-1, E 7018, E 7018-G)
The electrode shall be kept clean, dry, and properly stored. The electrode that is damaged, damp, greasy or oxidized shall be scrapped.
After unpacking, welding electrode shall be drying to the baking oven at temperature 260oC - 350 oC for minimum 2 hours and the holding oven at temperature 120 oC 150oC before distribution to production area. ( Appendix-2)
Method of drying, baking and oven in accordance with electr ode manufacturer’s recommendation.
5.2. Electrode For Stainless Steel (E 316L-15) and Duplex Stainless Steel (E 2209-17)
The electrodes for Stainless Steel welding shall not be in contact with metal iron, iron oxide and paints containing zinc
Drying temperature is 260 oC – 350oC for minimum 2 hours before use and the holding oven at temperature 120 oC – 150oC before distribution to production are ( appendix-3 )
Method of drying, baking and oven in accordance with electrode manufactu rer’s recommendation.
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BP BERAU LTD 6.0.
Distribution of Low Hydrogen, Stainless Steel and Duplex Stainless Steel Electrode for Production.
6.1
Issuance of the welding electrodes for production from the holding oven shall be placed in the quiver, no welding electrodes held in the hand.
6.2
It is the Supervisor’s or foreman’s responsibility that the welder and welding operator obtain the correct consumable as indicated on the approved Welding Procedure Specification and that they handle, store and return in accordance with this procedure.
6.3
Soon after the quiver is distributed to the production area, the quiver shall be heated to 70oC to 100 oC
6.4
After 4 hours, the remaining of unused electrodes in the quivers shall be returned for redrying and immediately marked silver paint to indicate Cycle – 1 finished (see appendix2&3). After re-drying, the welding electrode shall be transferred to the holding oven and the baking oven. The temperature and duration time of re-drying, oven and baking are same as the temperature of Cycle – 1.
6.5
Distribution for Cycle – 2 use same procedure as Cycle – 1. The welding electrode with silver marking shall be priority over the new welding electrode.
After 4 hours, the
remaining of unused electrodes with silver marking in the quivers shall be returned to the store keeper and immediately marked red paint for scrapping. 6.6
Low Hydrogen, Stainless Steel and Duplex Stainless Steel electrode have been directly contacted with water shall be definitely rejected and removed from the site.
7.0.
Vacuum Pack Electrode ( E 2209-17, E 7016-1, E 7018,E 7918-G )
7.1. During Cycle – 1, the welding electrodes from vacuum pack do not need drying before use, because it is provided with the undamaged package, indicated by vacuum in the package.The welding electrode in vacuum pack will not pick up any moisture during storage. During handling protect vacuum pack from damage at all times. 7.1. Issuance of the welding electrodes for production from the holding oven shall be placed in the quiver, no welding electrodes held in the hand. 7.3 Soon after the quiver is distributed to the production area, the quiver shall be heated to 70oC to 100 oC 7.4. After 6 hours, the remaining of unused electrodes in the quivers shall be returned for redrying and immediately marked silver paint to indicate C y c l e – 1 finished (see appendix-2).
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BP BERAU LTD For Stainless Steel and Duplex Stainless Steel, the remaining of unused electrodes in the quivers shall be returned for re-drying and immediately marked silver paint to indicate Cycle – 1 finished after 12 hours (see appendix-3)
7.5. For distribution of Cycle – 2 shall use same method as appendix-2 & 3
8. Solid Wire (ER 2209)
8.1.
The wire shall be identified with brand name and lot number.
8.2.
The wire shall be kept clean, dry and free from damage, damp, and grease.
8.3.
Wire to be cleaned or degreased prior to being used.
8.4.
All wire shall be protected from weather and stored in accordance with manufacturer’s recommendation.
8.5.
Unidentified wire, showing signs of contamination and rust damage shall not be used and shall be discarded.
8.6.
All unused wire shall be identified, covered and returned to the warehouse, unless it to be used by continuing shift.
8.7.
The wire for Stainless Steel, Duplex Stainless Steel and Carbon Steel shall be separated storage.
9. Flux for Submerged Arc Welding (OK Flux 10.71, OK Flux 10.62)
9.1. The flux shall be kept clean, dry and free from damage, damp, and grease before use 9.2. Unopened flux bag must be stored under warm, clean from foreign materials and dry conditions and maintained 24 hrs a day 7 days a week. The relative humidity of the storage is not exceeding 70 %. 9.3. During and after welding, flux may be recovered. The un-melted flux will be sieved to remove all coarse particle, fuse flux, mill scale, dirt or other foreign matter. 9.4. The flux will be reused as necessary during each welding period or added with new flux as required. 9.5. The remaining of flux in the opened bags or flux hopper should be stored at a temperature at 150° ± 25°C. ( Appendix-4 ) 9.6. If the fluxes have for some reason become wet, it shall be scrapped.
10. Appendixes.
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BP BERAU LTD
Appendix-1 PT. GUNANUSA UTAMA FABRICATORS
CONSUMABLE RECEIVING INSPECTION REPORT
Purchase Order Supplier Specification / Class Description Initiated By
: : : : :
Item No.
:
Class Quantity Data
: : :
* Condition Material MFG Brand
Size
Manufacture
Reported by Sent to Welding * Engineer
Date
Material Agree with Manufacturer Documentation Manufacturer Doc. Agree with Ordering Requirement Non-Conformances Disposition of Non-conformance
: :
Material release for fabrication By Copy to Store Room
: : :
Lot/Batch/Marking
Quantity
:
Yes
No
Yes
No
Date :
* If not acceptable : Quarantine and Contract Welding Engineer
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BP BERAU LTD Appendix-2 FLOW CHART FOR ELECTRODES DISTRIBUTION CARBON STEEL LOW HYDROGEN TYPE (E 7016-1, E 7018, E 7018-G)
RECEIVING CHECK
ELECTRODE STORAGE AREA CHECK
START CYCLE-1
START CYCLE-1
(***) (*)
BACKING OVEN O o 260 C-350 C HOURS MINIMUM
HEATEDQUIVER o o 70 C-100 C
(****) HOLDING OVEN o o 120 C-150 C
WELDING OPERATION CONSUMED
EXPOSED ATMOSPHERE
HEATED QUIVER (s)
START CYCLE-1
WELDING OPERATION CONSUMED
(**) T > 6 HOURS
MARK BY SILVER PAINT
EXPOSED ATMOSPHERE SURPLUS RETURN T > 4 HOURS
START CYCLE-1 MARK BY RED PAINT START CYCLE-1
(*) GS 118-4 (**) Essab Recommendation (***) Essab Recommendation & AWS D1.1 (****) Essab Recommendation
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DISCARDED / SCRAPPED MARK BY SILVER PAINT
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BP BERAU LTD Appendix-3 FLOW CHART FOR ELECTRODES DISTRIBUTION STAINLESS STEEL (E 316L-15) AND DUPLEX STAINLESS STEEL (E 2209-17)
RECEIVING CHECK
ELECTRODE STORAGE AREA CHECK
START CYCLE-1
START CYCLE-1
(***) (*)
BACKING OVEN O o 260 C-350 C HOURS MINIMUM
HEATED QUIVER o o 70 C-100 C
(****) HOLDING OVEN o o 120 C-150 C
WELDING OPERATION CONSUMED
EXPOSED ATMOSPHERE
(**)
START CYCLE-1
HEATED QUIVER (s)
WELDING OPERATION CONSUMED T > 12 HOURS
MARK BY SILVER PAINT
EXPOSED ATMOSPHERE SURPLUS RETURN T > 4 HOURS
START CYCLE-1 MARK BY RED PAINT START CYCLE-1 DISCARDED / SCRAPPED (*) Essab Recommendation (**) Essab Recommendation & AWS D1.1 (***) Essab Recommendation
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MARK BY SILVER PAINT
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BP BERAU LTD Appendix-4
Flow Chart for Handling of Flux of Submerged Arc Welding
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