WELDING CONSUMABLE

CONTROL PROCEDURE

DOCUMENT NO : QA/QC-XXX

PREPARED REVIEWED & APPROVED

REV. DESCRIPTION DETAILS
BY BY

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1 REVISED
DATE

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REVISION CONTROL SHEET

REV. DATE PAGE No. DESCRIPTION

FEBRUARY
0 - -
2005
PROCEDURE COMPLETELY REVISED.
SEPTEMBER
1 THIS SUPERSCEDES PROCEDURE
2006
VEW/10.01 REV.0
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INDEX

1. SCOPE

2. APPLICATION

3. OBJECTIVES

4. RESPONSIBILITIES

5. DEFINITIONS

6. PROCEDURE

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

Appendix 4 DAILY ELECTRODE BAKING LOG

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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.
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Ensure that re-baked electrodes are issued prior to issuing electrodes 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

6.0 PROCEDURE
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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).
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Unused Fluxes at the end of the shift shall be transferred to baking oven
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.
 TABLE - 1
TREATMENT OF WELDING CONSUMABLES
BAKING / REDRYING HOLDING MAX. No. OF
TIME FOR
CONSUMABLE TYPE REMARKS
TEMP. TIME TEMP. TIME BAKING
(Note 1)
Carbon Steel Low Hydrogen
Electrodes
300-350C 2 Hrs. 120 - 150C Indefinite 2 Times
E7016-1, E7018,
E 7018-1, E 7028
L.A.S. Electrode
E 8016G
E 8018-B2
370-420C 1-2 Hrs. 120-150C Indefinite 2 Times
E 8018-C1,C2,C3
E 9018 - M
E 11018 M
Stainless Steel Electrode,
E 308L-16,
E 316L-16
250-300C 2 Hrs. 120-150C Indefinite 2 Times
E 347-16,
E 309-16
E 309 MOL-16
Ni alloy electrode 260-280C 2 Hrs.
E NiCr Mo-3 or - 1 120-150C Indefinite 2 Times
E NiCu 7 300-320C Hr.

Cellulosic Electrodes
(LINCOLN) 93-110C 10 to 20
38-49C Indefinite 1 Time
E 6010, E 7010G (Note 2) Min.
E 8010G
SAW FLUXES
OK 10.62, 250-300C 2 Hrs. 120-150C Indefinite 3 Times
OK 10.71
SAW FLUXES
200-300C 2 Hrs. 120-150C Indefinite 2 Times

Notes: 1. Inclusive of initial baking.

2. No initial baking required.