Doc. No.

: 14062– CSPR-01
TECHNICS OFFSHORE ENGINEERING PTE LTD
Doc. Title : WELDING CONSUMABLES STORAGE
GAS BOOSTER COMPRESSOR FOR NSG-A PROCEDURE
PRODUCTION FACILITIES Revision : C2
Page : 3 of 9

TABLE OF CONTENTS

1.0 PURPOSE .................................................................................................................. 2

2.0 SCOPE....................................................................................................................... 2

3.0 CODES & STANDARDS ............................................................................................ 2

4.0 WORK INSTRUCTIONS ............................................................................................ 2

5.0 ATTACHMENTS ........................................................................................................ 4

 Doc. No. : 14062– CSPR-01
TECHNICS OFFSHORE ENGINEERING PTE LTD
Doc. Title : WELDING CONSUMABLES STORAGE
GAS BOOSTER COMPRESSOR FOR NSG-A PROCEDURE
PRODUCTION FACILITIES Revision : C2
Page : 4 of 9

1.0 PURPOSE

The objective of this work instruction is to give a guideline to the Production Manager, Store
man, Welding Supervisor and QC personnel & welders on the correct Manner of controlling
and issuing welding consumables.

2.0 SCOPE

The Work instruction applies to controlling and issuing welding consumables as per code or
manufacturing instruction to make sound weld metals

3.0 CODES & STANDARDS

ASME SEC II, PART C (Specification for Welding Rods, Electrodes and Filler metals)

ASME SEC IX, (Qualification Standard for Welding and brazing procedures,

Welders Brazers and welding and brazing operators)

ANSI / ASME B31.3 (Process Piping)

AWS D1.1 (Structural Welding Code)

4.0 WORK INSTRUCTIONS

4.1 All welding consumables shall be issued in accordance to this document

And Stainless steel electrodes will not be mixed up with carbon steel electrodes and
Dedicated holding oven for stainless steel electrode.

4.2 GTAW filler rods shall be kept in the original packaging and maintained in the store
until such time they are required, upon which the Welding Supervisor shall review the
selected WPS to determine the correct filler rods to draw from the stores and issue to
the welder.

4.3 SMAW -Non Low Hydrogen Electrodes - shall be kept in the original packaging and
maintained in the store until 2-3 years depends on manufacturer's guarantee,upon
which the Welding Supervisor shall review the selected WPS to determine the correct
electrodes to draw from the stores and issue to the welder.

4.4 Electrodes shall be examined by the issuing person for soundness, cracked coating,
physical damage or other flaws. If any such flaws are observed, the electrode shall
be discarded.

4.5 SMAW - Low Hydrogen Electrodes - shall be kept in the original packaging and
maintained in the store until 2-3 years depends on manufacturer's guarantee.
 Doc. No. : 14062– CSPR-01
TECHNICS OFFSHORE ENGINEERING PTE LTD
Doc. Title : WELDING CONSUMABLES STORAGE
GAS BOOSTER COMPRESSOR FOR NSG-A PROCEDURE
PRODUCTION FACILITIES Revision : C2
Page : 4 of 9

4.6 The Welding Supervisor shall be responsible for the control and issuing of low
hydrogen welding consumables. As indicated in the attached flow chart
(Attachment1).

4.7 QHS personnel & welding supervisors are responsible for ensuring that baking and
holding ovens are in good working condition including calibration of the controlling
temperature gauges and shall be responsible for taking immediate action to restore
them if found out of service. Storage and baking of welding consumables will be
carried out in separate ovens.

4.8 The Welding Supervisor or his designate is responsible for locking up the ovens to
prevent unauthorized access.

4.9 Electrodes shall be examined by the issuing person for soundness, cracked coating,
physical damage or other flaws. If any such flaws are observed, the electrode shall
be discarded.

4.10 The Welding Supervisor or his designate is
hydrogen electrodes when opened from their
transferred to the baking oven maintained
manufacturer's recommendation. As per AWS
Attachment: 4.
responsible for ensuring that low
hermetically sealed containers are
at 350ºCFor 2 hours or as per
D1.1 Annex V. Sample Format in

4.11 The Welding Supervisor or his designate shall upon completion of the two hour
baking period transfer the electrodes from the baking oven to the holding ovens that
shall be pre heated and maintained at 150ºC.

4.12 The Welding Supervisor or his designate shall ensure low hydrogen electrodes are
issued in sufficient quantities for a maximum 4 hour welding duration. (Approximately
50 sticks). He shall log in all relevant information on the electrode issue form
including welders name, project number, electrode type, size and quantity and
ensure the receiving welders sign for the electrodes on the electrode issue form.
Sample Format in Attachment: 5.

4.13 Any unused electrodes at the end of this period shall be returned and re-dried at
350ºC max for 2 hours or as per manufacturer's recommendation in a specifically
allocated drying oven to distinguish between new and re-dried electrodes before
transferring them to the re-dried holding oven.

4.14 Electrodes can be dried a maximum two times or as per manufacturer

recommendation. All re-dried electrodes shall be cleared first before issuing new
electrodes and re-dried electrodes will be color code system and color code will be
red.

4.15 Welding electrode shall be re-baked no more than once, any electrodes returned
after re-backing shall either be discarded

4.16 SAW - welding consumables shall be kept in the original packaging and maintained
in the store until such time they are required.

4. 1 7 The Welding Supervisor or his designate shall be responsible for the control and
issuing of SAW welding consumables. As indicated in the attached flow chart
(Attachment-2).
 Doc. No. : 14062– CSPR-01
TECHNICS OFFSHORE ENGINEERING PTE LTD
Doc. Title : WELDING CONSUMABLES STORAGE
GAS BOOSTER COMPRESSOR FOR NSG-A PROCEDURE
PRODUCTION FACILITIES Revision : C2
Page : 4 of 9

4.18 Unopened flux bags are to be kept under properly maintained storage conditions and
should not be exposed to direct moisture or rain.

4.19 The welding supervisor & QHS shall be responsible for ensuring that the SAW flux
silos are in good working condition including calibration of the controlling temperature
gauges and shall be responsible for taking immediate action to restore them if found
out of service.

4.20 The Welding Supervisor or his designate is responsible for ensuring that upon
opening any SAW flux container, the flux is stored in a heated flux silo maintained at
150ºC. Flux is to be heated for a minimum of 2 hours before use or as per
manufacturer’s recommendation. As per AWS D1.1 Annex V (Page no 399-409).
Sample Format in Attachment: 4.

4.21 Flux in the silo is identified either by mill certificate or label attached to the silo by the
Welding Supervisor or his designate.

C2 4.22 SAW flux should be limited to two cycles through the system, after this flux should be
mixed with same volume as less than 50% of new flux prior to further use or As per
Manufacturer's recommendation (The contents of the central flux hopper should be
consumed by approximately 50% after which re-filling with new flux from the
OERLIKON DRYBAG packaging) All recycled flux shall be cleared first before issuing
new flux. The format of record in attachment 5.

4.23 Recycling of flux is permitted provided the following are adhered to:

i. Flux is removed from welded component naturally; i.e. it falls or drops of from
the welded component into a tray. Flux that is removed by other means such
as grinding or is collected directly from the shop floor shall be discarded.
ii Flux is sieved through a mesh( 8 X 48 )Size into the flux oven at the holding
Temperature
iii Flux remaining on the mesh and contaminated fluxes shall be discarded.

4.24 Flux that has become wet shall be discarded without any re-baking.

4.25 Coils mounted on the wire feed unit shall be protected to prevent moisture or rust
formation on the wire. Rusty Coils shall be discarded.

4.26 Identification of the submerged arc filler wire on the machine shall be maintained by
maintaining the batch number traceable to the consumable report.

5.0 ATTACHMENTS

6.1) Attachment-1: Issuance of Low Hydrogen Electrode

6.2) Attachment-2: Issuance of submerged arc welding & flux
6.3) Attachment-3: Summary list of welding electrodes
6.4) Attachment-4: Baking Oven Temperature Record for submerged arc welding & flux
6.5) Attachment-5: Electrode Issue log SMAW, submerged arc welding & flux.
 Doc. No. : 14062– CSPR-01
TECHNICS OFFSHORE ENGINEERING PTE LTD
Doc. Title : WELDING CONSUMABLES STORAGE
GAS BOOSTER COMPRESSOR FOR NSG-A PROCEDURE
PRODUCTION FACILITIES Revision : C2
Page : 4 of 9

Attachment-1: Issuance of Low Hydrogen Electrode

 Doc. No. : 14062– CSPR-01
TECHNICS OFFSHORE ENGINEERING PTE LTD
Doc. Title : WELDING CONSUMABLES STORAGE
GAS BOOSTER COMPRESSOR FOR NSG-A PROCEDURE
PRODUCTION FACILITIES Revision : C2
Page : 4 of 9

Attachment-2: Issuance of submerged arc welding & flux

 Doc. No. : 14062– CSPR-01
TECHNICS OFFSHORE ENGINEERING PTE LTD
Doc. Title : WELDING CONSUMABLES STORAGE
GAS BOOSTER COMPRESSOR FOR NSG-A PROCEDURE
PRODUCTION FACILITIES Revision : C2
Page : 4 of 9

Attachment-3: Summary list of welding electrodes

 Doc. No. : 14062– CSPR-01
TECHNICS OFFSHORE ENGINEERING PTE LTD
Doc. Title : WELDING CONSUMABLES STORAGE
GAS BOOSTER COMPRESSOR FOR NSG-A PROCEDURE
PRODUCTION FACILITIES Revision : C2
Page : 4 of 9

Attachment-4: Baking Oven Temperature Record for submerged arc welding & flux
 Doc. No. : 14062– CSPR-01
TECHNICS OFFSHORE ENGINEERING PTE LTD
Doc. Title : WELDING CONSUMABLES STORAGE
GAS BOOSTER COMPRESSOR FOR NSG-A PROCEDURE
PRODUCTION FACILITIES Revision : C2
Page : 4 of 9

Attachment-5: Electrode Issue log SMAW, submerged arc welding & flux .