Welding Consumable Control Procedure - Flare KOD Rev A

Wasco Engineering International Limited
Contract Number:
CM620-167466
Issued For Review A 01-12-2021 Anup M Nikhil MS Rajesh Pillai

REASON FOR ISSUE REVISION REV. DATE PREP. BY CHECKED APPROVED
Document Family: No. of pages

D-OPER 8
Doc. type:
Project: Ruche Phase 1 Topside
KA – TECHNICAL PROCEDURE
Production Facility
Discipline:
Unit: Hibiscus Alpha PROCESS
System no:
IMO No:
00
Client: BW Energy Gabon S.A.
Document Title:
Wasco Engineering WELDING CONSUMABLE CONTROL

International Limited PROCEDURE FOR FLARE KO DRUM AND PUMP
Contractor Doc. No.: Client Doc. No.: Rev.
WEIL-C371-0846 A
© BW Energy 2021
Ruche Phase 1 Topside Production Facility
WELDING CONSUMABLE CONTROL PROCEDURE FOR FLARE KO DRUM AND PUMP
Doc. No: WEIL-C371-0846 Rev.: A
Revision History
Revision Section Paragraph Description of changes
A - - Initial Submission
Page 2 of 8
© BW Energy 2021
Ruche Phase 1 Topside Production Facility
WELDING CONSUMABLE CONTROL PROCEDURE FOR FLARE KO DRUM AND PUMP
Doc. No: WEIL-C371-0846 Rev.: A
TABLE OF CONTENTS
Sr. No. Description Page No.
1 SCOPE 5
2 PURPOSE 5
3 WELDING ELECTRODES 5
4 FLUXES 7
5 HANDLING OF WIRES 7
6 ASSOCIATED DOCUMENTS 8
Page 3 of 8
© BW Energy 2021
Doc. No.:
DANEM ENGINEERING WORKS FZE DEW-4604-110310
WELDING CONSUMABLES CONTROL PROCEDURE Rev.: A Page: 1 of 5
Danem Job No. : 4604
Client Name : WEIL / BWE
RUCHE PHASE 1 TOPSIDE PRODUCTION

Project Name :
FACILITY
Scope : FLARE KO DRUM AND PUMP
WEIL PO Ref. : 618659
Document Type : QA/QC
WELDING CONSUMABLES CONTROL PROCEDURE

FOR FLARE KO DRUM AND PUMP
Rev. No. Date of issue Reason of revision

A 01 Dec 2021 Initial submission
Prepared By Reviewed and Approved By
Anup M Rajesh K Pillai

QA/QC Engineer QA/QC Manager
DANEM ENGINEERING WORKS FZE Doc. No.: DEW/QCM/SEC. 7-1
WELDING CONSUMABLES Rev.:03 Page: 2 of 5

CONTROL PROCEDURE
1.0 SCOPE
1.1 This procedure describes the control of welding electrodes, fluxes and wires.
2.0 PURPOSE
2.0 The purpose of this document is to describe the method to be used for
storage, drying and its control of welding consumables (welding electrodes,
fluxes and welding wires).
3.0 WELDING ELECTRODES

3.0 Welding Supervisor is responsible for control of welding materials to be used
on the job as per Weld Plan and WPS.
3.1 Store-in-charge is able to distinguish the type of welding electrodes and rods
to prevent misuse. Receiving Inspection of all welding electrodes, rods &
fluxes shall be inspected as per Quality Control Manual.
3.2 All batch certificates (if requested) of welding electrodes, rods & fluxes are
reviewed, accepted and maintained by QA/QC Engineer.
3.3 Welding electrodes and rods shall be stored in racks and shall not be stored
directly on ground, and not to be opened until just before use.
3.4 Welder / Welding operator draws electrodes, rods and fluxes from
storekeeper using Material Requisition (Exhibit #7-5).
3.5 Different types of welding consumables shall not be mixed in baking ovens,
holding ovens and portable ovens.
3.6 In case of vacuum packed electrodes / hermetically sealed containers, they
can be used on the job directly without baking as per the manufacturer’s
instructions. These electrodes are transferred to Holding Oven, upon
opening, which is kept at a temperature recommended by the manufacturer.
If the electrode is exposed to the atmosphere for more than 12 Hours, this
electrode need to be re-baked as per the manufacturer recommendation
before next issue. If this electrode is kept in the Quiver with temperature is
maintained at minimum 70°C through out the shift, then this electrode is not
required to re-baked at the time of return, this electrode can be directly
shifted to the holding oven.

CONTROL PROCEDURE
3.7 The moisture sensitive electrodes are baked in the Baking Oven as per the
recommendations of electrode manufacturer. After required baking is
completed at the temperature recommended by electrode manufacturer, the
electrodes are transferred to the holding oven which is kept at temperature
recommended by the manufacturer. The baking temperature recommended
by the various manufacturer’s brands of electrodes are given in the following
table.
Manufacturer Drying Temperature & Time Holding Temp. Minimum
ESAB, 350 °C for 2 Hours 70°C ~ 150°C
KISWEL, 300°C ~ 350 °C for 1 Hour 70°C ~ 150°C
SAF-FRO 250 °C ~ 350 °C for 2 Hours 70°C ~ 150°C
GEE 300 °C for 2 Hours 70°C ~ 150°C
MOST 300°C ~ 350 °C for 1 Hour
70°C ~ 150°C
(Vacuum Pack) (Note1)
ADOR 300 °C for 1 Hour 70°C ~ 150°C
LINCOLN 250°C ~ 400 °C for 1 Hour 70°C ~ 150°C
As per manufacturer
Others 70°C ~ 150°C
Recommendation
Note1: Re-drying is required if the electrodes are kept outside & exposed to the
atmosphere.
3.1 In case manufacturer’s instructions are not available, electrodes are dried at
temperatures provided in the following table.
Parameters Carbon & Low alloy steel
Drying Temperature 310 °C ± 50 °C
Drying Time 1 Hours Minimum
Holding Temperature 70 °C ~ 150 °C
3.2 Each SMAW welder shall have a portable oven which is kept at 70°C minimum.
3.3 All baking and holding oven shall have an individual ID no and calibration sticker.
Recalibration is to be carried out every 12 months. These may be calibrated any
time whenever there is a reason to believe that they are in error.
3.4 Drying of electrodes are recorded in electrode baking control record by Store In-
charge. The data includes batch no, AWS specification, Brand name, Size, Start

CONTROL PROCEDURE
time, Baking period, Baking temperature, Temperature down time, Hold
Temperature and date.
3.5 Unused electrodes returned to stores in quivers are inspected for damage. If the
condition of electrodes is acceptable (No damage to flux, Not wet, Not bent, No
loss of identification etc.) and the electrodes have not been exposed to
atmospheric conditions, then these are stored in holding oven directly. If there is
reason to suspect or if the electrodes had been exposed to atmospheric conditions,
then they are re-dried and kept in the holding oven.
3.6 Returned electrodes are colour coded at the metal tip. Colour coded electrodes
when returned shall not be accepted.
3.7 Electrodes can be dried maximum twice only.
3.8 Records of baking and issue of electrodes are maintained by Stores-in-Charge.
4 FLUXES
4.1 Flux Drying
4.2 The flux is dried in a hopper type oven. The drying temperature is 300 to 350 °C for
2 hours. After drying time is over, the temperature of drying oven is brought down
to 120 to 150 °C and the flux is held in the oven.
4.3 The flux shall be identified by trade name, batch no and AWS specification.
4.4 The flux is issued by Store In-charge and recorded in the issue register.
4.5 The quantity issued is such that no return of flux is envisaged. Unfused flux while
welding is recycled in to the welding machine hopper. Sieving is done prior to
recycling in to the hopper.
4.6 Returned flux is collected and stored properly, mixed with unused fresh flux with
1:1 ratio, dried and issued for use.
5 Handling of Wires
5.1 Solid and flux cored wires shall be removed from packing just before use.
5.2 At the end of each shift the wire spools shall be covered by suitable cover to avoid
contamination.
5.3 If the wires are not used in the consecutive two shifts, the spools shall be stored in
the environment-controlled room in covered condition.

CONTROL PROCEDURE
6 Associated Documents
6.1 Electrode Backing Record (Form# DEW/FORM/STR/010).
6.2 Electrode Issue Record (Form # DEW/FORM/STR/011.

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Wasco Engineering International Limited

Issued For Review A 01-12-2021 Anup M Nikhil MS Rajesh Pillai

Document Family: No. of pages

Wasco Engineering WELDING CONSUMABLE CONTROL

Contractor Doc. No.: Client Doc. No.: Rev.

Doc. No: WEIL-C371-0846 Rev.: A

Doc. No: WEIL-C371-0846 Rev.: A

WELDING CONSUMABLES CONTROL PROCEDURE Rev.: A Page: 1 of 5

Danem Job No. : 4604

Client Name : WEIL / BWE

RUCHE PHASE 1 TOPSIDE PRODUCTION

Scope : FLARE KO DRUM AND PUMP

WEIL PO Ref. : 618659

Document Type : QA/QC

WELDING CONSUMABLES CONTROL PROCEDURE

Rev. No. Date of issue Reason of revision

Prepared By Reviewed and Approved By

Anup M Rajesh K Pillai

WELDING CONSUMABLES Rev.:03 Page: 2 of 5

3.0 WELDING ELECTRODES

WELDING CONSUMABLES Rev.:03 Page: 3 of 5

WELDING CONSUMABLES Rev.:03 Page: 4 of 5

WELDING CONSUMABLES Rev.:03 Page: 5 of 5

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