SYARIKAT STEELCON SDN. BHD.

CLIENT : INDEPENDENT TECHNOLOGY SDN. BHD.

PMC : KEJURUTERAAN QKS SDN. BHD.

ENDUSER : PETRONAS GAS BHD. (PGB)

PROJECT : EPCC FOR LION LATERAL EXTENSION & METERING

STATION FOR ND PAPER (BOUGAINVILLEA PROJECT)

ITEM : DRY GAS FILTERS

TAG NO : S-211/221

DOCUMENT TITLE : WELDING CONSUMABLES HANDLING PROCEDURE

DOCUMENT NUMBER : SCP-202

REV. PREPARED BY DATE APPROVED BY DATE

A SHAKILA 14/09/22 NAZAR 14/09/22

SYARIKAT STEELCON SDN BHD

ISSUED FOR APPROVAL JOB NO.: SC-11/22 REV. A

MANUFACTURING AND CONSTRUCTION TO BE CARRIED OUT STRICTLY IN ACCORDANCE WITH THE REQUIREMENT OF THIS SPECIFICATION
NO CHANGES ARE TO BE MADE WITHOUT THE PRIOR AGREEMENT OF THE CHIEF ENGINEER OF THE ORGANISING SECTION WITHIN ENGRG. DEPT

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WELDING CONSUMABLES HANDLING PROCEDURE

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WELDING CONSUMABLES HANDLING PROCEDURE

SECTION DESCRIPTION

1.0 PURPOSE

2.0 SCOPE

3.0 REFERENCE

4.0 ORDERING PROCEDURE

5.0 RECEIVING INSPECTION

6.0 STORAGE OF WELDING CONSUMABLES

7.0 BAKING, ISSUING & RETURN PROCEDURE

8.0 RECORDS

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WELDING CONSUMABLES HANDLING PROCEDURE

1.0 PURPOSE

To provide proper control of welding consumables during Receiving, Storage &

Issuance of welding consumables & to ensure the welding consumables that will be used
during fabrication comply with Code and approved WPS requirements. The consumables
covered under these procedure are for SMAW, GTAW & SAW welding processes.

2.0 SCOPE

The following procedure covers the minimum requirement for the efficient Handling and
Storage of the Welding Consumables.

3.0 REFERENCE

i) ASME Section-II Part C 2021 Edition

ii) ASME Sec VIII Div.1 2021 Edition
iii) PTS 12.20.01 June 2015 Pressure Vessels
iv) PTS 15.12.01 Jan 2017 Welding for Chemical, Oil, and Gas Industries
v) Syarikat Steelcon Sdn Bhd's Quality Control Manual
vi) Kobelco & Metrode Welding Handbooks
vii) Manufacturer’s recommendation.

4.0 ORDERING PROCEDURE

Material Requisitions for Welding Consumables based on Stock & WPS, shall be prepared
by Fabrication Manager, Consumable controller or QA/QC Manager. MR shall include
Consumable AWS Specification, Brand Name, Trade Name, Size (Diameter), Quantity & any
other additional requirements (for ex: Charpy Impact Tests at a Particular Temperature) as per
Code / Client Spec. / WPS Requirements.

Completed MR is reviewed for Code Compliance by the Engineering Manager or his

Designee who makes any required corrections and /or approves the MR and forwards to the
Purchasing Manager.

Purchasing Manager will issue the Purchase order (P.O), to the selected vendor with
reference to the approved MR. Approval of PO shall be either by the Purchasing Manager, the
Engineering Manager, or the Director.

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5.0 RECEIVING INSPECTION

Store Keeper shall receive the Welding Consumables and check using the Purchase Order
(P.O) & Delivery Order (D.O). Consumable certificates shall always be provided with the
delivery and if not, Storekeeper & Purchasing manager shall contact the supplier to provide
with them immediately. Storekeeper shall mark the received consumables with the Job No.

QC Inspector, using the QC Copy of the Material Requisition, D.O and Consumable Certificates
examines the Welding Consumables for Specification, Brand Name, Trade Name, Condition,
Size, Quantity & any other additional requirements as per Code / Client Spec. / WPS
Requirements and if all found complying to the requirements marks them with ''Accept'' Sticker
with QC initial & date.

Consumable Certificates shall be retained in the QC Department & Receiving Inspection

Report for those inspected consumables shall be documented by the QA/QC. On Acceptance of
welding consumables by QC Inspector, Storekeeper provides the consumable controller with
those welding consumables and their delivery order.

Welding Consumables which doesn't meet all M.R / P.O / D.O & Code Requirements and
additional Requirements shall be segregated from those accepted materials and shall be kept in a
quarantine area and controlled with the ''Reject'' Sticker on to the Consumable Packs. Non
Conformance report shall be issued by the QC Inspector for those rejected welding consumables.

6.0 STORAGE OF WELDING CONSUMABLES

6.1 LOW HYDROGEN ELECTRODES

6.1.1 Welding Consumables shall be received in hermetically sealed containers or packages

and in other moisture resistant packing.

6.1.2 Welding Consumables shall be stocked in Dry Storage area with lower humidity since
moisture will destroy the desirable characteristics of the consumables. Stock records are
kept by the Store Keeper.

6.1.3 Welding electrodes shall be stored in the original Packing/boxes in which they were
supplied by the Manufacturer until they are required to be opened & used. The storage
temperature shall be not less than 20º C and a maximum relative humidity
shall be in accordance with the Manufacturer's instruction.
6.1.4 To avoid damage to the coatings, the stacking of cartons should not be more than Nine
high.
6.1.5 Controls shall ensure that identification of consumables shall be maintained. Issue and
return of the consumables shall be recorded. To assist shelf life, it is recommended that
stock should be rotated, based on date of receipt.

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6.2 OTHER COATED ELECTRODES & FILLER WIRE RODS.

6.2.1 Welding consumables shall be supplied in moisture resistant packing &

shall be stored and controlled as per 6.1.2 ~ 6.1.5 above.

6.2.2 Welding consumable shall be identified & segregated if the containers been damaged &
show an evidence that it have lost its hermetically seal.

6.2.3 SAW spool or GTAW filler rod containers shall be stored in dry storage area.

6.2.4 SAW & GTAW Filler wires shall be maintained continuously at Manufacturer's
Recommended temperature.
Wires and electrodes should be stored in their original packaging in a dry heat
stored with a minimum temperature of 20º C and a maximum relative humidity
shall be in accordance with the Manufacturer's instruction.

6.2.5 Any non-identified, contaminated (ie grease, oil or paint etc..), Rusty or otherwise
damaged consumables found in the storage or fabrication must be isolated and scrapped.

6.3 WELDING FLUX (FOR SAW)

6.3.1 Fluxes also shall be stored as per welding consumable conditions as above with original
moisture resistant packing and as recommended by the Manufacturer. Identification must
state the Manufacturer's grade and Batch number.

All Welding consumables shall be stored separated according to each type & size. The
location of storage shall be well protected from moisture absorption and shall not be
accessible from unauthorized personnel.

7.0 BAKING, ISSUING & RETURN PROCEDURE

Welding Consumables shall be checked for Specification, Brand Name, Trade Name, Batch
Number, Condition, Size, Quantity & any other additional requirements as per Code , Project
Specification and WPS Requirements.

In addition to the above, the following items shall be checked prior to baking of electrodes:
1. Validity of calibration for the Baking and Holding Ovens
2. Working condition and usability of the Baking and Holding Ovens
3. Proper Visibility of the Temperature gauges at the Ovens
4. Trays inside the Ovens identified properly to indicate segregation of different types and
diameters of electrodes and segregation of return electrodes.
5. Ensuring Baking Temperature and Time as per Manufacturer Recommendation.
(As per Data sheets and Electrodes Packing Label )
6. Ensuring the electrodes are not damaged or contaminated
7. Ensuring only the Electrodes as per Approved WPS are only to be baked and used.

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Baking and Holding ovens shall be provided with Calibrated temperature indicator fixed in them,
to measure the heating temperature.

Baking and Holding ovens shall be periodically calibrated within 1 year interval and the copy of
the calibration certificates shall be displayed nearby the ovens location. Evidence of calibration
shall also be available (Calibration stickers) attached in the ovens.

Low hydrogen coated electrodes are received and stored in sealed packing. When opened, the
electrodes requires to be placed in a heated oven maintained at the temperature recommended by
their manufacturer, before being issued to welders.

The Authorized personnel (Fabrication Manager or Shop supervisor or QA/QC ) shall prepare
“Requisition Of Welding Consumable” - for baking, in advance for the project / work planned
and shall forward a copy to Consumable controller through Shop Supervisor for issuing welding
consumable.

Based on the Requisition for baking, Consumable controller shall ensure the welding
consumables are placed in the oven for baking at temperature and time as recommended by the
electrode manufacturer. Type, Electrode batch no., Size, time period and temperature shall be
recorded in “Electrode Baking Log” by the consumable controller.

Electrodes after baking shall be transferred to the holding oven by the Consumable Controller
and maintained at temperature recommended by the electrode manufacturer until the issuance of
consumables. (Holding is the intermediate storage to prevent moisture pick-up of coated
electrodes).

Refer to Table 1 for Temperature and time of baking & holding as per manufacturer
Recommendations.

The Authorized personnel (Fabrication Manager or Shop supervisor or QC Inspector) shall

request for welding electrodes from the consumable controller by a Requisition slip – for issue.

Based on the information in the requisition slip, Consumable controller shall issue the welding
consumables to the welder and shall record in the Welding Consumables issuing report. All
Low Hydrogen Electrodes shall be issued only in the quivers. All heated Quivers shall be in
good condition and capable of maintaining a minimum temperature at 70º C. Prior to transferring
the electrodes into the quiver, consumable controller shall ensure that the quiver is free from
moisture, dust or grease. Transferring the electrodes into the quiver shall be done carefully, so as
not to contaminate the electrodes. Any electrodes dropped onto the ground and found
contaminated shall be discarded.

Welding consumables which not requires baking shall be issued to welder to sufficient amount
in the same manner with Requisition slip – for issue & Welding electrodes issuing report.

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At the end of the day, the welder's shall deposit the quiver at the specified area. Unused coated
electrodes returned are examined by the consumable controller for condition, cleanliness and
identification. Damaged or unidentified electrodes shall be scrapped.

If the returned electrodes are in good condition, then the Consumable Controller shall Color
'White' on such Electrode butts and then place those left over (unused) electrodes back in the
baking oven on the rack marked “RETURN” accordingly and record in ''Electrode Re-Baking
Log. Then electrodes shall be transferred to holding oven. The next morning, these electrodes
shall be first issued to the welder(s) by the Consumable controller.

All re-baked electrodes shall be used before issuing the newly baked electrode .The re-baked
electrode shall be discarded if they are not consumed within 8 hours after issuing.

Note: Low Hydrogen Coated electrodes are issued only in a quantity sufficient to complete
the welding work for a period of four hours maximum. Low hydrogen coated
electrodes are allowed to return only once. Such electrodes if returned more than once
( ie, will be subjected to more than 2 baking cycles), shall be scrapped.

Flux for Submerged Arc welding, after opening from their original bags shall be heated in a
oven at a temperature as recommended by the Manufacturer, whenever prior to use. In case of
moisture contamination, Flux shall be re-dried as recommended by the Manufacturer. Flux shall
be issued complying to the same procedure as for the other welding consumables.

All welding materials issued to Welder shall be controlled with Welding Consumables
Issuing Report by the Consumable Controller.

Any damaged, wet, rusty, contaminated and untraceable welding consumable found in
any storage and fabrication area shall be immediately discarded.

During the absence of the Consumable controller, receiving of requisition slips, baking, holding
& issuing of welding consumables and all relevant records update shall be done by the storekeeper.

QC Inspector shall monitor the adherence to the sequence and procedures as above and any
nonconformity if discovered , shall be reported.

Refer to Consumable Flow chart (Attachment – 1 ), for further clarification regarding all the
details above.

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8.0 RECORDS

i) Purchase Orders
ii) Delivery Orders
iii) Consumable Certificates
iv) Welding Consumables Receiving Report
v) Requisition of Welding Consumables – for Baking
vi) Requisition of Welding Consumables – for issue
vii) Electrode Backing Log
viii) Electrode Re-Baking Log (if applicable)
ix) Welding Consumables Issuing Report

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TABLE 1

Drying condition (Baking & Holding) of welding electrodes

Baking Baking
Brand / Covered Electrode Holding
Base Metal Temperature ° Duration, Min.
Product Name AWS Classification Temperature °C
C (minutes)

KOBELCO
* C.S + C.S SFA 5.1 - E7018 300 - 350 30 - 60 100 - 150
LB-52-18

* C.S = Carbon Steel Materials including A106 GRB, A516 GR70, A105, A234 WPB, EN10025 S275JR

NOTE :

1. The above details as per Table 1 are general requirements only.

2. Manufacturer Recommended Temperature & Time mentioned in the Electrode packing and as per
''Manufacturer Welding hand books- latest Ed.'' shall be strictly followed, in case of deviation with
the above table.
3. Manufacturer Recommended Temperature & Time mentioned in the Electrode packing and as per
''Manufacturer Welding hand books'' shall be strictly followed, for other Manufacturer trade
names/brands. (Ex.: Metrode, Esab, RevAlloy, Bohler, Sandvik etc..)

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Attachment-1

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