Welding Consumables Handling Procedure.

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QUALITY CONTROL

PROCEDURE

Industrial Projects Company (INPEC)

WELDING CONSUMABLES

HANDLING

PROCEDURE

0.0 First issue 01/09/2012

Name Sign/date Name Sign/date Name Sign/date

REV. COMMENTS DATE PREPARED BY APPROVED BY ACCEPTED BY

Copy No.

Controlled

Uncontrolled

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1) General

2) Receiving and receiving inspection 3) Welding consumables Store

4) Welding consumables ovens

5) Disbursement of Welding Consumables

6) Return or reassignment of unused filler material 7) Optional Welding Consumables Color Coding 8) Attachments

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1 General:

1.1 This procedure describes the requirements for receipt, storage and disbursal of

welding consumables used for fabrication and installation of pressure retaining items constructed in accordance with the requirements of the ASME Code.

1.2 Welding consumables includes covered electrodes, fluxes and/or bare wire. 1.3 The recommendation of the welding consumables manufacturer shall be used

as a guide for all handling stages. In case of a conflict between the manufacturer recommendation and code requirements, the code requirements shall govern.

2 Receiving and receiving inspection:

2.1 Upon receipt, each welding consumables container shall be inspected for

proper packaging, marking, identification, and damage. The documentation specified in the Welding Consumables Requisition Form (WCR) (Exhibit No. (15)) shall accompany the filler material.

2.2 Welding consumables received without the documentation specified in WCR

and/or received in damaged containers shall be held in segregated storage until inspection and disposition have been made.

2.3 Low-hydrogen covered electrodes received in containers whose moisture seal

has been broken shall be rejected. Low-hydrogen covered electrodes received in damaged containers but with the moisture seal unbroken shall be inspected for physical damage to the electrode coating. Covered electrodes with chipped or broken coatings shall be rejected.

2.4 The QC inspector shall document the receiving detail in the Welding

Consumables Receiving Inspection Form (WCRI) (Exhibit No.: (34))

3 Welding consumables Store:

3.1 The welding consumables store may be any suitable closed container. 3.2 The Welding Foreman and the QC Inspector shall be responsible for the

correct storage of the welding consumables.

3.3 Storage and disbursal of welding filler materials shall be controlled through a

single central location.

3.4 Unopened containers shall be stored separately according to the AWS/SFA

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3.6 Cellulose type covered electrodes (E6010….e.g.) shall be stored in a clean,

dry area and shall not be heated.

3.7 Electrodes of different classifications shall be stored separately, either in

different holding ovens or segregated within the same oven.

4 Welding consumables ovens:

4.1 Backing (Re-drying) Ovens:

Used at the first usage of the low hydrogen welding consumables or for re-drying of the returned low hydrogen welding consumables.

Backing temperature of (250 ± 50 ºC) and baking time of (2 hr: 3 hr) shall be used unless otherwise advised by the welding consumables manufacturer.

4.2 Storage Ovens:

Used for continuous storage of the opened low hydrogen containers baked as in par.4.1.

Storage temperature of (150 ± 20 ºC) shall be used unless otherwise advised by the welding consumables manufacturer.

4.3 Portable Ovens:

Used for field storage of the low hydrogen consumables of 4.2 above for a period of (8: 10Hr).

Portable Ovens shall operate at temperature of (70 ± 20 ºC) unless otherwise advised by the welding consumables manufacturer.

4.4 Storage, baking and portable ovens should be calibrated every 12 months and

checked periodically to verify proper maintenance and operation. Documentation of this verification is not required. A maintenance check shall be performed semiannually to ensure that each unit is operating satisfactorily. The check may be performed using temperature indicating crayon.

5 Disbursement of Welding Consumables:

5.1 The Welding Foreman shall be responsible for the disbursement of the

welding consumables to the welder.

5.2 This is documented by the welding foreman in the Welding Material

Request/Release Note(Exhibit No.: (25))

6 Return or reassignment of unused filler material:

6.1 At the end of each shift, unused filler material and the issue container, ovens

or heaters shall be returned to the designated disbursal area and examined for condition by the Welding Foreman.

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7 Optional Welding Consumables Color Coding:

7.1 Color coding of coated or bare filler material is not mandatory unless

specifically required by the job specifications.

7.2 When color coding is required, for coated and bare filler metals the colors

shall be the same for each generic grouping whether bare or coated. Each electrode type or classification shall be assigned a different distinct color (the colors shall be assigned by the QCM). Color-code paint shall be applied to the uncoated end of the rod and shall not be applied to the sides, or “deep-dip” applied.

7.3 Paint used for color-coding coated electrodes shall be capable of withstanding

temperatures of 300oF for prolonged periods of time. This paint may also be used on bare filler material. Paint may be obtained from any supplier acceptable to the job site. When replenishment of paint supplies is needed, every effort shall be made to obtain the same shade, preferably from the same manufacturer. If a color code is used a color matrix must be posted at electrode issue location.

8 Attachments:

- Welding Consumables Requisition Form (WCR) (Exhibit No.: (15)) - Welding Consumables Receiving Inspection Form (WCRI) ( Exhibit No.:

(34))