Welding Consumable Control Procedure 1

DOCUMENT NO : QA/QC-XXX

REV. DESCRIPTION DETAILS PREPARED BY

REVIEWED & APPROVED BY

1 REVISED

SIGN DATE

0 FIRST ISSUE SIGN.

REVISION CONTROL SHEET

REV. DATE PAGE No. DESCRIPTION

0 FEBRUARY₂₀₀₅ -

-1 SEPTEMBER₂₀₀₆

PROCEDURE COMPLETELY REVISED. THIS SUPERSCEDES PROCEDURE VEW/10.01 REV.0

INDEX

INDEX

6.1 WELDING CONSUMABLES STORAGE

6.2 TREATMENT OF WELDING CONSUMABLES 6.3 MAINTENANCE OF BAKING/HOLDING OVENS

APPENDICES

Appendix 1  MATERIAL ISSUE VOUCHER (MIV)

Appendix 2  TABLE FOR TREATMENT OF WELDING CONSUMABLES Appendix 3  ELECTRODE BAKING / HOLDING OVEN AND FLUX OVEN

STATUS

1.0 SCOPE

This procedure describes the minimum requirements to be complied with for receipt, storage, issue, handling, and treatment of welding consumables prior to use in order to ensure acceptable weld quality during fabrication & erection.

2.0 APPLICATION

This procedure is applicable for Velath Engineering works & Velath Engineering International FZC workshop facilities.

3.0 OBJECTIVES

The objective of this procedure is to ensure that adequate control is being exercised for receipt, storage, handling and issuance of welding consumables.

4.0 RESPONSIBILITIES

4.1. Store Incharge / Store Keeper His duties include the following:

• Verify that batch/lot nos. of the consumables received tally with those in the batch/lot certificates.

• Inspect the incoming welding consumables received with regard to types, sizes, quantities and any visible damage and sign off the delivery note from supplier, if the consignment is accepted.

• The damaged consumables will be segregated in the designated quarantine area for return to the supplier.

• Offer the cnsumable to QA/QC for inspection.

• Store the accepted batches of consumables in the stores.

• Store the various consumables in specified location in a clean area in the Store.

• Properly bake the electrodes in baking ovens in accordance with table 1 of this procedure (Refer appendix 2) and transferring the same to holding ovens prior to issue to workshop.

• Register electrodes / baking details on “Daily electrodes Baking Log ” (Refer appendix 3).

• Ensure that electrodes are properly stacked in the baking ovens.

• Distributing electrodes to shop once or twice a shift, reporting on electrodes issue by coordinating with the Production Engineeer, who will specify the types and sizes of electrodes to be issued.

• Segregate the collected unused electrodes at the end of each shift and re-baking.

baked for the first time by storing the re-baked electrodes in separate section in the holding oven.

• Issue the required electrodes on a first in, first out basis to the work shop. 4.2. Production Engineer:

Production Engineer is responsible for the following:

• Arrange the issuance of the correct type, size and quantities of consumables to the Welders as required.

• Arrange the collection of unused electrodes at the end of each shift and return the same for re-baking. If any of the re-baked electrodes are unused, they are returned to the quarantine area for disposal.

• Ensure that Welders under his control store the electrodes in heated quivers and that quivers are in good working condition.

4.3 Q.C. Engineer:

The Q.C.Engineer is responsible for the following:

• Check that welding consumables are stored, treated and issued in accordance with this procedure.

• Check the temperature of all baking and holding ovens twice a day and record the same in electrode baking/ holding oven status record (See appendix 2).

• Inform the concerned personnel of any discrepancy or deviation from the specified baking cycle and holding temperature.

• Ensure that quivers used by Welders are in good working condition through routine inspection and notify Production Engineer of any discrepancy. In case any quiver is found not working, he shall ensure that such quivers are replaced and the electrodes kept in those malfunctioning quivers are returned for re-baking.

5.0 DEFINITIONS

5.1 SMAW Electrodes Electrodes that are used for Shielded Metal Arc welding process

5.2 GTAW Filler Wires Filler Wires that are used for Gas Tungsten Arc welding process

5.3 SAW Filler Wires Filler Wires that are used for Submerged Arc welding process

5.4 SAW Flux Granular flux that are used for submerged Arc welding process

6.1. Welding Consumables Storage:

Welding consumables received in manufacturer's original factory packing, after inspection, and approval of batch certificates by QC Engineer shall be stored in a clean and covered storage area and handled in such a manner that would prevent any damage or contamination.

Consumables shall not be directly exposed to sun or rain. 6.2 Treatment of Welding Consumables:

6.2.1. SMAW Electrodes Low hydrogen Type:

Prior to use, all the welding electrodes except vacuum packed shall be baked in baking ovens at specified temperature and duration, and held in baking/ holding ovens. The baking and holding temperature, and duration for various types of electrodes based on applicable code/ manufacturer's recommendations are specified in Table 1(See appendix - 2). The vacuum packed electrodes can be used directly from its packets and shall be exposed upto a duration as mentioned by the manufacturer. The electrodes exposed more than this shall be send for baking.

Unused electrodes returned at the end of each shift shall be re-dried in a separate compartment as specified in Table 1. Consequently these electrodes shall be held in a separate compartment in holding oven and issued prior to issuing any electrodes baked for the first time.

All electrodes shall be baked for 2 times only (initial baking and once re-baking) and it shall be ensured that these are consumed. Re-baked Electrodes, which are issued to the welder and not used, shall be scrapped and removed from site.

The Stores Incharge / Stores Keeper shall maintain a daily log, showing type, size, batch no. and quantity of electrodes baked, time of start and finish of baking for various types of electrodes. (See appendix-3).

Baked electrodes can be stored in holding ovens for an indefinite period at the specified temperatures, but it is good practice to issue electrodes from holding ovens on a first-in first-out basis.

If holding ovens are not available, electrodes may be stored in baking ovens at specified holding temperature, prior to issue.

6.2.2 SMAW Electrodes - Cellulosic Type:

All Cellulosic electrodes from opened containers shall be used directly or stored in heated quivers.

If exposed to humid air for a period exceeding 48 hours, cellulosic electrodes shall be dried in heated ovens, strictly as per the cycle recommended by the manufacturer which is specified in table 1 (appendix 2). The temperature and time specified shall not be exceeded. 6.2.3 SAW Flux:

Prior to use all the SAW Fluxes are baked/held at specified temperatures and duration (refer Table 1).

for re-drying as per the specified cycle.

It shall be ensured that slag particles are removed by sifting, prior to re-drying of flux.

6.2.4. Filler Wires:

GTAW Filler Wires shall be stored in manufacturer's packing and issued to Welders on a daily basis based on requirement. Unused filler wires shall be returned to stores at the end of the shift.

Care shall be taken to prevent damage to colour coding/ identification marking on each filler wire.

GMAW, FCAW and SAW Filler Wire Spools/Coils shall be stored in original packing until they are issued to operators for use.

GMAW, FCAW & SAW Filler Wires showing signs of rusting shall not be used.

6.3 Maintenance of Baking/Holding Ovens

A monthly maintenance / check-up shall be conducted by the Maintenance Department electricians to check the condition of the baking/holding ovens. Any malfunction detected shall be repaired in situ or at the workshop. The control thermostat of the baking ovens, temparature gauge of holding ovens shall be calibrated every year or when there is a discrepancy between the actual temperature and the indicated temperature.

CONSUMABLE TYPE _BAKING (Note 1)

REMARKS

TEMP. TIME TEMP. TIME

Carbon Steel Low Hydrogen Electrodes E7016-1, E7018, E 7018-1, E 7028 300-350°C 2 Hrs. 120 - 150°C Indefinite 2 Times L.A.S. Electrode E 8016G E 8018-B2 E 8018-C1,C2,C3 E 9018 - M E 11018 – M 370-420°C 1-2 Hrs. 120-150°C Indefinite 2 Times

Stainless Steel Electrode, E 308L-16, E 316L-16 E 347-16, E 309-16 E 309 MOL-16 250-300°C 2 Hrs. 120-150°C Indefinite 2 Times Ni alloy electrode E NiCr Mo-3 E NiCu 7 260-280°C or 300-320°C 2 Hrs. - 1 Hr. 120-150°C Indefinite 2 Times Cellulosic Electrodes (LINCOLN) E 6010, E 7010G E 8010G 93-110°C

(Note 2) 10 to 20 Min. 38°-49°C Indefinite 1 Time

SAW FLUXES OK 10.62, OK 10.71 250-300°C 2 Hrs. 120-150°C Indefinite 3 Times SAW FLUXES 200-300°C 2 Hrs. 120-150°C Indefinite 2 Times

Notes: 1. Inclusive of initial baking.