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I.E.M.S.

Code

WELDING
CONSUMABLE
HANDLING &
STORAGE

UAN (for QMHA)

Page

11-3090

1 of 6

WELDING CONSUMABLE
HANDLING & STORAGE
Owner
: ENPC
Main contractor : Uhde
Project name
: AMMONIA UREA ENPC PROJECT

00
Rev

Status

CC Category Code:
1 = for approval
2 = for review
3 = for information
4 = for internal use
AC Acceptance Code:
1 = approved / reviewed
2 = approved / reviewed as
noted
3 = not accepted
4 = received

First Issue

19/7/2010

Emad Omar

19/7/2010

Hassan Basha

Description

Date

Prepared

Date

Checked

Date

Approved

Acc.

Status Code:
A = Issued for Design
D = Issued for Inquiry
E = Issued for Order
F = Issued for Prefabrication
G = Issued for Construction /
Fabrication
H = Issue for Work
Preparation
I = As- built
M = General Issue

Copyright 2007 Uhde GmbH

Doc. ID-Code
PT-BM-183-DC-00009

Category
1

Code

WELDING CONSUMABLE
HANDLING & STORAGE

I.E.M.S.A

CONTENTS
1
2
3
4
5
6

ENPC
UAN (for QMHA)

Page

11-3090

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PAGE
3
3
3
3
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5

Purpose
Scope
Reference
Definitions
Procedure
Documentation

1. PURPOSE:

Copyright 2007 Uhde GmbH

Doc. ID-Code
PT-BM-183-DC-00009

Rev.

00

Code

I.E.M.S.A

WELDING CONSUMABLE
HANDLING & STORAGE

ENPC
UAN (for QMHA)

Page

11-3090

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The purpose of this procedure to demonstrate the operation of process of welding


consumable storage and handling at shop and site according to UHDE specs.

2. SCOPE:
This procedure describes the management activities used for storage and handling control operations of welding
consumables within the site.

3.REFERENCES
Manufacturer recommendations
UHDE Specification

4. DEFINITIONS
Welding consumables it is the material, which consumed by means of fusion welding process other than
gasses. Like Electrodes, Wire, Rods, Fluxes, etc.

5. PROCEDURE
5.1 Welding consumable receipt & stora ge
5.1.1
Welding consumable receipt
At point of welding consumable receipt shall have all details verified against accompanying
certificates. Consumable certificates shall be submitted to the QA/QC department for verification of
acceptance. The stated mechanical values and chemical analysis shall conform to recognized
standard, client specifications and W.P.S requirements. Welding consumable certificate show the
batch number, manufacturer, trade name and brand name shall be kept for each kind of welding
consumable.
5.1.2
Welding consumable storage
Electrodes shall be stored whilst in their containers (prior to any form of backing and/or before use)
in a dry well ventilated environment condition storage should be on wooden duckboards, or
cardboard shielding. Electrodes shall not be stored in a manner that could induce moisture. Welding
consumable shall be stored by type within classification according to trade name, diameter and
batch number also in fashion, which will ensure that air can circulate freely around the stored
containers, and spools shall be stored in flat position.
5.2 Electrode control
5.2.1 Moisture control
In order to avoid weld porosity and cracking in the heat affected zone particularly with "hydrogen
controlled electrode" it is important to be sure that the electrodes are dry before use the QC
engineer shall be responsible for ensuring that "Low hydrogen" electrodes are pre-backed before
use in order to achieve full manufacturer stated levels of performance and efficiency and
consequently it is a mandatory requirement that "Low hydrogen" electrode will be pre-backed
irrespective of their condition of storage. The welding foreman is responsible for pre-backing of low
hydrogen electrode and for returns and re-backing unused electrodes of each welder at the end of
the period

5.2.2 Moisture indications - typical.


Copyright 2007 Uhde GmbH

Doc. ID-Code
PT-BM-183-DC-00009

Rev.

00

Code

I.E.M.S.A

WELDING CONSUMABLE
HANDLING & STORAGE

ENPC
UAN (for QMHA)

Page

11-3090

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Generally electrodes affected by moisture will exhibit the following: - white covering or coating,
visible rusting of the core wire, cracks and breaking of actual flux covering. Where such findings
are in evidence the QC engineer shall be responsible for ensuring that such electrodes are
immediately removed from service with IEMSA site quality manager being notified Similarly visual
indications whilst welding will result in swelling of the coating, flaking of the coating, coupled with
an unstable arc, excessive weld spatter and a high pitched crackle. Where such findings are in
evidence, the site quality manager shall be responsible for ensuring that the welding operation is
immediately suspended and that the electrodes are immediately removed from service with IEMSA
QA/QC manager being notify
5.3 electrodes handling at site & shop
5.3.1 Stationary baking & holding oven
5.3.1.1 Electrode identity
A multi-fusion baking and storage oven is provided for baking and holding of low hydrogen
electrodes to the site and shop welding activities and the ovens shall be managed in such a
fashion as to ensure identify of the electrode. There shall be no instance of storing contraband
[food] within the oven.
5.3.1.2 Temperature control

Both the multi-function baking and storage oven provided to site operation, and the static
ovens at the fabrication shop are fitted with electronic temperature controls which are also backed
up by the use of thermometers to ensure constant temperature controls are maintained. The
welding foreman and QC engineer shall be responsible to follow up oven temperature according to
instructions of welding engineer for storage and handling temperature for each kind of electrodes
basis to ensure the temperature perimeters are maintained and managed in line with established
IEMSA welding consumable storage and handling procedure.
Verification for the performance of ovens and quivers is performed basis using calibrated
digital thermometer, to be sure that all of them are working properly. This check is made and
registered in accordance with the attached forms
5.3.1.3 Backing (Drying)
Prior to use all electrode dried AS PER MANUFACTURE INSTRUCTION, the drying backing step
may be deleted if the electrodes are supplied in the dried condition in hermetically sealed metal
can with position indication of seal integrity, electrode may be re-backing to a maximum three times.

5.3.1.4 Storage
After drying the electrodes shall be stored continuously in ovens AS PER
MANUFACTURE INSTRUCTION.
5.3.1.5 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 2 hours for any high strength electrodes.
The exposure times may be doubled (to 4 hours) if the electrodes are continuously stored in a
portable electrode oven heated to 70 C minimum. All electrodes exposed to the atmosphere for less
than the permitted time period may re-conditioned. All electrodes exposed in excess of the
permitted time must be re-dried. Higher strength electrodes (above ESOxx) must be re-dried after
Copyright 2007 Uhde GmbH

Doc. ID-Code
PT-BM-183-DC-00009

Rev.

00

Code

I.E.M.S.A

WELDING CONSUMABLE
HANDLING & STORAGE

ENPC
UAN (for QMHA)

Page

11-3090

5 of 6

any atmospheric exposure. Electrodes that have become wet or moist shall not be used and shall be
discarded.
5.3.1.6 Re-Conditioning
Any electrodes exposed to the atmosphere for less than the permitted time period may be returned
to a holding oven maintained at 120 C minimum the electrodes may not reissued.
NOTE:
Portable electrode storage ovens with a minimum temperature of 120 C are considered equivalent
to storage ovens. Proper use of the oven (e.g. closed lid, continuously on while in use) and
periodic checks of the temperature achieved with each portable oven are required.
5.3.1.7 GTAW
All electrodes and wires shall be stored in sealed containers in a dry environment. Any wires that
have visible rusting or contamination shall not be used and shall be discarded.
5.3.2 Portable holding ovens - quiver control - site and shop
In order to maintain stability of the electrode at the point of the arc, welding foreman shall be
responsible for that. All site welders shall have their welding quiver which are taken to the welding
operations, and have the ability to electrically control its temperature. Quiver temperature
shall be kept according to flow chart of electrode baking and holding instructions. And no
instance of electrodes in the welding area out side the quiver, the welding foreman shall be
responsible and QC engineer to follow up quiver temperature according to instructions of welding
engineer for storage and handling temperature for each kind of electrodes basis to ensure the
temperature perimeters are maintained and managed in line with established IEMSA welding
consumable storage and handling

6.0 Documentation
Welding filler metal inspection

Copyright 2007 Uhde GmbH

Doc. ID-Code
PT-BM-183-DC-00009

Rev.

00

WELDING CONSUMABLE
HANDLING & STORAGE

I.E.M.S.A
Inspection check point
Bulk Storage

Code
ENPC
UAN (for QMHA)

Inspection
Accept
Reject

Page

Observation
6 of 6

N/A11-3090

Welding filler metal inspection


report

Identification
Holding Ovens
Segregation of electrode types in
ovens
Ovens cleanliness
Unused materials return
Others

Remarks

Copyright 2007 Uhde GmbH

Doc. ID-Code
PT-BM-183-DC-00009

Rev.

00