84097996 100 welding consumable control procedure

Welding Consumable

Control Procedure Document No. CO-GN-007

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of 10 Document No. CO-GN-007 Revision 0

WELDING CONSUMABLE CONTROL PROCEDURE

0 October 16, 2006 PS RC/SP DL Rev No Date PREPARED BY REVIEWED BY APPROVED BY

Welding Consumable


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Contents Sheet 1.0 Purpose 3

2.0 Definitions 3

3. Procedure 3 3.1 General 3 3.2 Stores Receipt 3 3.3 Storage 4 3.4 Traceability 5 3.5 Monitoring 5 3.6 Equipment 5 3.7 Audits 5

4.0 Electrode Flow Control 6

5.0 Documentation 9

Welding Consumable


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1.0 Purpose

This procedure specifies the manner in which TAC will control all welding consumables during all work campaigns/projects to effectively ensure the quality of the consumable is maintained prior to and during usage.

2.0 Definitions

TAC Thai Alliance Engineering and Construction Co., Ltd.

Consumable For the purpose of this procedure a consumable is any electrode, wire or flux that is consumed during the welding process.

Storeman Dedicated person elected by the Warehouse Manager to issue welding consumables.

3. Procedure

3.1 General All covered electrodes and fluxes are sensitive to moisture absorption therefore care must be taken during storage and handling to prevent excessive moisture intake. Unacceptable moisture levels may adversely affect welding quality and performance.

Where practicable, only one batch of any given size/type of consumable will be in use at any one time.

Consumables will be used in order of receipt to minimise storage time. Recognition should be made of expiry dates when issuing consumables in case a later delivery has an earlier expiry date.

The person responsible for applying this procedure is the Warehouse Manager monitored by the Quality Control Department.

Baking and holding oven temperatures shall be in accordance with the manufacturers’ recommendations for the consumable in use.

3.2 Stores Receipt

On delivery of welding consumables the storeman will check the following:

• Consumable containers, such as packets, hermetically sealed tins and bags shall be inspected for damage.

• Certification accompanies consumables upon delivery.

Deliveries without Certification will be quarantined and not issued until receipt of Certification.

Batch numbers of delivered consumable are verified as complying with consumable certification.

Any damage shall be reported in accordance with the Procedure for Materials Control & Handling.

Welding Consumable


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Consumables delivered without accompanying certification will be isolated in quarantine and not issued, until the relevant certificate is forwarded by the supplier.

Consumables may be issued in special circumstances (i.e. if impacting schedule) only when written confirmation from the supplier confirms the certificate is available and as agreed by the Quality Department.

3.3 Storage

3.3.1 General

It is the responsibility of the Warehouse Manager to ensure that all storage requirements are adhered to at the Erection Yard.

It is important that the conditions outlined below are maintained 24 hours a day and 7 days a week. Consumables are to be stored as follows:

• Unopened containers of consumables are to be stored in warm and dry (ambient) conditions.

• Properly arranged off the ground and on shelving/pallets that cannot hold moisture.

• Under cover and protected from any inclement weather.

3.3.2 Low Hydrogen Electrodes

After removal from packaging the welding electrodes shall be stored in a holding oven at between 110°C to 140°C prior to issue.

Electrodes, where there is evidence of damage to the packaging, shall be dried in a baking oven at approx. 370°C for a minimum of 1 hour before transferring to the holding oven.

A control form shall be completed by the storeman recording the time, type and amount of electrodes baked. After removal from the baking oven the electrodes shall be stored in a holding oven as previously described. In general, electrodes shall only be issued from a holding oven directly for use. Should the electrodes be placed in quivers prior to commencement of shift (ready for welders’ collection), they shall not remain in the quiver for longer than a period of 1/2 hour.

Onsite electrodes will be held in heated portable electrode quivers.

Any electrodes returned at the end of the shift shall be identified by marking the end with indelible white paint and re-baked as per this procedure. Any electrodes returned after re-issue (with white marking) shall be taken out of circulation. No electrodes will be re-baked more than once.

Electrodes vacuum packed during the manufacturing process are intended for use directly from the pack. Any vacuum pack electrodes not used by the end of a shift or during the time recommended by the manufacturer shall be returned to the store for marking (with white paint) and storage in the holding oven. Due to the possibility of over drying (which could directly affect the welding quality or performance), re-issue is permitted only once and baking is not permitted under any circumstances.

Welding Consumable


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3.3.3 SAW and GTAW Electrodes/Wire

SAW and GTAW electrodes and wire shall be stored as per the manufacturer’s recommendations but generally in a dry area off the floor or ground.

3.3.4 SAW Flux

SAW flux is normally supplied in sealed containers or moisture preventative bags. Provided that they are stored in dry condition off the ground and the containers/bags have not been damaged prior to issue, the flux can be used directly from the container/bag.

If the flux is not used directly then the remaining flux must be held in heated holding drums/containers at a temperature of 150°C (+/-25°C).

3.3.5 Inconnel 625 (SMAW)

After removal from their container/package Inconnel 625 consumables shall be baked for a minimum of 2 hours at 200°C. On completion of baking they shall be stored in a holding oven at a temperature of between 120°C and 170°C.

3.4 Traceability

The Warehouse Manager will maintain a Welding Consumable Register and continually update the register on an as required basis (as consumables are delivered). When consumables are issued, the storeman shall record type, size and batch no., the welders I.D. no. and the date of issue on the consumable issue form.

3.5 Monitoring

Ovens shall be identified as either baking or holding with the required operating temperature posted near the oven.

Temperature monitoring sheets shall be posted on each oven and will be completed during monitoring checks by the QC Department or Storeman.

Periodical checks shall be carried out on portable quivers to ensure the operating temperature is maintained. Should the quiver be found to be cold the contents will be re-baked or disposed of.

3.6 Equipment

All Baking/Holding ovens shall be calibrated to a recognized International standard or in accordance with CO-GN-008 ‘Procedure for Calibration Control’ annually or after repair.

3.7 Audits

The QC Inspector shall conduct periodical checks to verify compliance to this procedure and report all findings to the Construction Manager.

Welding Consumable


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4.0 Electrode Flow Control

Note : (1) is for ’New batch No.’ (2) is for ‘Remaining’

(3) is for ‘Reject’

Oven 1

For Backing Oven 2

For Holding

Portable Oven

Remaining

Reject

Issue (2) Before (1)

Separate Shelf

Separate Color Marking

Welding

SMAW ELECTRODE

(1)

(1), (2)

(1)

(2)

(2), (1)

(2)

(3)

Procedure I : for Large Amount of Electrode

Color Marking

Color Marking

(2), (1)

Welding Consumable


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Note : (1) is for ’New batch No.’ (2) is for ‘Remaining’

(3) is for ‘Reject’

Oven

For Backing, Holding

Portable Oven

Remaining

Reject

SMAW ELECTRODE

Procedure II : for Small Amount of Electrode

(1)

Welding

(2)

(3)

(1)

(2)

Color Marking

Color Marking

Issue (2) Before (1)

(2), (1)

(2), (1)

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Drying Condition of Welding Electrodes

Covered Electrode

Base Metal

Brand/ Product Name

(ชื่อผลิตภัณฑ) AWS JIS

Backing

Temperature (°C)

อุณหภูมิในการอบ

Backing Duration (Minutes)

ระยะเวลาในการอบ

Holding Condition

Temperature (°C)

อุณหภูมิในการอุน

C/S + C/S KOBELCO RB-26

A5.1 E6013

Z3211 D4313 70~100 30~60 50~70

C/S + C/S KOBELCO LB-52

A5.1 E7016

Z3212 D5016 300~350 30~60 100~150

C/S + C/S KISWEL KK-50LF

A5.1 E7016

Z3212 D5016 350~400 30~60 150~200

C/S + C/S YAWATA L-55

A5.1 E7016

Z3212 D5016 300~350 30~60 100~150

C/S + C/S Low Temp.

KOBELCO LB-52NS

A5.5 E7016-

G

Z3212 D5016 350~400 30~60 150~200

Alloy P11+ Alloy P11

KOBELCO CMA-96

A5.5 E8016-

B2

Z3223 DT1216 325~375 30~60 150~175

Alloy P22+ Alloy P22

KOBELCO CMA-106

A5.5 E9016-

B3

Z3223 DT2416 325~375 30~60 150~175

SUS 304 +SUS 304

KOBELCO NC-38

A5.4 E308-16

Z3221 D308-16 150~200 30~60 80~130

SUS 304 +SUS 304

YAWATA 308.R

A5.4 E308-16

Z3221 D308-16 150~200 30~60 80~130

SUS 304 +SUS 304

WEL 308

A5.4 E308-16

Z3221 D308-16 150~200 30~60 80~130

SUS 304L +SUS 304L

KOBELCO NC-38L

A5.4 E308L-16

Z3221 D308L-

16 150~200 30~60 80~130

SUS 316 +SUS 316

KOBELCO NC-36

A5.4 E316-16

Z3221 D316-16 150~200 30~60 80~130

SUS 316L +SUS 316L

KOBELCO NC-36L

A5.4 E316L-16

Z3221 D316L-

16 150~200 30~60 80~130

SUS 347 +SUS 347

KOBELCO NC-37

A5.4 E347-16

Z3221 D347-16 150~200 30~60 80~130

C/S + SUS 304

KOBELCO NC-39

A5.4 E309-16

Z3221 D309-16 150~200 30~60 80~130

C/S + SUS 304L

KOBELCO NC-39L

A5.4 E309L-16

Z3221 D309L-

16 150~200 30~60 80~130

Welding Consumable


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5.0 Documentation

The following standard TAC forms are used in conjunction with this procedure:

Welding Consumable Control Sheet

Consumable Request Form

Welding Consumable


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Project : ___________________ Job No.__________

Electrode Oven No. : __________ Date : __________________

A. Welding Electrode Baking and Holding

No. Brand Size Batch No. Q'ty (Kg) Time-in Temp. Time-out Holding Temp.

1

2

3

4

5

B. Welding Rod and Electrode Issue / Return

Q'ty Time Q'ty Time

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

Summary Usage Today kg.

kg.

kg.

ReturnIssue Today Use (kg.)


Brand Size

Storekeeper Signature

No. Welder's Name Welder I.D.

Portable No.

=

=

=

Cumulative =

84097996 100 welding consumable control procedure

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