This working instruction specifies the requirements and instructions for control of welding consumables.
Store Keeper shall responsible to store all welding consumables and issue for construction as per request by Production Department.
The Welding Consumable Controller (WCC) shall responsible to store and handle of the welding consumables as per manufacture recommendation, and issue to welders for fabrication.
Welder shall responsible to use the consumable as per WPS applicable.
3. IDENTIFICATION OF WELDING CONSUMABLES
Welding consumables shall be identified by their manufacturers marking on the package include manufacture’s name, filler metal specification/ classification, and batch/lot number
Welding consumables were not identified or showing signs of damage, deterioration or dampness shall be segregated and report to QHSE department for dealing with it.
Welding consumables shall be stored in its original packing up to the time of usage. The packing shall be stored in a dry, covered store and on shelves or racks with a minimum clearance of 150 cm from the floor or wall to ensure ventilation.
The receiving material and issuing material shall be in accordance with FIST IN FISRT OUT principle.
5. CONSUMABLE DRYING AND HOLDING
Low or extra/ultralow-hydrogen electrodes shall be baked and then dried prior to use, except that electrodes in vacuum package.
Baking and drying conditions shall be followed to the electrode manufacture’s recommendation; or to the typical condition below.
|Classification||Designation||Baking temperature (0C)||Time (hrs)||Holding temperature (0C)|
|Low hydrogen||Exx15/16/17/18||350||2||120 – 150|
|Rutile||Exx012/13||N/A||N/A||90 – 120|
All electrodes under baking/drying treatment shall be logged by WCC as follow:
• Electrode classification or designation.
• Electrode size.
• Batch No./Lot No.
• Initial drying or re-drying.
On completion of baking, electrodes shall be transferred to the holding oven or in case of an oven only, the oven shall be switch on to holding time.
The drying and holding ovens shall be marked for separating – “DRYING OVEN” & “HOLDING OVEN”.
SAW flux shall handle as flux’s manufacture recommendation.
6. CONSUMABLE ISSUANCE AND RETURN
Each welder shall be issued not more than 5 kg of electrodes per time.
Dried electrodes shall be promptly placed in welder’s heater quiver with adequate method to protect the electrodes covered end from being contaminated in order to avoid porosity.
Only electrodes of the same class are held in the quiver at one time.
The quiver shall be powered during working time and be opened only at each withdrawal.
After each haft working shift (4 hours), welder shall return unused electrodes to the WCC. He shall inspect electrodes for damage or loss of identification.
Damaged or loss-identification shall be immediately discarded and separated another container with identification markings “DISCARDED ELECTRODES – DON’T USE”.
Excess electrodes returned in good condition shall be marked at tip of end electrode and re-dried for re-use other purpose as follow:
– 2nd baking in yellow color for secondary structure welding only.
– 3rd baking in red color for support tacking only.
– 4th baking shall not allow and discarded.
SAW flux shall be removed from the welding unit hopper and transfer to the flux holding oven after each half working shift (4 hours).
7. VERIFICATION OF THE OVEN TEMPERATURE
The oven’s temperature and the temperature indicator shall be verified on weekly basic by WCC by using a thermometer.
Drying/holding ovens shall be external calibrated every 1 year and quivers shall be in-house maintenance or whenever damage or malfunction is suspected.
The WCC shall record all welding consumable received, storage, and issuance in applicable record form.
The completed record form shall be forwarded to QHSE Department for maintenance and audit purpose.
- Form no. F-11 – Baking and Drying Log
- Form no. F-12- Electrode Issuance and Return Log.