Welding Consumable and Storage Procedure

15-07-2013 Date

Description

Prepared

Checked

Reviewed

SILVER TEKNIK

VENTECH

TTOPCO

SUBCONTRACTOR

SILVERTEKNIK CONSTRUCTION COMPANY Document Title EPC CONTRACTOR

WELDING CONSUMABLE AND STORAGE PROCEDURE Document No. Org. Code

Area Code

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Document Title:

WELDING CONSUMABLE AND STORAGE PROCEDURE

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TABLE OF CONTENTS 1. PURPOSE 2. SCOPE 3. REFERENCE DOCUMENTS 4. GENERAL GUIDELINES FOR WELDING MATERIAL 4.1 Receiving Inspection 4.2 Storage and Release 4.3 Welding Filler Materials 4.4 Baking and Holding 4.5 Issuance 4.6 Return of Unused Welding Material 4.7 Oven Calibration 4.8 Selection of Covered Electrodes and Filler Material

ATTACHMENTS 1. SILVER-TEK-01 Material Receiving Inspection Form 2. SILVER-TEK -02 Welding Material Control Record Form 3. SILVER-TEK -03 Welding Material Baking From 4. SILVER- TEK-04 Welding material Request Form

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PURPOSE The purpose of this document is to describe the method to be used for storage of Welding Materials.

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SCOPE The scope of this document covers the Welding Materials of atmospheric storage tanks (TAQ TAQ DEVELOPMENT – PHASE II)

3.

REFERENCE DOCUMENTS 1. ASME Sec II, Part C – Specification for Welding Rods, Electrodes and Filler Metals 2. ASME sec IX Welding and Brazing Qualification 3. API 650

4. 4.1

GENERAL GUIDELINES FOR WELDING MATERIAL Receiving Inspection

A receiving inspection of all welding consumables shall be carried out by Welding Engineer and / or Welding Supervisors. Mill test certificates of welding consumables shall be required for each batch, lot or heat. All welding consumables including electrodes shall be initially received in the main consumable warehouse, which has a controlled environment; a daily record of temperature and humidity shall be recorded. The recommended minimum storage temperature is 18°C and maximum relat ive humidity is 60%; situations where these conditions cannot be maintained shall be brought to the attention of the Welding Engineer and/or QA/QC department. Receiving inspection of welding consumable shall be performed to highlight any damages. All consumables shall be stored on open rack shelves; electrodes shall be stacked no higher than 6 cartons or as per manufacturer’s recommendations. No unauthorized personnel are allowed into the main consumable warehouse o r satellite stores and only the Store man is allowed to issue welding consumables. The control of satellite consumable stores remains the responsibility of the store man and welding supervision. The Welding inspector shall carry out random checks on the storage and issue of welding consumables. All electrodes shall have their type and identity stencilled on the flux.

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All consumables shall be supplied and certified in accordance with the Manufacturers product data sheet. On receipt of consumables in the stores the store man shall inspect the consumables for damage verify that their batch numbers and consumable t ype corresponds with the batch certificates supplied and complete the welding consumable approval sheet form. This form is then presented to the Welding Engineer or appointed QA/QC representative along with the Batch certificate for approval or in the case of defect ive consumables a corrective course of act ion. After review and approval by the Welding Engineer or an appointed QA/QC representative, the certificate shall be endorsed and a copy shall be forwarded to the consumable store man to enable release of the consumables for production. All original certificates are held on file by the QA/QC department. Consumables received without certification are quarantined until certificates are received and approved by the Welding Engineer/Inspector. 4.2

Storage and Release

After receiving inspection upon approval from Welding Engineer/Inspector, the Warehouse releases only the accepted materials to the welding Material Crib after recording the date, quantity and welding material identification on the Welding Material Control Record Covered electrodes received with damaged packages shall be put aside from other packages, inspected for coating integrity and baked as necessar y. The damaged electrodes shall be discarded. All welding materials shall be properly protected while in storage (temperature and humidity controlled) in the Welding Material Crib. The Welding Material Crib shall be a controlled access area. Unauthorized personnel including welder, welding operator shall be prohibited from entering the Crib. The Welding inspector shall carry out random checks on the storage and issue of welding consumables. The storage conditions shall be such that the properties of the welding materials are preserved. Welding materials shall be stored under the classification of grades, brands and size in welding material crib to prevent any moisture absorption, contamination or rust generation. For this purpose, the materials shall be stored in dry place. All packages of electrodes shall not be stored directly on the ground or in an area subject to any humidity. Packages shall not be opened until just before using. The Welding Material Crib keeper shall be responsible for keeping the welding materials in the proper storage conditions. During storage, the materials shall remain in their original intact packages. Any material which has been deteriorated or whose identification has been lost shall be discarded. Particular care shall be taken when handling covered electrodes to prevent any possible damage to their coverings. The following details for welding material shall be identified during storage in the Crib: 1) Trade designation, specification and class of welding material, 2) Size,

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3) Heat / Lot No

4.3

Welding Filler Material

Selection of the welding consumables is the responsibility of Contractor. Welding consumables shall conform to API Standard API 650 Section 2.2 shall closely match the base metal chemistry, and meet the same minimum strength and toughness requirements as the base metal. Low hydrogen consumables shall be used. 4.4

Baking and Holding

The covered “low hydrogen” electrodes received in hermetically sealed containers or in vacuum packing may be issued for use without baking treatment provided that manufacturer instructions allow it. Immediate after opening the hermetically sealed container, electrodes shall be stored in ovens held at temperature of at least 120 C. The electrodes in other than hermetically sealed containers shall be baked after removal from manufacturer's packages but before issuance. The temperature and time of baking and holding treatment shall be as shown in the Table-A1. When the range of the manufacturer's recommended temperature and time is different from the ranges specified in the Table-A1, the welding engineer shall specify the temperature and time of baking to the Welding Material Crib keeper. Welding Material Crib Keeper shall complete Welding Material Baking Form ( SILVER-TEK-03 ) when baking the electrodes. 

The holding oven should contain only welding materials of the same specification and classification. However welding materials of more than one trade name may be placed and dried in the same oven, provided: -Baking or holding conditions are identical, -Reasonable physical separation exists between baking oven and holding oven, -Identification is maintained on materials and on a panel at tached during baking or holding. The temperature of the oven shall not exceed 180 C at the time the welding electrode is placed in it. After baking, the electrodes shall be stored in the holding oven and treated per Table- A1. 

Each welder shall have a heated-quivers allowing him to keep his electrodes dry. Covered electrode that has become wet during use by extraneous material shall be discarded. All electrodes including vacuum packed electrodes manufacturer instructions shall also be given consideration.

Table-A1: Temperature Ranges for Baking and Holding of Electrodes

Trade Name ASKAYNAK 7018

Baking Hours 2

Temperature 300 – 350ºC

(1)

Holding Temperature

120 - 180ºC

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This section will be completed at site

(1)

4.5

Instructions of the manufacturer shall also be given consideration

Issuance

For the issuance of the welding consumables from the Main Crib to site Welding Material Request Form (SILVER-TEK-04) shall be used. Welding Supervisor/Inspector/Foreman shall issue Welding Material Request Form (SILVERTEK-04) to a qualified welder or welding operator. The Crib keeper shall check the Request Form and issue the material. The Crib keeper shall complete the Welding Material Request Form by writing down the lot number and issued time and weight or quantity. The Welding Material Request Card shall be kept by the Crib keeper for inventory purpose. Only one type of covered electrode shall be issued to a welder at any time. Previously issued electrodes must be consumed or returned to the Welding Mater ial Crib before issuing of additional covered electrodes. Each welder shall not use the welding material except delivered for him. During use, portable containers shall be continuously heated, and the cap shall be c losed at all times except when taking out electrodes. Covered electrodes to be used shall be clean of defects as the extra foliation of covering fluxes, cracks, dirt etc. The slightest damage of the coating of a low hydrogen electrode will cause porosity. Therefore every damaged low hydrogen e lectrode is to be discarded and must not be used in welding. Welding Engineer shall check that the electrode conform to correct type for the intended welding process and sign acceptance of conformance prior to issue for production.

4.6

Return of Unused Welding Material

At the end of each shift or when the welding work is completed, unused welding material shall be returned to the Welding Material Crib and quantity shall be recorded on Welding Material Request Form.

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No welding material shall be left on the work site after the daily work is finished. The unused material shall be placed by the Crib Keeper in a designated storage area with the identification of returned materials. He shall store the covered electrodes in the baking ovens and bake them for minimum number of hours and temperature in Table-1 before re-issuance. Re-baking electrodes shall be compliance with electrodes manufacturer’s requirements. The Crib Keeper keeps the electrodes in a separate designated drying oven for the second use. When the quantity of returned electrodes reaches to a certain amount, they shall be re-baked and delivered to a specified welder(s). The bare ends of these electrodes shall be marked with white paint marker to prevent further re-baking. Any returned electrodes from those welders with white marking shall be discarded. 4.7

Oven Calibration

Valid calibration certification and/or tag shall be fixed to the equipment.

4.8

Selection of Covered Electrodes and Filler Material

Acceptable electrodes and filler material is shown in Welding Procedure Specifications (WPS). Only approved welding consumable identified in the project WPS shall be used, no substitution of consumables brand name or type is allowed without for mal approval on an engineering query.

WELDING MATERIAL CONTROL RECORD FORM

Manufacturer

Classification

Specification

Lot/Batch No

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SILVER -TEK-02

WELDING MATERIAL BAKING FORM

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Resp. Person

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WELDING MATERIAL BAKING FORM

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WELDING MATERIAL REQUEST FORM

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I nspector / F ormen / Welder Name

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Manufacturer

Lot/Batch No

Size

KG/PIECE

Remarks

WELDING MATERIAL REQUEST FORM

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Date of Delivery

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Material Controller

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Welding Consumable and Storage Procedure

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