APP CONSORTIUM

.Document Ref
WI -05-0199

Work Instruction

Revision

Page 1 of 5

MARINE FACILITIES WORK

EGYPTIAN LNG PROJECT-Idku
WORK INSTRUCTION
FOR
HANDLING OF CONSUAMABLE
MATERIALS

Issue Status &

Description

.Issued for Use

R
e Issue Date
v.

Document

WI-05-0199

30/08/2003

Prepared by
Construction
Manger

Reviewed by
QA Manger

Approved by,
Project
Manager

APP CONSORTIUM
Work Instruction

.Document Ref
WI -05-0199

Revision

Page 2 of 5

APP CONSORTIUM
Work Instruction

.Document Ref
WI -05-0199

Revision

Page 3 of 5

LIST OF CONTENT

1.0

Scope

2.0

Reference Documents

3.0

Receiving and Storage

4.0

Stick Electrode Baking , Maintenance And Handling

5.0

Flux Baking, Maintenance And Handling

6.0

Handling And Maintenance Of Solid Wires

7.0

Vacuum Pack Stick Electrodes Storage And Handling

APP CONSORTIUM
Work Instruction

.Document Ref
WI -05-0199

Revision

Page 4 of 5

1.0 Scope
The procedure defines the condition to be followed for storage, drying maintenance and
handling of welding material during fabrication.
The parameters as here indicated for drying / holding shall be applied unless different
manufacture's consumable recommendation.
1.0 References
ASME Code Sec. II Part C
ASME Code Sec. IX
AWS SFA Classification
Manufacture Data Sheets
3.0 Receiving and Storage
Upon receipt from supplier consumables will be checked / verified against consumable
certificates by one full time qualified inspector
Any consumable which do not conform to certificates received and those with no
certificates will be stored in a quarantine area until the right certificate is received
Unopened container of welding consumables shall be identified and stored separately
by classification and sizes
In case of damage boxes / consumables shall be identified quarantined and stamped
HOLD
All welding consumables shall be stored in a dedicated area under environmental
condition as per manufacture recommendation.
If required the color code or identification marking of all welding material for use
marking shall be performed by welding material manufacture or material controller
prior to issue and color coding is identified as follows :
Carbon Steel Welding Electrode and rod: colorless (for 7018 - 1)
Carbon Steel Welding Electrode and rod: White (for 7018 - G low temp carbon steel)
Carbon Steel Welding Electrode for X65 material: Gray (for 8018 - G)
Stainless Steel Welding Electrode and rod: Yellow (for ER 316 L)
Stainless Steel Welding Electrode and rod: Green (for E309 DISSIMILAR METAL)
Nickel alloy welding electrode and rod: Red (for INCOLOY 625 and 112)
4.0 Stick Electrode baking, Maintenance and handling
4.1 Drying
All low hydrogen electrodes (not vacuum pack) shall be baked before use. They shall
be dried in baking oven using the following parameters (for low hydrogen electrodes).
Electrodes must be placed in baking oven not more than 50 mm per layer.

APP CONSORTIUM
.Document Ref
Revision
WI -05-0199
Baking temp shall be 280 -/+ 30 C or minimum 1 hr.
Baking / Drying temp : 280 -/+ 30 C
Minimum drying time : 1 hour
Maximum drying time : 1 hour
Work Instruction

Page 5 of 5

Or as per manufacture recommendation.

Electrodes for stainless steel and all electrodes for non - ferrous metal shall be baked
as follows:
Baking temp shall be: 1 hour at 280 C
Baking / drying temp: 280 C
Electrode for oncology 825 materials shall be dried as follows:
Baking temp: 1 hour at 280 C
Baking / drying temp: 280 C
Note; as per manufacture recommendation (Max. 3 times electrode to be baked)
Should repacking be required manufacture recommendation shall be followed.
4.2 Maintenance Procedure
After completion of drying cycle but before the furnace temperature becomes lower
than 150 C all above mentioned electrodes shall be transferred into the holding
ovens (or in the same oven ) kept at temp of 120 = 30 C ( this will be controlled by
specialist )
Electrodes shall remain into the storage ovens before use but not more than one
month.]
4.3 Handling of Electrodes
One full time qualified individual (welding supervisor or welding foreman) will be
provided at each group to handle control and monitor welding consumables.
Electrodes and welding rod shall be distributed to welders by this authorized
individual. The electrodes are distributed in such a way that the electrodes are not
exposed to quiver atmosphere for more than 6 hours. These are achieved by issuing
electrodes at the start of the shift and once again after lunch break.
Electrodes are to be transferred directly from oven to quiver welder shall use
portable quiver to collect and store electrodes. These quivers shall be electrically
heated and maintained at 70 C. in some cases that there are still balance electrodes in
quiver before the end of shift and or before the permissible atmospheric exposure is
reached. The welders shall return the balance electrodes in quiver. These electrodes
shall be retrieved and kept in the top tray of the holding oven.
The welders in the subsequent shift will use these electrodes first.
All welding consumables which have deteriorated in any way from their original
specifications or which have been contaminated by grease, oil, water, ETC. Shall
be removed from the welding site and discarded.
5.0 Flux Baking Maintenance and handling (Attachment 4)
5.1 Baking / drying Procedure
Welding fluxes shall be baked in suitable ovens whether in conventional (with boxes)
or
automatic drying oven.
Drying in a conventional oven: the flux received from main store is loaded into the
drying oven and the drying cycle adopted is as below:
Baking / drying temp. : 300 C
Minimum drying time: 2 hours

APP CONSORTIUM
.Document Ref
WI -05-0199
Maximum drying time: 4 hours

Work Instruction

Flux height max.

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: 50 mm

Note: as per manufacturer's recommendations

Should re-baking required manufacturers recommendation shall be followed.
When using automatic drying oven only drying time shall be considered, which is 300
C. a timer is set to maintain the drying time after which the flux is automatically
transferred into the holding chamber. The temp. Of the holding chamber is
automatically maintained at 150 C
5.2 Storage of Flux
When using a conventional drying system, the flux is transferred to a holding oven
kept at 150 C (or as per manufacture recommendation)
5.3 Identification
The flux that is being dried shall be identified by trade name and batch no.
Drying cycle, etc such identification shall be clearly exhibited on the respective
Oven.
6.0 handling and maintenance of solid wire
6.1 Solid wire shall be taken out of the manufactures packing, just before actual use.
6.2 At the end of the shift a suitable plastic cover shall cover the wire spool mounted
on the Machine
6.3 If spool is not to be used for more than 24 hours, it shall be kept in the humidity
controlled room to avoid moisture absorption.
7.0 Vacuum Pack Stick Electrodes
7.1 Storage
After receiving from supplier, the warehouse man will verify the packing integrity
and then boxes shall be stored in a dedicated area inside the warehouse. (Refer to
Sec 3)
7. 2 Handling
The welding foreman will record the date, time and his signature on each package
electrodes, before giving them to the welders. All electrodes shall be used within
6 hours after that time; the residual electrodes unused must be handled according
to sec 4 paragraph 3.