RUMAILA PROJECT

Document

Number: 0279STX-N-WM-PW01-QA-PRO-0011 Rev A02

Document
NR PWRI PHASE 1 – WELDING CONSUMABLE HANDLING
Title:
PROCEDURE

ProjectTitle: ENGINEERING, PROCUREMENT AND CONSTRUCTION FOR THE

PROVISION OF PRODUCED WATER RE-INJECTION PHASE 1 FACILITY

Tag No’s

(if applicable)
Contractor: Sae-A STX Entech Co., Ltd.

Contractor
H19201-PW01-QA-PRO-0011 Rev 01
Document No:

Digitally signed by Rajesh Sekar

Rajesh Sekar
DN: cn=Rajesh Sekar, o=Quality,
Code-1 ou=woodplc on behalf of ROO,
email=rajesh.sekar2@woodplc.com, c=AE
Date: 2022.08.26 21:33:58 +04'00'

A02 Issued for Review 11/08/2022 Raja Peela Eswar Reddy BS CHUNG

A01 Issued for Review 22/07/2022 Raja Peela Eswar Reddy BS CHUNG
Rev. Revision Description Date Originated Reviewed Approved
 NR PWRI PHASE 1 –
WELDING CONSUMABLE HANDLING
PROCEDURE
Doc. 0279STX-N-WM-PW01-QA-PRO-0011 Rev A02
No.

REVISION DESCRIPTION SHEET

Rev.
Para./sec Reason for Revision
No.
A01 All Issued for Review
A02 Updated Sec 3.2, Issued for Review
4,6, 6.3.3, 6.3.5,
Appendix -3
Hold
Para. Description of Hold
No.
 WELDING CONSUMABLE CONTROL PROCEDURE
1 SCOPE ....................................................................................................................................................4
2 GENERAL...............................................................................................................................................4
3 REFERENCES .......................................................................................................................................4
3.1 Applicable Codes ............................................................................................................................4
3.2 Specification.....................................................................................................................................4
4 ABBREVATION / DEFINITION ...........................................................................................................4
5 RESPONSIBILITIES .............................................................................................................................5
5.1 Workshop/Store...............................................................................................................................5
5.2 Field or Site Location .....................................................................................................................5
6 PROCEDURE.........................................................................................................................................5
6.1 Consumable Certification .............................................................................................................5
6.2 Receiving ..........................................................................................................................................5
6.3 Handling of Manual Metal Arc Electrodes ................................................................................6
6.3.1 Storage and Withdrawal...........................................................................................................6
6.3.2 Baking ...........................................................................................................................................6
6.3.3 Drying ...........................................................................................................................................7
6.3.4 Use .................................................................................................................................................7
6.3.5 Distribution at workshop and sites .......................................................................................7
6.4 Welding Wires ..................................................................................................................................8
6.
6.5
5 Shi
hiel
eldi
ding
ng G ................................................................................................................................
Gas
as ...................................................................................................................................
..... 8
6.6 Submerged Arc Welding fluxes...........................................................................................................8
7 DOCUMENTATION...............................................................................................................................9
8 HSE REQUIREMENT & HANDLING .................................................................................................9
9 ATTACHMENTS ....................................................................................................................................10

Page 3 / 10
 WELDING CONSUMABLE CONTROL PROCEDURE

1 SCOPE
This procedure describes the methodology to be followed during receiving, storage issuing and
handling of welding Consumables and equipment, and defines the relevant responsibilities. The
procedure shall be applied in both workshop and in the field during the Project execution with respect
to the handling of various types of consumables (welding rods and wires, fluxes as applicable,
gas cylinders, welding inserts etc)
2 GENERAL

All filler materials and fluxes shall be in accordance with ROO specifications .The basis for
equivalence may be determined by review of Consumables (electrodes and fluxes) from the
manufacturer’s catalogue and/or by chemical analysis and mechanical examination of the weld
deposits.
In general the nominal analysis of the principal elements in the deposited weld metal shall meet the
nominal analysis of the base metal.
Storage and control of all welding consumables shall be in accordance with the manufacturer’s
recommendations and Company specification.

3 REFERENCES
3.1 Applicable Codes

• ASME Sec II Part C Specification for Welding Rods, Electrodes

and filler metals
• ASME Sec IX 2017 Edit. Welding & Brazing Qualification.

3.2 Specification
• 0000BF-C-G0-G000-SPC-0001 Rev B08;RUMAILA BROWNFIELD PROJECTS
SPECIFICATION FORWELDING, PWHT AND NDE OF PROCESS AND UTILITY
PIPING
• 00100W-C-G0-G000-ML-SPC-0003-Rev B03;SPECIFICATION FOR WELDING
PWHT AND NDE OF PLANT EQUIPMENT
4 ABBREVATION / DEFINITION
Company ROO Rumaila Operating Organization
Contractor Sae-A STX Entech Co., Ltd.
ASME American Society of Mechanical Engineers
WPS Welding Procedure Specification
BAKING 1hr at 300-350℃ or as per manufacturer recommendations

Holding 2hr at 120-150℃ or as per manufacturer recommendations

Page 4 / 10
 WELDING CONSUMABLE CONTROL PROCEDURE
5 RESPONSIBILITIES
Responsibilities are different depending upon the working place and shall be as follows:
5.1 Workshop/Store
• The storekeeper shall verify quality, quantity, compliance with the order and availability of
the required certification.
• The Logistics Department personnel shall submit a “Materials Receiving Report” to the
QA/QC Dept.
• The storekeeper shall store welding materials in a suitable place, in accordance with this
procedure. Moreover, supported by the Welding Foreman, he is in charge of distribution
and transport of welding materials to baking/holding ovens (as applicable).
• The QA/QC Engineer shall verify documents conformity and sign the “Materials Receiving
Report”.
• The Welding Inspector shall verify the compliance of welding materials receiving, handling
and delivery to workshop/field for fabrication purpose with the requirements settled thereof.
He should therefore validate the welding consumable register form attached to this
document.

5.2 Field or Site Location

• STX Welding Inspector shall verify in field the documents related to Welding
Consumables and/or calibration of equipment used during Welding and, if deems
necessary, he may require their re-calibration/re-adjustment.
• In the case of Non compliance, QA/QC Engineer shall have right to stop the work until
then documents shall verified
6 PROCEDURE
The operational Procedure includes the following:
6.1 Consumable Certification
As a minimum, welding consumables shall be delivered in accordance with their product data sheet
and shall have with certification including chemical analysis. Each consumable, or consumable
batch, shall have individual marking relative to its certification. The welding consumables listed in
Company specification are acceptable for fabrication subject to the limitations stated therein.
Request to use any other welding consumables shall be submitted to COMPANY for approval.List
of consumables used at site are listed under Appendix -3

6.2 Receiving
Whenever welding materials are received, the Logistics Department issues a Report. Supplier's
certificates shall be attached to this report. All the documents shall be filed by the Welding
Department and upon demand, given to the Quality Control Department.
During the receiving inspection of welding materials, the person in charge shall:

Page 5 / 10
 WELDING CONSUMABLE CONTROL PROCEDURE
• Verify that quantities of materials received correspond to what indicated on the purchase
order and on the delivery note.
• Verify that markings recorded on packing comply with certificates.
• Inspect material packing.
• Transmit the delivery note to the Logistics Department personnel and the certificate to the
Welding Department for review.
• Materials with acceptable inspection results are released for fabrication.
• Whenever any non-conformity is identified during the inspection, the Q.C. Inspector shall
issue NCR report.
• The non-conforming material shall be moved to a separate area or clearly identified as
“not to be used” material.
• Consumable handling shall be controlled by a procedure approved by COMPANY.
Storage shall be in accordance with the manufacturers’ recommendations for the
consumable type.

6.3 Handling of Manual Metal Arc Electrodes

Low hydrogen electrodes shall not be stored in heated cabinets containing electrodes of other types,
such as rutile type electrodes.
Handling of welding electrodes includes the following phases:
6.3.1 Storage and Withdrawal

• After receiving, electrodes shall be stored in the warehouse (workshop) or in containers

(workshop and/or temporary sites).Electrodes shall be placed on shelves adequately
identified to allow their correct identification.
• All consumable storage areas (including the quarantine area) shall be dry, i.e. relative
humidity equal to or less than 60%, and maintained at a minimum temperature of 20°C.
as per ROO Specs 0000BF-C-G0-G000-QA-SPC-0001 Para 11.2
• The Storekeeper following the Welders Foreman instructions distributes materials and
they are recorded on a Consumable Issue Log. Cellulose coated electrodes shall be kept
apart from low hydrogen electrodes. The packs of electrodes shall be taken out of storage
in the sequence in which they were received. Cellulose coated electrodes, exposure to
air moisture and excessive differences in temperature shall be avoided.

6.3.2 Baking
• Basic Low hydrogen electrodes shall be baked in special furnaces paying attention that
Ovens should not be overloaded. For the purpose of holding, oven shelves shall
not be stacked with more than three layers of electrodes
Electrodes shall be backed at a temperature of 300°-350°C for 1 hour or shall follow
manufacturer Recomendation

Page 6 / 10
 WELDING CONSUMABLE CONTROL PROCEDURE
.Basic low hydrogen electrodes shall be hold to ensure the weld metal hydrogen level
does not exceed 8 ml of diffusible hydrogen per 100g of weld metal.

• “Vacuum-pack” electrodes shall not undergo this treatment at the first time opening of the
box. However, in case if the vacuum packs box is damaged, the electrode shall not be
used before baking.
6.3.3 Holding
• Electrodes hold as indicated into the previous paragraph may be left to cool in the same
furnace to a temperature of 120°-150°C or as per Manufacturer recommendation.
• As alternate they can be moved into a storage oven and maintained at a temperature of
120°-150°C until their utilization.

6.3.4 Use

• Electrodes withdrawn from storage ovens shall be kept in heated quivers at a temperature
not less than 70°C. Duration for usage of low-hydrogen electrodes since the packet is
opened or removed from storage oven shall not be more than 6 hr. In case of humid
atmosphere this time shall reduce at 2 Hr.
• “Vacuum-pack” electrodes with an integral wrapping may be used without undergoing the
Baking/hol treatment providing the follows:
• The opening date/time shall be marked on electrodes cover;
• One electrode at a time shall be withdrawn and the packaging shall be always closed
again as per manufacturer indication as a maximum shall elapse after the package
opening.
• Electrodes which have been contaminated by water, oil, grease, or otherwise deemed
unsuitable, shall not be employed and shall be removed from the worksites.
• Electrodes without regular marking and/or damaged shall be rejected.
• Vacuum packed electrodes unused at the end of the period recommended by the
manufacturer shall be discarded unless the CONTRACTOR obtains the COMPANY
approval for re-baking and recycling

6.3.5 Distribution at workshop and sites

• At the beginning of every shift the Welders Foreman, on the basis of the welding
specifications withdraws the necessary welding materials and distributes them to welders
and welding operators.
• Electrodes will be distributed for work minimum two times per shift.
• New electrodes and re-backed electrodes shall not be mixed, if happened, all of them
shall be considered for re-baking.
• In case no complete marking are found on pack, shall be consider wetted and whole box
shall be discarded.

Page 7 / 10
 WELDING CONSUMABLE CONTROL PROCEDURE
• At the end of shift all electrodes shall be collected from workplace and shall be keptin
holding oven if were exposed less than 6 hrs or shall be re-baked if were exposed
more than 6hr.No welder shall be issued with more electrodes than can be used in a four
hour period. Returned electrodes shall be identified by the blue color to control the re-
baking process. No electrode shall be re-baked more than once
6.4 Welding Wires

• Wire for GTAW, shall be dry and free from rust, oil or any other foreign matter. GTAW
wire shall have the grade stamped on the wire GTAW filler wires shall be cleaned with a
solvent immediately prior to their use. Any wire that cannot be cleaned without damage
to the surface, change in size or other damage that would adversely affect its use should
be discarded.
6.5 Sub merged Arc Welding fluxes

• Flux shall be supplied and stored in accordance with manufacturer’s instructions.

• Flux shall be supplied in moisture resistant sealed containers and stored in controlled
environment as recommended by the manufacturer.
• Each batch of flux shall be labelled with the information from the supply container.
• The CONTRACTOR/SUPPLIER shall issue drying instructions based on the
manufacturer's recommendations for all submerged arc fluxes as required.
• Flux remaining unused at the end of each shift shall be returned to the storage facility.
Surplus submerged arc flux shall not be reclaimed and re-used.
• Flux shall not be left in machine hoppers for extended periods, when welding is not
being carried out, e.g. overnight or during non-productive shifts.
• Recycling of flux shall only be allowed if the procedure is endorsed by the consumable
manufacturer and by the COMPANY.

6.6 Shielding Gas

• The composition of shielding gas used for welding shall be compatible with the material
being welded and the weld properties required, with a dew point of less than or equal
to minus 40ºC, with the essential variables of composition, purity and flow rate stated
on the WPS.
• Changing gases from the PQR shall only be considered with specific COMPANY
approval.
• All bottles containing shielding gases shall have clear identification labels
• Cylinders must be positioned upright and secured during Use and transportation.

Page 8 / 12
 WELDING CONSUMABLE CONTROL PROCEDURE

• Valves caps should be firmly screwed on cylinders, not to be transported with

gauges, hoses and torch attached under any circumstances.
• Flash Back arrestor fitted on the gas cylinder hoses.
• MSDS shall be available for all gases.
• Cylinders shall be checked visually for damage / corrosion prior to use on site.
• Shielding gases shall have a nominal composition and a purity grade conforming to
the requirements of the qualified WPS In any case gas purity shall be ≥ 99.99% and
its dew point shall be ≤ 50°C. The Company’s Representative is authorized to check
chemical analysis of used gases.
7 DOCUMENTATION
• On daily basis the Welding Inspector shall ensure that only COMPANY approved
electrodes are employed in fabrication.
• The Batch Number, size, type of electrodes shall be recorded and at every moment the
traceability of electrodes employed shall be achieved.
8 HSE REQUIREMENT & HANDLING
• All personnel who are involved in handling of welding consumables shall strictly
adhere to site safety requirement.
• Appropriate Protective gloves shall be used while handling cold and hot consumables.
• All personnel shall wear proper PPE.
• MSDS shall be displayed at storage area and baking area.
• The welding consumables which are rejected shall be disposed as per
safety procedure and disposal methodology .
• All electrical connection points shall be inspected and certified and tagged.
• Adequate fire extinguishers shall be provided.
• Adequate signage shall be provided for hot & cold surfaces.
• Area shall be well ventilated.

9 ATTACHMENTS
9.1 Appendix-1
Electrode Baking log.
9.2 Appendix-2
Welding Consumable Issuance Log.
9.3 Appendix-3
List of consumables used at site

Page 9 / 12
 Welding consumable control procedure

ELECTRODE BAKING LOG

Manufacture transferred to holding

Brand Quantity Manufacturer’s
SI No Date Class Lot No Dia baking time Start time End time holding oven Qty ovenTemp Remarks
Name (kg) baking temp (0c)
(hrs) (time) (0c)

DESCRIPTION STX GCMC ROO

Signature

Name

Date

Page 10 / 12
 Welding consumable control procedure

WELDING CONSUMABLES ISSUANCE LOG

Consumable Details Issuance To Welder Issuance Control

SN Date Qty
Brand Available issued Returned Date of Time of Balance in
Class Lot No Dia issued Size Remarks
Name Quantity (Nos) Time QTY return return holding oven
(Nos )

DESCRIPTION STX GCMC ROO

Signature

Name

Date

Page 11 / 12
 Welding consumable control procedure

APPENDIX -3

List of Consumables Used at Site

Type of welding Manufacurer Baking Baking Holding
Slno AWS No Holding time
consumables Brand temperature time Temperature
1 SMAW-STICK(CS) LINCOLN E7018 320-350° C 1hr 150° C 1hr
2 SAW-FLUX KISWELL F7A8-EH-14 320-350° C 1hr 150° C 1hr
3 GTAW-Wire (CS) LINCOLN ER 70S-6 NA NA NA NA
SMAW-
KISWELL E2594-16 320-390° C 150° C 1hr
4 STICK(SDSS) 1hr
5 GTAW (SDSS) KISWELL ER2594 NA NA NA NA
6 GTAW (DS) LINCOLN ER309L NA NA NA NA

Page 12 / 12