AZAAN In-processes and final Inspection procedure

CONSORTIUM AZAAN CONSORTIUM-OFFSITES AND

INTERCONNECTION PROJECT
DOC NO.: W-455 REV.: 0 FILE: 260/Mechanical PAGE: 1of 6
Procedure /Doc. W-455

HANDLING AND STORAGE

WORKING INSTRUCTION

FOR WELDING CONSUMABLES

0 Apr 22. 2003 QA / QC F.F. A.M.

Rev Date Made Checked Approved
 AZAAN In-processes and final Inspection procedure
CONSORTIUM AZAAN CONSORTIUM-OFFSITES AND
INTERCONNECTION PROJECT
DOC NO.: W-455 REV.: 0 FILE: 260/Mechanical PAGE: 2of 6
Procedure /Doc. W-455

REVISION RECORD SHEET

Revision Number Purpose List of Updated/Modified Sections, if any

0 Issued for Approval -----
0 A.F.C. -----

Note: Third column is to be filled in, when the document is being updated/modified.

0 Apr 22. 2003 QA / QC F.F. A.M.

Rev Date Made Checked Approved
 AZAAN In-processes and final Inspection procedure
CONSORTIUM AZAAN CONSORTIUM-OFFSITES AND
INTERCONNECTION PROJECT
DOC NO.: W-455 REV.: 0 FILE: 260/Mechanical PAGE: 3of 6
Procedure /Doc. W-455

Contents
1.0 Scope
2.0 References
3.0 Responsibilities
4.0 Receiving Inspection
5.0 Storage
6.0 Handling before use
7.0 Issue and return of consumable
8.0 Handling during welding
9.0 Documentation

1.0 Scope
This procedure defines the responsibilities and activities that are necessary to
ensure the required level of quality as far as receiving, storage, and handling
of welding consumable are concerned. This document is part of AZAAN
quality system for offsite and interconnection of Mobin Petrochemical
Company.

2.0 Reference Code And Standards

Latest edition of all following code and standards shall be used:
 AZAAN quality manual
 Piping & structural ITP
 ASME Sec. V
 ASME Sec. VIII
 ASME B31.3
 API 650

3.0 Responsibilities
3.1 Warehouse superintendent & Storekeeper
The warehouse superintendent shall be responsible for adherence to
this procedure for all consumables held in stores, baking ovens or
holding ovens. In particular, he will maintain a Record Book and
maintain the consumable certificates file.

3.2 Welding Foreman Responsibilities

The welding foreman shall be ensured that all following rules have
been followed.
- Low hydrogen electrodes shall be issued from holding ovens in
warehouse, which is at a temperature range of 120º C to 150º C in
quantities necessary for the work. All low Hydrogen electrodes
shall be baked at a temperature range of 300º C to 350 º C for a
period of 2 hours, but not exceeding 3 hours, before putting them in
holding oven of ware house.

0 Apr 22. 2003 QA / QC F.F. A.M.

Rev Date Made Checked Approved
 AZAAN In-processes and final Inspection procedure
CONSORTIUM AZAAN CONSORTIUM-OFFSITES AND
INTERCONNECTION PROJECT
DOC NO.: W-455 REV.: 0 FILE: 260/Mechanical PAGE: 4of 6
Procedure /Doc. W-455

- Low Hydrogen electrodes shall be kept at a minimum temperature

of 75º C in quivers.
- Proper electrodes shall be used by welders

3.3 Welder
Each welder shall be responsible for adherence to this procedure for all
consumables issued to him. i.e. keeping electrodes in the quivers and
returning unused electrodes to the stores.

3.4 QA/QC Manager

The QA/QC Manager shall ensure that weekly checks and inspections
are carried out and if required shall make spot checks also on the
welding quality, consumables conditions during storage, transfer and
welding.

3.5 Mechanical superintendent

Shall be ensured that welding foreman, welders follow the procedures
entrusted to them.

3.6 Material controller

Will be responsible for ascertaining the temperature, humidity and
physical conditions of the consumables falling within the specifications
requirements.

4. Receiving inspection
- After receiving welding consumables, packages shall be inspected by
the warehouse foreman for identification and hermetically sealing.
- All consumables with damaged packing shall be separated and marked.
- Each batch of welding consumables shall be checked against the
certificates by the QA/QC Manager and signed for acceptance.
- The Warehouse superintendent shall be responsible for taking the
certificates from the manufacturer and issuing them to the QA/QC
Department.
An overall shortage and Damage Report will be issued if damage occurs or the
certificates are not correct in accordance with the site Receiving Procedure.

5.0 Storage
All consumables, electrodes, wires and flux shall be stored in their original
and hermetically sealed packaging, properly identified and stored by type in a
climatically controlled room with a minimum temperature of 20º C.
The Storekeeper will establish a daily log for humidity and temperature.
Take-off shall be per batch in accordance with the delivery sequence as shown
on the stock cards.

0 Apr 22. 2003 QA / QC F.F. A.M.

Rev Date Made Checked Approved
 AZAAN In-processes and final Inspection procedure
CONSORTIUM AZAAN CONSORTIUM-OFFSITES AND
INTERCONNECTION PROJECT
DOC NO.: W-455 REV.: 0 FILE: 260/Mechanical PAGE: 5of 6
Procedure /Doc. W-455

6.0 Handling before use

6.1 Backing of Electrodes
All low hydrogen electrodes shall be baked at a temperature range of
300º C to 350ºC for a period of 2 hours, but not exceeding 3 hours.
All different types of electrodes (E7018, E8018-B2, etc) shall be put in
backing oven separately not to be mixed together.
A backing oven thermometer within an accuracy of +/-10º C at 400º C
shall be considered acceptable. The location of the baking ovens shall
be near the work areas under the direct control of the storekeeper.
The storekeeper shall establish a written log per oven for temperature,
baking time and shifts.

6.2 Holding of baked electrodes

Baked Low Hydrogen electrodes intended for use within one week
shall be stored in holding ovens with a temperature range of 120ºC to
150ºC. All different types of electrodes (E7018, E8018B2, etc.) shall
be put in holding oven separately not to be mixed together.
These holding ovens shall be uniquely identified and be located near
the shop floor.
The QA/QC Welding Engineer shall check on a regular basis the
holding ovens temperature and contents and verify against the Record
Book.

6.3 Welding Wires and Rods

After checking for identification, damage, dirt and rust the wires can
be issued directly from stock.

7.0 Issue and Return of consumable

The issue of low hydrogen electrodes out of the holding ovens shall be under
the control of the Welding Foreman.
The quantity to be issued shall be necessary for the work to be carried out for a
period not exceeding two hours. Remaining electrodes are to be returned at
lunchtime and at the end of the day.
Electrodes are to be returned by each Welder to the Storekeeper.
The storekeeper shall visually examine the electrodes and only identified and
undamaged electrodes shall be accepted.
The storekeeper shall store the returned electrodes separated by type and
identified as required until a reasonable quantity is available for baking.
The quantity shall be that necessary to till a complete section of a baking oven.
The number of rebaking cycles of electrodes will be according the
manufacturers or as advised by the company.

0 Apr 22. 2003 QA / QC F.F. A.M.

Rev Date Made Checked Approved
 AZAAN In-processes and final Inspection procedure
CONSORTIUM AZAAN CONSORTIUM-OFFSITES AND
INTERCONNECTION PROJECT
DOC NO.: W-455 REV.: 0 FILE: 260/Mechanical PAGE: 6of 6
Procedure /Doc. W-455

8.0 Handling electrodes during Welding

During welding, the welding consumables must be properly
identifiable.
Low hydrogen electrodes must be kept in portable quivers and
maintained at a minimum temperature of 75ºC. Electrodes unused after
a period of two hours shall be returned and baked as specified.

9.0 Documentation
All above – mentioned activities shall be recorded properly according
to procedure No. P-114 (Materials Storage, Handling, Issuing And
Preservation Procedure)

0 Apr 22. 2003 QA / QC F.F. A.M.

Rev Date Made Checked Approved