Procedure for Receipt, Storage and Handling of Welding Consumable (Rev 1) Doc

8/10/2019 Procedure for Receipt, Storage and Handling of Welding Consumable (Rev 1) Doc

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Document : 9501-PRC-QC-5932 Page 4 of 11Revision : 0

1.0. Purpose.

This procedure describes the system of receipt, storage, handling and treatment of welding

consumable in all fabrication area of the workshop and the yard (Open Area).

2.0. Reference.

2.1. ASME Section II Part C.

2.2. EEMUA Publication No. 158 paragraph 5.3.2.

2.3. AWS D1.12004

2.4. ESAB Six Edition - Consumables for Manual and Automatic Welding.

2.5. GS 118-4

3.0. Responsibility.

3.1. Contractor welding engineer is responsible to issue procurement requirement,

warehousing requirement, reviewing the manufacturing test certificate, specifying

additional handling and reconditioning requirements.

3.2. The warehouse supervisor is responsible for withdrawal, handling and storage of

consumables. He is also responsible to monitor who check the temperature of oven.

3.3. The store keeper is responsible to issue welding rod, electrode and flux to the welder

or the welding operator. He is also responsible for scrapping damaged consumables.

3.4. The welding inspector is responsible for the periodic inspection or audit of stored

materials.

4.0. Warehousing.

4.1. All welding consumable will be received at the warehouse.

4.2. Then, the warehouse supervisor will issue the Consumables Receiving Inspection

Report (CRIR) which indicate batch / lot number, brand name, manufacturer, delivery

date, dimension and quantity ( See appendix-1 )

The welding engineer will check the batch certificate against specification and the

CRIR. The welding engineer will sign the certificate and CRIR for approval. A copy of


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approved CRIR will be sent to warehouse for releasing the consignment, the original

certificate and CRIR will be kept by the welding engineer.

4.3. All additional and issuance of welding consumable from storage will be carried out on

a rotation basic to ensure to correct stock rotation.

4.4. All welding consumable shall be stored in their original sealed container packing.

Each packet of welding consumable shall be stored on the pallets or shelves. The

welding consumable shall not be stacked excessively high (do not stack more than

eleven layers of electrodes ) so as will damage the packaging of the lower layers.

4.5. Unopened packets of electrode shall be stored under warm and dry conditions.

These conditions shall be maintained, 24 hours a day 7 days a week, to avoid

promoting pick up of the moisture which permeates through the packaging and be

absorbed into the flux coating. Upon receipt the main stock of consumables shall kept

and maintained in a close and dry environment with a minimum of temperature 20 oC

and a relative humidity equal to or less than 60%.

5.0. Baking, Oven and Drying for Low Hydrogen Electrode.

5.1. Low Hydrogen Electrode AWS A5.1 (E 7016-1, E 7018, E 7018-G)

The electrode shall be kept clean, dry, and properly stored. The electrode that is

damaged, damp, greasy or oxidized shall be scrapped.

After unpacking, welding electrode shall be drying to the baking oven at temperature

260oC - 350oC for minimum 2 hours and the holding oven at temperature 120oC -

150oC before distribution to production area. ( Appendix-2)

Method of drying, baking and oven in accordance with electrode manufacturers

recommendation.

5.2. Electrode For Stainless Steel (E 316L-15) and Duplex Stainless Steel (E 2209-17)

The electrodes for Stainless Steel welding shall not be in contact with metal iron, iron

oxide and paints containing zinc

Drying temperature is 260oC350oC for minimum 2 hours before use and the holding

oven at temperature 120oC150oC before distribution to production are ( appendix-3 )

Method of drying, baking and oven in accordance with electrode manufacturers

recommendation.


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For Stainless Steel and Duplex Stainless Steel, the remaining of unused electrodes in the

quivers shall be returned for re-drying and immediately marked silver paint to indicate

Cycle 1 finished after 12 hours (see appendix-3)

7.5. For distribution of Cycle2 shall use same method as appendix-2 & 3

8. Solid Wire (ER 2209)

8.1. The wire shall be identified with brand name and lot number.

8.2. The wire shall be kept clean, dry and free from damage, damp, and grease.

8.3. Wire to be cleaned or degreased prior to being used.

8.4. All wire shall be protected from weather and stored in accordance with manufacturers

recommendation.

8.5. Unidentified wire, showing signs of contamination and rust damage shall not be used and

shall be discarded.

8.6. All unused wire shall be identified, covered and returned to the warehouse, unless it to be

used by continuing shift.

8.7. The wire for Stainless Steel, Duplex Stainless Steel and Carbon Steel shall be separated

storage.

9. Flux for Submerged Arc Welding (OK Flux 10.71, OK Flux 10.62)

9.1. The flux shall be kept clean, dry and free from damage, damp, and grease before use

9.2. Unopened flux bag must be stored under warm, clean from foreign materials and dry

conditions and maintained 24 hrs a day 7 days a week. The relative humidity of the

storage is not exceeding 70 %.

9.3. During and after welding, flux may be recovered. The un-melted flux will be sieved to

remove all coarse particle, fuse flux, mill scale, dirt or other foreign matter.

9.4. The flux will be reused as necessary during each welding period or added with new flux

as required.

9.5. The remaining of flux in the opened bags or flux hopper should be stored at a

temperature at 150 25C. ( Appendix-4 )

9.6. If the fluxes have for some reason become wet, it shall be scrapped.

10. Appendixes.


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Appendix-1

CONSUMABLE RECEIVING INSPECTION REPORT

Purchase Order : Item No. :

Supplier :

Specification / Class : Class :

Description : Quantity :

Initiated By : Data :

* Condition

Material

MFG Brand Size Manufacture Lot/Batch/Marking Quantity

Reported by

Sent to Welding Date :

* Engineer

Material Agree with ManufacturerYes No

Documentation

Manufacturer Doc. Agree with OrderingYes No

Requirement

Non-Conformances :

Disposition of Non-conformance :

Material release for fabrication :

By : Date :

Copy to Store Room :

* If not acceptable : Quarantine and Contract Welding Engineer

PT. GUNANUSA UTAMA FABRICATORS


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Appendix-2

FLOW CHART FOR ELECTRODES DISTRIBUTION

CARBON STEEL LOW HYDROGEN TYPE (E 7016-1, E 7018, E 7018-G)

RECEIVINGCHECK

ELECTRODE STORAGEAREA CHECK

START

CYCLE-1

START

CYCLE-1

HEATEDQUIVER70

oC-100

oC

WELDING OPERATIONCONSUMED

EXPOSEDATMOSPHERE

T > 6 HOURS

SURPLUSRETURN

BACKING OVEN

260OC-350oC HOURS MINIMUM

HOLDING OVEN120

oC-150

oC

HEATEDQUIVER (s)


EXPOSEDATMOSPHERE

T > 4 HOURS

MARK BY SILVERPAINT

START

CYCLE-1

START

CYCLE-1

MARK BY SILVERPAINT

START

CYCLE-1

DISCARDED /SCRAPPED

MARK BY REDPAINT

(**)

(***)

(****)

(*) GS 118-4(**) Essab Recommendation(***) Essab Recommendation & AWS D1.1(****) Essab Recommendation

(*)


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Appendix-3

FLOW CHART FOR ELECTRODES DISTRIBUTION

STAINLESS STEEL (E 316L-15) AND DUPLEX STAINLESS STEEL (E 2209-17)

RECEIVINGCHECK

ELECTRODE STORAGEAREA CHECK

START

CYCLE-1

START

CYCLE-1

HEATED QUIVER70

oC-100

oC


EXPOSEDATMOSPHERE

T > 12 HOURS

SURPLUSRETURN

BACKING OVEN260OC-350

oC HOURS MINIMUM

HOLDING OVEN120

oC-150

oC

HEATEDQUIVER (s)

WELDING OPERATION

CONSUMED

EXPOSEDATMOSPHERE

T > 4 HOURS

MARK BY SILVERPAINT

START

CYCLE-1

START

CYCLE-1

MARK BY SILVERPAINT

START

CYCLE-1

DISCARDED /SCRAPPED

MARK BY REDPAINT

(**)

(***)

(****)

(*) Essab Recommendation(**) Essab Recommendation & AWS D1.1(***) Essab Recommendation

(*)


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Procedure for Receipt, Storage and Handling of Welding Consumable (Rev 1) Doc

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