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No.: 5 Subject: Structural (Consumables) Performed By: Item No.

Item Description

Aramco Overseas Company Saipem Karimun Fabrication Yard (Tie-in Platroms) Focussed Assessment Report Project Title: Al Wasit Project Contractor: PT. Saipem Indonesia Date: November 2012 Reference Para Yes No N/A Remarks

Personnel involved in handling, storage, conditioning, issuance & controls for use of welding consumables are identified with detailed responsibilities & are trained in the procedure as follows: A) Material Controller (Receipt, Control, Storage, Handling, Issue, etc) B) Welding Foreman/Supervisor (Issue, Distribution, Control, Return) C) QC Inspector (Monitors approved procedure and all activities) D) Welders (Follows approved procedures and controls) Note:Clearly detail all consumable control responsibilities, ensure procedure is available & understood by all responsible for controls Procedure has provided details on how welding consumables are controlled by the following but not limited to: A) Receipt & Storage requirements - prior to issuance B) Material controller- Stock control (First in, First out) & issuance C) Requestor/User - Receiving of consumables (Daily Basis) D) Return of un-used consumables, ID system & reconditioning E) Disposal Authorization (Rejected Consumables, etc) SAIC-W-2010, SAIC-W-2009 & SAICW-2032 are utilized in development & revision of Procedures Procedure contains these relevant QC Report Forms (Records) for documenting & monitoring control of welding consumables: A) SATR-W2009 - Rod Oven Calibration (Storage, Bake, Portable) B) SATR-W-2010 - Welding Consumable Issuance Record C) SATR-W-2020 - Recv Insp Detail Form & QC log (Consumables) Electrodes, filler wires, and fluxes shall conform to ASME SEC IIC. Other consumables may be used only with the approval of CSD Procedure lists Instruments & Equipment that will be used for storing, handling and conditioning of welding consumables. Humidity & temperature control requires use of calibrated hygrometers, temp gauges, ovens and cabinets for Dry Environment. See Att. 1. Condition of existing electrodes shall be evaluated per the detailed requirements of Attachment 1.

Sch. Q, Attachment VI Tables Special Process (Welding)

Sch. Q, Attachment VI Tables Special Process (Welding)

Sch. Q, Attachment VI Tables Special Process (Welding) SAES-W-013, 6.1 Para.

SAES-W-013, Para. 6.2

Procedure contains applicable elements (Notes, etc) SAES-W-013, Conditioning, Storage & Exposure of SMAW & SAW Consumables. See Attachment 3. Copy & paste in procedure as applicable. Shielding gases shall conform to the following requirements: A) AWS A5.32 Specification for Welding Shielding Gases 1. Carbon dioxide (CO2): Federal Specification BC-C-101, Type B or Compressed Gas Association CGA G-6.2, Type F. 2. Argon (Ar): Compressed Gas Association CGA G-11.1, Grade A. 3. Use of other gases and gas mixtures shall require CSD approval. B) The requirements for other gases and gas mixtures shall be submitted to CSD for approval.

SAES-W-011, Para. 6.2

SAES-W-013 Para. 6.7

Submerged Arc Welding Fluxes A) Active type Submerged Arc Welding fluxes shall not be used without approval (obtained prior to welding procedure qualification) B) Fabricator shall clearly identify the proposed use of active fluxes in their welding procedure submissions. C) Flux fused during welding is not reused (recrushed slag, etc) D) SAW fluxes that the flux manufacturer recommends for single pass welding shall not be used for multiple pass welding. All consumables shall be stored and dried, per the requirements of Appendix- 1 for SMAW electrodes, and Appendix- 2 for other consumables in SAES-W-013.

SAES-W-013 Para. 6.5

SAES-W-013, 6.2


F-Nos. 1 and F-Nos. 2 SMAW electrodes are prohibited on: 10 Mat'ls requiring impact tests (Per Code or spec). Maximum allowable SMAW electrode sizes that can be used are: A) Low hydrogen: 5 mm = 1G/1F position; 4 mm = all other positions. B) Non-low hydrogen electrodes: 5 mm = all positions. 11 Sizes larger than those listed are acceptable only if approved by CSD and only if the PQR was performed using the electrode size and positions to be used in production. The approval shall be obtained through the welding procedure review process. Drying & Re-Drying: Prior to use all electrodes shall be dried at 260-430C for 2 hours minimum. The drying step may be deleted if the electrodes are supplied in the dried condition in a hermetically sealed metal can with a positive indication of seal integrity or 12 vacuum sealed package. Electrodes may be re-dried only once.

SAES-W-013 Para. 6.6

SAES-W-013 Para. 10.1

SAES-W-011, 6.2



Storage: After drying, the electrodes shall be stored continuously in ovens at 120C minimum.


Para. 6.2

Exposure: Upon removal from the drying or storage oven or hermetically sealed containers, the electrodes may not be exposed to the atmosphere for more than 4 hours. The exposure may be extended to 8 hours if the electrodes are continuously stored in a portable electrode oven heated to 65C minimum. Electrodes exposed to the atmosphere for less than the permitted time period may be re-conditioned. Electrodes exposed in excess of the permitted time period must be re-dried. Electrodes that have become wet or SAES-W-011, 14 moist shall not be used and shall be discarded.

Para. 6.2

Re-Conditioning: Electrodes exposed to the atmosphere for less than the permitted time period may be returned to a holding oven maintained at 120C minimum; after a minimum holding period of four hours at 120C minimum the electrodes may be reissued. Note:This can allow endless reconditioning the same electrodes over and over again, SAES-W-011, 15 resulting in Electrode degradation

Para. 6.2

After any exposure > permitted time period, the electrodes must be Re-dried. Wet or moist electrodes are not used. Break/discard. System exists to ID any Redried electrodes (Coat the ends). These once re-dried electrodes may be reissued (once). Redried electrodes returned unused are broken/discarded. Inspectors know difference SAES-W-013, 16 between reconditioned & redried 6.2


Welding consumables shall be selected based on their mechanical properties, compatibility with mat'ls to be joined, their suitability for the intended service, consideration of polarity, 17 position, & direction of welding. (Extreme Caution for older electrode lot usage). Again, this cannot be emphasized enough to QA/QC Mgrs.

SAES-W-013 Para. 6.4

Welding consumables which are being used outside of their rated tensile or impact ranges listed in the manufacturing specs must be batch tested or have CSD approval. Batch testing 18 must be per the ASME SEC II C SFA 5.01 to verify they meet base material reqmts. Check SAIC-W-2010, Section B & Attachment 4 Low hydrogen consumables, measured per AWS A4.3, are used. 19 Verify consumables have less than or equal to 8 ml of hydrogen per 100 g of deposited weld metal, measured per AWS A4.3 QA/QC Mgrs are tasked with CPI in the Critical Area of Consumable Control. Please ensure 21 that procedure contains BEST PRACTICES. Procedure contains Welding Consumable Issuance Record or an approved equivalent. Take Note of Improvements: A) List of all Consumables to be used on the Project. (Important) B) Issue & Expiry Times (Critical) & Atmospheric Exposure Time C) Batch/Lot/Heat Numbers (Critical) 22 D) QC Comments Area (Allows Surveillance) E) Stub End Returns Daily (Stub Buckets) Stop Poor Practices*. F) Color-Code & Segregation of 1-Time Reconditioned SMAW rods

Sch Q, Att. 6 Tables

SAES-W-013 Para. 6.4 Sch Q, CPI Clause

Sch. Q, Att VI Tables (Welding)

A detailed list of checkpoints are added to this checklist after approval of the procedure for 23 control of electrode issuance, receiving & return is approved. Add best practices. PROCEDURE UTILIZES RESOURCES OF: A) SAICW-2010 Receiving Insp of Welding Consumables B) SATR-W2020 Welding Consumable Receiving Insp Report These 24 resources are reviewed and used in the Procedure as they are applicable to the workscope and this process. Be Prepared for SA Assessments that check records & details of consumables. These documents may change the way you do Recv Inspection.

Sch Q, CPI Clause

Sch. Q, Att VI Tables (Welding)

Electrodes older than 2* years shall not be used to make production welds on Saudi Aramco Projects. Electrodes shall be discarded or removed from site to prevent their inadvertent use. Contractor shall assure electrode issue control follows a "First In, First Out" Rule. *Note 1: Three (3) years shelf life is acceptable when demonstrated that mfg storage guidelines were met. (Temp/Humidity Controls) *Note 2: When storage climate is questionable* (*Dry Environment = Air conditioned/dehumidified with calibrated hygrometer in use) electrodes shall be limited to a shelf life of 2 years (max). See AWS Table for acceptable "storage 25 before opening" limits. *Note 3: Lincoln currently recommends a 3-year shelf life in certain brands of SMAW electrodes. When a manufacturer data sheet specifically states detailed storage conditions (humidity & temperature) and a shelf life beyond three years, and storage requirements have been followed (as verified by Quality), electrodes may be used for a period per manufacturer's instructions (to a three-year limit).

manufactures recommendation

All Welding Consumables (electrodes*, filler wires, and fluxes) shall conform to ASME SEC IIC. (SAES-W-011, Para. 6.1) & shall meet an applicable AWS specification & classification as packaged. Identification labelling shall clearly identify the product & Manufacturer certs (test reports) shall attest to the correct AWS specification & classification. When "other" Non-ASME electrodes have been specified & are CSD approved (through the WPS process), the same general controls shall apply. A Roster or Log shall be kept for each project(s) with documentation available for Receiving and storage. Storage shall conform to the mfg SAES-W-013 27 detailed storage requirements as listed and available (attach to records with Mfg Certs for 6 all consumables). All welding consumables shall have manufacturer data sheets that show detailed storage requirements (temperature & humidity limits at a minimum), or correspondence to provide adequate instruction in this regard. Shelf life shall be considered.