038-PRO WELDING CONSUMABLE CONTROL PROCEDURE.pdf

Pearl GTL Project

LINDE ENGINEERING

Contractor Project No: 5887 Shell Project No: HP-3000-QAT

Project Document Number: T- 4.250.931 Project Rev.: A Page 2 of 19

Purchase Order Number: 2MH127

N/A Tag/Item Number(s):

ASU Unit(s):

Z PCWBS:

QATAR SHELL GTL PROJECT (PEARL) C2 AIR SEPARATION UNITS CONSTRUCTION

D A 21.04.2008 Ready For Construction BR UA ZG RFC

C O 10.12.2007 Issued for Company comments BR AU/MC ZG ICC

B 26.11.2007 Issued for Review BR AU/MC ZG IFR

A 20.11.2007 Issued for Internal Review BR AU/MC ZG IIR

Approved By

GAMA Project Rev Rev. Date Description

Prepared By

Checked By Status

No. No. ORIGINATOR

Document Title:

LINDE ENGINEERING AG

PROCEDURE FOR WELDING CONSUMABLE CONTROL

Document No.

GAM PRO QAC GTL 038 D LOC470

Contractor

Gama Qatar Co. W. L. L. Org.

Code Doc. Type

Disc. Code

Geogr. Area

Seq. No

Rev. No Vendor Code

Project Document Number: T-4.250.931 Rev No: A

Doc. Title : PROCEDURE FOR WELDING CONSUMABLE CONTROL

Doc. No: : GAM-PRO-QAC-GTL-038 Rev. D Date 21.04.08

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TABLE OF CONTENTS

1. SCOPE ________________________________________________________________________5 2. PURPOSE _____________________________________________________________________5 3. HSSE _________________________________________________________________________5 4. REFERENCES _________________________________________________________________5 5. DEFINITIONS _________________________________________________________________6 6. SAFETY _______________________________________________________________________6 7. RESPONSIBILITIES ____________________________________________________________7

7.1. Welding Engineer __________________________________________________________________7 7.2. Welding Inspector__________________________________________________________________7 7.3. Welding foreman __________________________________________________________________7 7.4. Consumable Store-Man _____________________________________________________________7

8. EQUIPMENT___________________________________________________________________8 9. PROCEDURE __________________________________________________________________8

9.1. GENERAL _______________________________________________________________________8 10. RECEIPT AND BULK STORAGE OF CONSUMABLES _____________________________9 11. ISSUE OF WELDING CONSUMABLES _________________________________________13 12. QUALITY ASSURANCE_______________________________________________________13 13. ATTACHMENTS_____________________________________________________________14



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1. SCOPE The scope of this procedure is to present the controls adopted by GAMA-QATAR for storage, handling, identification, conditioning and issue of welding consumables to be applied in the C2 ASU PEARL GTL PROJECT.

2. PURPOSE The purpose of this procedure is to define the requirements for consumable handling and assign corresponding responsibilities.

3. HSSE All works shall be in compliance with the State of Qatar laws and regulations, Ras Laffan Industrial City and International standards, codes, LINDE ENGINEERING AG and QSGTL and/or its PMC requirements and instructions. In addition all employees and GAMA subcontractor employees on site will have through LINDE ENGINEERING AG Site Safety Induction and GAMA Qatar Safety induction for site safety, health, environmental and security prior to work activities. Other training courses will be attended as required by LINDE ENGINEERING AG or QSGTL and/or its PMC as required.

4. REFERENCES ASME Section IX: Welding & Brazing Qualification ASME Section II: Part C- Specification for Welding Rods, Electrodes

And Filler Metals

T-13.377.441: Quality control requirements for welding T-13.377.438: Specification for Traceability, Alloy verification and material

substitution T.4.096.687: Welding Consumable control DEP 31.38.01.31 GEN: Shop and field fabrication of piping DEP 30.10.60.18-Welding of metal (Amendments/supplements to API RP 582)



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5. DEFINITIONS Company : QSGTL or its PMC Contractor : LINDE ENGINEERING AG Sub Contractor : GAMA QATAR Contract : QSGTL Pearl Plant - C2 ASU Project ITP : Inspection and Test Plan QCP : Quality Control Procedure QCR : Quality Control Record WPS : Welding Procedure Specification PQR : Procedure Qualification Record WPQT : Welding Procedure Qualification Test NDT : Non Destructive Testing WQT : Welding Qualification Test SMAW : Shielded Metal Arc Welding SAW : Submerged Arc Welding GTAW : Gas Tungsten Arc Welding GMAW : Gas Metal Arc Welding

6. SAFETY

All Operations shall be conducted in line with the requirements of the construction Safety Procedures.

Necessary personnel protective equipment will be provided and worn.



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7. RESPONSIBILITIES Responsibilities of project personnel relative to this procedure are described below:

7.1. WELDING ENGINEER Prepares the welding procedures and requirements for consumables as per the approved

welding procedures. Reviews purchase requisitions to ensure correct order specifications. Reviews welding consumable batch certificates accordance with ISO10474 3.1B

specification. Establishes re-order levels for welding consumables in line with project requirement. Supervises Consumable Room personnel and operations. Compiles Welding Consumables Identification Tables. Compiles Welding Consumables Conditioning Instructions. Has a responsibility for welding consumables control up the time of issue.

7.2. WELDING INSPECTOR Carries out Daily inspection/audit of the consumable room operations according to the

requirements of this procedure. Monitors, oven, hoppers and portable quiver(s) temperature on site and check calibration

status is valid. Monitors implementation of this procedure. Carries out weekly documented surveillance of consumables usage on site (check list)

7.3. WELDING FOREMAN

Monitors handling of welding consumables on site in line with this procedure. Prepares Welding Consumables Request Card per WPS requirement. Ensure that all unused electrodes have been returned to the Consumables Store at the end

of the shift/day.

7.4. CONSUMABLE STORE-MAN Maintains effective general storage of consumables in the site storage room. Requisitions consumables from main stores. Carries out electrode conditioning per conditioning instructions and maintains Welding Consumables Treatment Record. Preheats portable quivers for issue of SMAW electrodes. Issues consumables against GAM-QCR-QAC-GTL-060 Receives and handles returned consumables per procedure requirements and marks the

returned electrodes for re-baking or dispose-off previously re-baked electrodes. All the returned electrodes shall be colour coded white at grip end or electrodes for re-bake and reported in GAM-QCR-QAC-GTL-060



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8. EQUIPMENT

Baking and holding ovens and portable heated quivers for use with SMAW consumables will be designed for that purpose. All these items shall be checked and calibrated periodically in accordance with T-4-250-915.

All calibration certificates shall be retained and filed for future reference and kept at the

QA/QC department.

Temperature measuring devices on heating equipment above shall be indicator only. Checks shall be by proprietary temperature sensitive crayon or by calibrated digital thermometer on frequent basis (when in use).

Measurement of atmospheric conditions shall be by thermometers and hygrometers. 9. PROCEDURE

9.1. GENERAL Approval of welding consumables

Welding consumables for use on this project (in the permanent works) shall be approved by the Contractor through the approval of WPS' & PQRs.

The Welding Engineer shall determine batch-testing requirements for welding

consumables per project specifications. These requirements shall be incorporated into the purchase orders.

Packaging of Low-hydrogen SMAW electrodes & SAW Flux

Low-hydrogen SMAW electrodes shall be supplied in standard packaging or, alternatively, extra low moisture conditioned in specially designed vacuum packaging (Vac Pac). SAW flux, shall be supplied in polythene lined bags (If applicable).

Purchase

Purchase orders shall be reviewed by the Welding Engineer to ensure correct and adequate specification with respect to approved brand, and testing/certification requirements. All certification shall be retained and filed for reference. All certification to be submitted to Linde for approval before using.



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Identification of Welding Consumables

In order to permit effective surveillance & checking, individual consumables shall be visually identifiable against brand/AWS class, which shall be marked on the electrodes by the manufacturer or on site. The Welding Engineer shall establish the consumable identification system, which shall be documented and distributed to all relevant personnel.

10. RECEIPT AND BULK STORAGE OF CONSUMABLES Receipt

Incoming welding consumables shall be unloaded to an area segregated from other certified stock. The Storekeeper shall receive deliveries of welding consumables checking brand, AWS class, size, quantity and packing is as per the purchase order and delivery document, and that certification is provided. Packaging shall be examined for damage, which shall be reported to the Welding Engineer to determine the effect of damage and advise disposition. The consumable certification shall be reviewed by the Welding Engineer to determine conformance with order specification and he shall endorse the certificate accordingly. Return of the certificate to the Store man shall release the consumable for entry to stock and transfer to bulk storage area in the warehouse. Stacking of electrodes shall be carried out as per manufacture(s) recommendations. Tagging of the electrodes is not required as electrodes are clearly marked by the manufacturer(s) and they are separated in the consumable store based on their trade name, AWS number and size.

Bulk Storage of Welding Consumables

Bulk storage of welding consumables shall be in a designated area, which shall only be used for storing welding consumables. The area shall be dry and protected according to the manufacturer's recommendations. The consumables shall be segregated by type (e.g. SMAW electrode, SAW flux, SAW wire (If applicable), GTAW wire etc.), AWS class, brand, size, and batch number and shall be maintained in original shipping bundles/pallets. Consumables shall be stacked with adequate Dunnage at stacking heights per manufacturer's recommendations and shall be tagged for ease of identification. Consumables shall not be stored directly on the floor.



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ISSUE TO THE SITE CONSUMABLE ROOMS

The Consumable Room Store man shall issue welding consumables to the site Consumable Rooms against a Stores Requisition prepared. The form to be checked and signed by Gama Qatar Welding Engineer Consumables shall be issued on a First-in/First-out (FIFO) basis whenever practical.

SITE CONSUMABLE ROOM The consumable room atmosphere shall be subject to control within the following criteria:

5-15 C < 60% 15-25 C < 50% Above 25 C < 40% Relative humidity

The QC Inspector on a daily basis, using a thermometer and hygrometer and reported on the GAM-QCR-QAC-GTL-061, shall check consumable room atmospheric conditions. The consumables shall be segregated by AWS class (e.g. SMAW electrode, SAW flux, SAW wire, GTAW wire etc.), brand, and size - batch and shall be maintained in original packaging until split for conditioning or issue.

METHOD OF MARKING BAKED, UN BAKED & RE-BAKED CONSUMABLES

Colour code for marking of baked and Un baked consumables will be as per manufacturers standard colour chart .All returned consumables should be marked with white at the grip end of electrodes before re-bake.

CONDITIONING OF SMAW & ALUMINIUM WELDING CONSUMABLES

Conditioning thermal treatment of welding consumables shall be according to the manufacturer's recommendations. The Welding Engineer shall establish conditioning requirements based on manufacturer's recommendations and supply conditioning instructions to the Consumable Store-man stating temperature/time cycle for baking and holding via the Welding Consumables Conditioning Table. Baking and holding ovens shall be uniquely numbered and temperatures shall be checked daily by the QCI, reporting on the GAM-QCR-QAC-GTL-062. Temperature checks shall be by calibrated digital thermometer.



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LOW-HYDROGEN SMAW ELECTRODES Extra-low moisture type electrodes supplied in 'Vac-Pac' does not require baking before first use (only returned electrodes require baking) or the baking shall be according to the manufacturers recommendation. Electrodes supplied in standard packaging shall be baked as per Manufacturer's instructions and as specified in the attached "Welding consumables conditioning treatment table". During baking, electrodes may be stacked to permit adequate heat distribution and to avoid damage. There shall be no restriction for stacking in holding ovens. Contents of the oven shall be clearly marked on the oven door.

Baking shall be the responsibility of the Consumable Store man and activities shall be logged in the GAM-QCR-QAC-GTL-063, which shall record:

Date Brand AWS class Batch number Size Quantity Oven number Treatment temperature Time when electrodes reach soak temperature Time of removal from baking oven.

In baking oven Temperature 300C/Mfg Recommendations, on completion of the baking cycle, the electrodes shall be transferred to a holding oven at temperature of 150C/Mfg Recommendations. Austenitic Stainless steel SMAW consumables shall be held in separate ovens, segregated, identified properly, and the contents shall be displayed on the oven door. Vacuum-packed electrodes do not require baking prior to use. Returned SMAW low hydrogen electrodes may be re baked once only. On receiving returned electrodes, the Store man shall check the electrodes, discarding any showing coating damage. He shall mark the bare end of the electrode with high temperature dye prior to re-baking. Further returned electrodes displaying the dye indicator shall be discarded and remove from the consumable room. Returned consumables shall be recorded. Returned electrodes being held for re-baking shall be placed in a storage location segregated for this purpose.



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AUSTENITIC SMAW ELECTRODES

Control of baking and holding requirements shall be In Baking oven Temperature 300C & Holding oven Temperature 120C to 150C or Manufacturer's recommendation shall be strictly followed and as specified in "Welding consumables conditioning treatment table". Consumables shall be stored in segregated area/shelving within the consumables Store/issue room.

SAW FLUX (IF APPLICABLE) Basic and semi-basic SAW Flux shall be pre-treated in a heated flux holding oven according to the Welding Engineer's instructions and the flux shall be transferred to machine hoppers as required.

At the end of each shift any unused flux shall be removed from the SAW machine hopper and returned to the heated flux holding oven. Flux shall not be used direct from the bag. Used SAW fluxes, may be re-circulated up to 3 cycles through the closed system. After this the flux should be mixed with twice its volume of new flux prior to further use. SAW Flux handling controls shall be in accordance with manufacturer's recommendation.

WELDING GASES

Gases used for weld protection purposes shall be of the welding grade composition having purity, as defined on the relevant WPS's. Protective gasses must be issued with appropriate conformance certificates and must be stored as per vendor's recommendations. The following provides guidance for the most commonly used gasses in welding: Composition Table:

Composition Percent by value Minimum Maximum Oxygen N/A 0.005 Hydrogen N/A 0.005Nitrogen N/A 0.005 Argon 99.9 100

Argon shall not contain more than 0.02 mm of vapour water per litre of gas measured at 21.1C at 1 atm absolute, or have a dew point of -53.8C or colder.



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11. ISSUE OF WELDING CONSUMABLES

Welding consumables shall be issued against the GAM-QCR-QAC-GTL-060 minimum the following information is required

Date Area Welders Name Stamp No Issued QTY Type/Size Batch No Returned QTY Initials/Signature consumable store man Initials/Signature welder

SAW & GTAW Wires

SAW & GTAW wires shall be issued in original packaging. SMAW Electrodes (General)

SMAW electrodes (Except Vac Pac) shall be issued into pre-heated portable quivers, which shall maintain a temperature of 70 C minimum. Quiver temperature shall be monitored by QCI on a daily basis as an element of the daily welding audit. Portable quivers shall be individually numbered for identification. Electrode issue quantities shall, as a maximum, be sufficient for one working shift. Electrodes may be retained in quivers up to 5 hours maximum. Quivers shall be returned to the consumable room at the end each session.

12. QUALITY ASSURANCE A Quality Assurance System shall be operated conforming to related standards. Controls and checks shall be established and documented.



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13. ATTACHMENTS GAM-QCR-QAC-GTL-060 GAM-QCR-QAC-GTL-061 GAM-QCR-QAC-GTL-062 GAM-QCR-QAC-GTL-063 GAM-QCR-QAC-GTL-082

C2 ASU PEARL GTL PROJECT RAS LAFFAN INDUSTRIAL CITY

WELDING ELECTRODE ISSUE REGISTER

Subcontract Ref.: Report No. Item Description: Inspection Date: Item Location / Area: Test Code No.: Subsystem: ITP No.: Ref. DWG / Documents:

Used Measuring and test equipment ref. (if applicable):

WELDER NAME BATCH NO AREA RETURN

ELECTRODE (WHITE PAINT)

SIGNATURE OF WELDERDATE

WELDING ELECTRODES AWS CLASS

SIZE IN MM

ISSUE

QUANTITY WELDER NO

SIGNATURE OF CONSUMABLE STORE MAN

ORGANIZATIONS DATE NAME SIGNATURE

THIRD PARTY REP.

GAMA REP.

LINDE REP.

A

c

c

e

p

t

e

d

B

y

QSGTL REP. GAM-QCR-QAC-GTL-060

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WELDING CONSUMABLE STORE ROOM CHECK LIST

Subcontract Ref.: Report No. Item Description: Inspection Date:

Item Location / Area: Test Code No.: Subsystem: ITP No.: Ref. DWG / Documents:


S.NO DATE INSTRUMENT ID HOURS TEMPERATURE

HUMIDITY

SIGNATURE


THIRD PARTY REP.

GAMA REP.

LINDE REP.

Acc

epte

d B

y


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WELDING CONSUMABLE HOLDING REGISTER




HOLDING TEMPERATUREOVEN NUMBER BATCH NO SIGNATURE DATE


SIZE IN MM QUANTITY HOURS


THIRD PARTY REP.

GAMA REP.

LINDE REP.

Acc

epte

d B

y


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WELDING CONSUMABLE BAKING REGISTER




BAKING TEMPERATUREOVEN NUMBER BATCH NO SIGNATURE DATE


SIZE IN MM QUANTITY HOURS


THIRD PARTY REP.

GAMA REP.

LINDE REP.

Acc

epte

d B

y


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C2 ASU PEARL GTL PROJECTRAS LAFFAN INDUSTRIAL CITY

WELDING CONSUMABLE REQUEST CARDItem Description: Report No:Iso.No : Date:Area :

SR.NO BATCH NO AWS CLASS DIA - mm QTY REQUESTED QTY ISSUED

DESCRIPTION DATE NAME SIGNATURE

REQUESTED BY

ISSUED BY

CHECKED BY

GAM-QCR-QAC-GTL-082

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WELDING CONSUMABLE CONTROL PROCEDURE.pdf ISSUE TO THE SITE CONSUMABLE ROOMS SITE CONSUMABLE ROOM CONDITIONING OF SMAW & ALUMINIUM WELDING CONSUMABLES LOW-HYDROGEN SMAW ELECTRODES AUSTENITIC SMAW ELECTRODES SAW FLUX (IF APPLICABLE) WELDING GASES

GAM-PRO-QAC-GTL-038-REV-C.pdfGAM-PRO-QAC-GTL-038-REV-C.pdfWELDING CONSUMABLE CONTROL PROCEDURE.pdf ISSUE TO THE SITE CONSUMABLE ROOMS SITE CONSUMABLE ROOM CONDITIONING OF SMAW & ALUMINIUM WELDING CONSUMABLES LOW-HYDROGEN SMAW ELECTRODES AUSTENITIC SMAW ELECTRODES SAW FLUX (IF APPLICABLE) WELDING GASES

CONSUMABLE CONTROL PRO.pdfWELDING CONSUMABLE CONTROL PROCEDURE.doc ISSUE TO THE SITE CONSUMABLE ROOMS SITE CONSUMABLE ROOM CONDITIONING OF SMAW & ALUMINIUM WELDING CONSUMABLES LOW-HYDROGEN SMAW ELECTRODES AUSTENITIC SMAW ELECTRODES SAW FLUX (IF APPLICABLE) WELDING GASES

060-ELECTRODE ISSUE REGISTER.doc061-CONSUMABLE STORE ROOM CHECK LIST.doc062-DAILY HOLDING REGISTER.doc063-CONSUMABLE BAKING REGISTER.doc082-STORE REQUESTION CARD.xlsSheet1

038-PRO WELDING CONSUMABLE CONTROL PROCEDURE.pdf

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