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TANJUNG TABALONG 2x30 MW COAL FIRED POWER

PLANT SOUTH KALIMANTAN, INDONESIA

METHOD STATEMENT FOR WELDING ELECTRODE


HANDLING AND STORAGE PROCEDURE

PT. MSW PROJECT NO.


SUBCON JOB NO
PROJECT NAME
OWNER
EPC
SUB.CTR

:
:
:
:
:
:

MSW/002/2008
TANJUNG TABALONG 2x30 MW COAL FIRED POWER
PT. MAKMUR SEJAHTERA WISESA
PT. PUNJ LLOYD INDONESIA
PT INDONESIA MARINE

BRW
A

MA

21-6-10

NAME DATE
PREPARED
REV

BRW 21-6-10
RH
21-6-10
NAM DATE NAME DATE
E
CHECKED
CHECKED

Issued for Comments


NAME DATE
CHECKED

PT. IM

NAME DATE
APPROVED

REVISON / DOC.
STATUS

PT.PLI
DOCUMENT TITLE

ERECTION MANUAL FOR CFBC BOILER


DOCUMENT NUMBER:
PT. MSW

TT-PLL-M-00000-0605

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THIS DOCUMENTIS THE PROPERTY OF PT. PLI AND MUST NOT BE COPIED IN WHOLE OR PART OR LENTOUT WITHOUT
THEIR WRITTEN PERMISSION

TABLE OF CONTENTS
COVER PAGE.................................................................................................................................. . 1

TABLE OF CONTENT....................................................................................................................... . 2
1.0 PURPOSE .................................................................................................................................... 3
2.0 SCOPE.......................................................................................................................................... 3
3.0 REFERENCE................................................................................................................................... 3
4.0 DEFINITION.................................................................................................................................... 3
5.0 RESPONSIBILITIES........................................................................................................................ 3
6.0 WELDING CONSUMABLE CONTROL REGISTER........................................................................3
7.0 DOCUMENTATION / ATTACHMENT............................................................................................... 6
7.1 FLOW CHART FOR ELECTRODE DRYING AND RECONDITIONING...................................7
7.2 FORMATS................................................................................................................................ 8

1.0

PURPOSE
The purpose of this procedure is to establish a system of control for the receipt, handling,
and usage of welding consumables.

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2.0

SCOPE
The scope of this procedure is applicable to all welding consumables, electrodes, Filler
wires, etc used for piping, tank and structural welding for the project.

3.0

4.0

REFERENCES

ASME / ANSI B31.3

: Process Piping

ASME Section II Part .C

: Specification for Welding Rod, electrode and Filler Metals

AWS Spec. and Class

: Welding Consumable Storage

DEFINITION
WPS

5.0

6.0

Welding Procedure Specification

RESPONSIBILITIES
5.1

Store keeper shall be responsible for the receipt, storage and issue of all welding
consumables.

5.2

PT. Indomarine QA/QC and PT. Punj Lloyd QA/QC shall be responsible to ensure
that the brand of welding consumables is same as used for qualifying the respective
Welding Procedure Specification. Change in brand of the welding consumables shall
be subject to the approval from the Engineer.

5.3

Supervisor/Foreman shall report to the QA/QC/Welding Inspector and shall be


responsible for the issue of welding consumables to the welders and for monitoring
correct implementation of the consumable management.

5.4

QA/QC / Welding Inspector shall be responsible for the selection of the welding
consumables, documentation and overall monitoring of the correct implementation
of the consumable management.

5.5

QA/QC / Welding Inspector / Foreman shall be responsible for the in process


inspection of the welding consumables control activities.

5.6

Welder shall be responsible for the correct use of welding consumable as per
Relevant WPS, ensure consumable which are damaged / deteriorated are not put to
use.

WELDING CONSUMABLE CONTROLPROCEDURE


6.1

Selection and procurement of welding consumables

All welding consumable shall be procured and issued by Purchasing / store


based on the material requisition and Welding Procedure Specification ( WPS )

PT. Indomarine QA/QC / Welding Inspector shall initiate material receiving


Inspection and review of welding consumable batch certificates.

6.2

Receipt and Inspection of Welding Consumables

PT. Indomarine Store Keeper shall receive the welding consumables and
confirm the type, quantity and size against the supplier delivery note. He shall

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also check for damages to the packing and ensure that the damaged and
deteriorated welding consumables are not received.
The store keeper shall keep the Welding Inspector informed of the receipt of the

consumables. The Welding Inspector shall confirm the consumables against


manufacturers test certificates and ensure conformance to WPS.
Manufacturers recommendations/ instructions regarding storing and handling

shall be strictly observed and ensure that all consumables to be used are
received on site together with their manufacturer original packing and
instruction.
All consumables found without original packing ( clearly identifiable ) will not be

accepted.
Any consumables (Electrode / wire / gas bottle ) which is unmarked or showing
signs of damage or deterioration shall be discarded.

6.3

CONSUMABLE STORAGE
All welding consumables shall be stored in accordance manufacturers instructions.
Electrodes shall be stored in clean dry conditions, in their original unopened
packing.
PT. Indomarine shall store all the welding consumables in store house, off the floor,
in rack specially allocated for welding consumable storage where the
temperature and humidity shall control. It should ensure that the consumables
are kept in a area of clean and free from grease, Oil and rust. Also shall provide
labels on the consumables storage racks to identity different types and sizes for
easy identification and retrieval.
All welding consumables shall be kept in store house. Different grades of electrode
shall be stored separately. No welding consumables shall be stored by welders
except during job. Each Electrode shall be distinguished with proper
identification or code mark.

6.4

CONSUMABLE BAKING
Baking of Electrodes before use, wherever recommended by the manufacturer
(especially for low hydrogen electrodes) shall be carried out as per
manufacturers recommendation. Maximum number of times electrode can be
baked shall not exceed the manufacturers recommendations.
Baking shall be carried out in electrically heated ovens, which are calibrated and
shall have temperature controls. Store keeper shall arrange to store different
grades of electrodes in different trays with identification labels in the oven, to
avoid mix up and wrong use of electrode. The baking temperature shall be as
per manufactures recommended instruction ( normally 300 - 350 C for 2
hours )
Shall have proper heating ovens of sufficient size to facilitate uniform drying of the
electrode with accurate temperature control as necessary. After completion of
baking, the electrode shall be stored in a holding oven at the recommended

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temperature (normally 100 - 120 C), before being used for use. Baking and
holding of electrodes shall be carried out in different ovens.
Heated Electrodes shall be directly transferred to welders heated quivers,
maintained at 100 C minimum. Electrodes kept in quivers for more than 8
hours shall be sent for re-baking. The issue of electrode from holding oven shall
be based on FIFO (First In First Out) circle. This shall be the responsibility of
the concerned store keeper and welder.
Daily temperature checks shall be carried out on baking and holding ovens and
recorded in Welding Consumable Control Register along with batch
certificate number and other details of welding consumables.
6.5

IN-PROCESS CONTROL OF WELDING CONSUMABLES

Welding Consumables shall be issued on daily basis to prevent excess issue,


misuse and damage. Low hydrogen electrode exposes to atmosphere shall be
used within 2 hours or as a recommended by manufacturer to get hydrogen
content less than 10 ML/100gm. Supervisor / Foreman shall complete a
Consumable Issue Control Form for the days requirement of welding
consumable as per the WPS and forward it to the stores for issue of
consumables. The requisition ( Consumable Issue Control Form ) shall clearly
state the type, size, quantity of the consumable and shall be authorized by the
welding Foreman.

The store keeper shall issue electrodes to the welder accordingly and enter the
batch certificates numbers details of the consumable issued in the same format
as a record.

Consumable not requiring baking / heating shall be directly issue by the


Welding Foreman to the concerned welders for use. Welders shall arrange to
store the electrodes for use in non-metallic plastic/paper containers so as to
avoid contact with floor and maintain cleanliness of the electrodes. Welder shall
ensure that other consumables GTAW filler wires are kept clean all the time
and not in contact with the floor / ground and other metallic objects.

Welding Foreman shall arrange for baking and holding of the consumables
requiring baking. The baked consumables shall be issued by the welding
Foreman directly from the holding oven to the welders quivers maintained at a
minimum of 70 C or as recommended by electrode manufacture. The welders
shall ensure that their quivers are working and lids are closed after during
welding. Also ensure only one type of electrode is stored in their quivers at a
time.

The Welding Foreman and the welders shall ensure that the type of
consumable used is as per the relevant WPS and also that the electrode in use
are identifiable during all stages of use. Electrodes have identification
(Electrode grade/type and brand) stencilled at the stub end TIG Filler wires
have the filler wires name embossed at the ends.

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Welding Inspectors shall ensure by periodic inspection that damaged, wet,


unidentified / deteriorated welding consumables are not used and re-drying /
holding of electrodes is carried out as per requirements and the welders quivers
are maintained at the required temperature at the time of receipt of electrodes
and throughout the period of use. Welding Inspector shall ensure that the
welding consumables used are as per the WPS.

Welders shall ensure that the unused electrodes are returned to the Foreman at
the end of the days work and the Foreman shall suitably return them to the
store for reuse / scrap. (Electrodes which have already been baked for the
maximum no. of times allowed by the manufacturer shall be scrapped). Welders
shall not use consumables found damaged, wet, unidentified, rusted and shall
return the same to the Welding Foreman for return to the stores for scarping or
quarantine.

7.0

6.6

Low Hydrogen electrodes shall be used within 8 hours when stored in quivers.

6.7

No electrodes shall be left lying around the site/workshop. Electrodes so left shall be
scrapped and removed.

6.8

GTAW consumables shall be clearly identified and stored in dry location at a


temperature of not less than 20 C. GTAW welding consumables shall be withdrawn
from the store as required for immediate use. Unused consumables shall be
returned to the store on completion of the welding operation.

DOCUMENTATION / ATTACHMENT
7.1

Flow Chart of Low Hydrogen Electrode

7.2

Formats
7.2a Welding Consumable Baking Control register ( Form : )
7.2b Consumable Issue Control Form ( Form :.)
7.2c Electrode Batch Certificate Record ( Form. :..

7.1

Flow Chart for Electrode Drying and Reconditioning


LOW HYDROGEN ELECTRODES (NON Vacuum Packed)

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UNPACK FROM ORIGINAL


PACKING BY MAT.
CONTROLLER (From
Storage)

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DRY ELECTRODES BAKING


IN OVEN

RE-BAKE ELECTRODES
IN OVEN AT 300-350 C
for 30 60 MINUTES TIPS
PAINTED AND RE-BAKE
ONCE ONLY

HOLDING OVEN

WELDING
ACTIVITIES + HEATED QUIVERS
70C MIN.

BAKED AT 300-350 C
for 30 60 MINUTES

HOLD AT 100C -120 C

ISSUE TO WELDER IN PORTABLE DRYER


( QUIVER ) SUFFICIENT AMOUNT TO BE
ISSUUED FOR TTHAT JOB

DISCARD

UNUSED ELECTRODES

CELLULOSE / RETILE ELECTRODES

CELLULOSA / RUTILE
ELECTRODES
(From Storage)

ISSUE FOR WELDING

WELDING ACTIVITY

Form MIS
Weld Consumable Request
Issue Requisition Form

7.2 Formats
7.2a Welding Consumable Baking Control register ( Form : FS-751-06-026_1R0 )
7.2b Consumable Issue Control Form ( Form : FS-751-06-026_2 R0 )
7.2c Electrode Batch Certificate Record ( Form. : FS-751-06-026_3R0 )
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7.2a. Welding Consumable Baking Control register ( Form : FS-751-06-026_1R0 )

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7.2b Welding Consumable Issuing Register ( Form : FS-751-06-026_2R0 )

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7.2c

Electrode Batch Certificate Record ( Form : FS-751-06-026_3R0 )

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