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Hitachi Power Africa Work Instruction Document No.

:
(Pty) Ltd
And HBP-QMS-WI-15/14
Murray & Roberts Control and Issue of Welding
Projects Consumables Revision No.: 01

Revision Grid

Section Change Section Change Section Change


1.3 Hitachi Specification added
1.5 HPE Added
2.5 Updated
Updated and rod markings
3
added on table

Table of Contents
1.  Preliminaries ........................................................................................................................................................... 3 
1.1.  Purpose .................................................................................................................................................................. 3 
1.2.  Scope ..................................................................................................................................................................... 3 
1.3.  References ............................................................................................................................................................. 3 
1.4.  Responsibilities ...................................................................................................................................................... 3 
1.5.  Definitions and Abbreviation ................................................................................................................................. 3 
2.  Process ................................................................................................................................................................... 4 
3.  Records ................................................................................................................................................................... 6 

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Hitachi Power Africa Work Instruction Document No.:
(Pty) Ltd
And HBP-QMS-WI-15/14
Murray & Roberts Control and Issue of Welding
Projects Consumables Revision No.: 01

1. Preliminaries

1.1. Purpose
To establish a standard process to cover the control and issue of welding
consumables.

1.2. Scope
This works instruction shall apply to all welding consumables.

The Welding Engineer and/or the Welding Manager shall be responsible for ensuring
compliance with these controls within Murray & Roberts Projects (MRP) and Hitachi
Power Africa (HPA) and their sub contractors.

1.3. References
 ISO 9001:2008 Quality Management System Requirements
 ISO 14001:2004 Environmental Management System Requirements
 OHSAS 18001:2007 Occupational Health and Safety Management System
Requirements
 HPES 12-1
 HBP-QMS-WI-14/02 Material receipt procedure.
 HBP-QMS-WI-14/06 Welding Procedure.
 Recommendations for baking and drying.
 Client requirements of applicable codes or specifications as per contract.

1.4. Responsibilities
Establish and maintain this Work Instruction: Senior Construction Manager
Welding Engineer
Implementation of this Work Instruction: Area Manager
Welding Manager

1.5. Definitions and Abbreviation


Approval Authority A person with the authority to approve a procedures/work
instruction.
Author A person or team assigned responsibility to draft or redraft a
procedure / work instruction.
Connection Two or more individual parts joined together by means of the use
of bolts

Note: This document becomes an uncontrolled


copy when printed. Page 3 of 6
Hitachi Power Africa Work Instruction Document No.:
(Pty) Ltd
And HBP-QMS-WI-15/14
Murray & Roberts Control and Issue of Welding
Projects Consumables Revision No.: 01

Controlled Copy A copy that has controlled or limited distribution, the text of
which cannot be corrupted.
HPA Hitachi Power Africa (Pty) Ltd
HPE Hitachi Power Europe
HBP Hitachi Boiler Power
HBP Management It is the framework of policies and procedures in terms of
System which Medupi and Kusile Boiler Project is to be managed.
Management Plan A high level document that provides an overview of specific
management processes for the project.
MRP Murray & Roberts Projects (Pty) Ltd
Procedure A document which describes the roles and responsibilities
for a specific activity
Quality Representative A person who has the authority to carry out the duties
related to quality assurance within the company.
Work Instruction A document that provides detailed process or technical
guidance to a specific function on the project.
WPC Weld Process Control

2. Process

2.1 On receipt, all consignments of welding consumables shall be checked for damage and
conformance to purchase order including compliance of certificate and batch no.
Should the consumables not comply with the purchase order, or should the containers
be damaged, then the consumables shall be rejected and returned to the supplier.

2.2 Packages shall be stored at least 50mm off the floor and shall be secured during
transportation so as to prevent damage.

2.3 Differing classifications and sizes of electrodes shall be segregated to reduce the risk
of mixing.

2.4 When required, electrodes shall have been baked and held in accordance with the
manufacturer’s recommendations and records of baking and consumable certificates
shall be kept by the store man.

Electrodes stored in vacuum packs may be issued for use without re-drying. Electrodes
issued in the vacuum packed state shall, after opening, be placed in a calibrated
heated quiver.

Note: This document becomes an uncontrolled


copy when printed. Page 4 of 6
Hitachi Power Africa Work Instruction Document No.:
(Pty) Ltd
And HBP-QMS-WI-15/14
Murray & Roberts Control and Issue of Welding
Projects Consumables Revision No.: 01

If the electrodes have been held in the heated quiver for the duration of the shift, they
may be returned to the holding oven for a maximum of one week (7 days) for further
use. When the electrodes are placed in the holding oven, the date, time, size, batch
number and quantity shall be recorded on The Log Sheet, Rods Returned for Re-issue
from Holding Oven.

2.5 Issues of electrodes and TIG wire shall be controlled and requested by the welding
supervisor or welding foreman with consumable request book or Weld Process Control
(WPC). Request will be presented to welding storeman by welding supervisor/welding
foreman or welder. Storeman will ensure the correct issuing of the consumable as per
request.

2.6 Welding rods shall be kept in a calibrated heated quiver with the electrode and welding
information (welder stamp, electrode size, type and quantity), recorded on a temporary
label attached to the quiver.

2.7 Any electrodes that have come into contact with liquid or that show evidence of
deterioration shall be discarded.

2.8 Any filler wire showing evidence of rust will be scrapped.


Subject to inspection by the Welding Supervisor/Welding Storeman, unused electrodes
that have been kept in a calibrated heated quiver may be returned to the holding oven.

2.9 Filler wires will be supplied, hard stamped with their identification or with manufacturers
colour code, where this is not possible wires will be colour coded to ensure ease of
identification.

2.10 All bare filler wire supplied to site without hard stamping is colour coded in the work
area consumable store as described in the table below before being issued for use.

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Hitachi Power Africa Work Instruction Document No.:
(Pty) Ltd
And HBP-QMS-WI-15/14
Murray & Roberts Control and Issue of Welding
Projects Consumables Revision No.: 01

3. Records
3.1 The relevant stores control system shall reflect the issues of welding consumables.

3.2 Where required for data books, applicable records shall be retained for this purpose.

3.3 Baking oven logs, where required, shall be included in data books.
PARENT COLOUR ROD
AWS CLASS BS-EN CLASS MARKING
MATERIALS CODING
(BÖhler welding)

WHITE WMoSi
P265 GH ER 70S-A1 W MoSi 1.5424
WHITE WMoSi
16 Mo 3 ER 70S-A1 W MoSi 1.5424
BLUE WCrMo1Si
13 CrMo 4-5 ER 80S-B2 W CrMo1Si 1.7339
BLACK WCrMo2Si
10 CrMo 9-10 ER 90S-B3 W CrMo2Si 1.7384
BROWN T/P 24
7 CrMo VTiB10-10 ER 90S-G W ZCrMo2VNb ER90S-G
GREY WCrMo91
X10 CrMo VNb 9-1 ER 90S-B9 W CrMo 91 ER90S-B9
WHITE WMoSi
15 NiCuMoNb 5-6-4 ER 70S-A1 W MoSi 1.5424
GREEN W19 9H
TP 347 HFG ER19-10H W19 9H ER19-10H
RED WZ CrCoW1122
VM 12-SHC ER110S-G W ZCrCo W1122 VM12-SHC
PINK 2.4831
Alloy 625 ERNiCrMo 3 NiCr 22 Mo 9Nb ERNiCrMo-3
X15CrNiSi20/12 to 13 YELLOW 2.4806
ERNiCr 3 NiCr 20 Mn 3Nb ERNiCr3
CrMo 4-5
PURPLE W2312L
350WC to 3 Cr12 ER 309L W23 12L ER309L

Note:
Welding consumables have to be in compliance to the HPES 12-1.
If deviations to the HPES 12-1 occur, HPE welding department has to confirm.

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