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SOHAR REFINERY IMPROVEMENT PROJECT

Method Statement for Welding consumable


control

Document No : OFD0137-BEC-MS-005,REV 0
BEC Project Number : OFD0137
DPJV Contract Number : 120476 / JI-02022
Package Number : 2 & 6

22-12-2014

Issue for approval

Rev.

Date

Description

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S.J.N

Prepared

S.J

G.V.A

Reviewed

Approved

Approved

Method statement for


Welding consumable control

Sohar Refinery Improvement Project SRIP


Doc Ref : OFD0137-MS-005 Rev-0

Project No: OFD0137

DPJV

INDEX

1. OBJECTIVE

2. SCOPE

3. ABBREVIATION

4. CODES&STANDARDS

5. ROLESANDRESPONSIBILITIES

6. MANPOWER

7. EQUIPMENTANDTOOLS

8. SEQUENCEOFACTIVITIES

9. SCOPEOFWORK

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Sohar Refinery Improvement Project SRIP


Doc Ref : OFD0137-MS-005 Rev-0

Method statement for


Welding consumable control
Project No: OFD0137

1. OBJECTIVE
This document is to define the requirements for the welding consumable control for the welding of carbon
steel,Nace,low temperature carbon steel, low alloy and austenitic stainless steels, Alloy 400/825 for package
number 2 and 6 shall be read in conjunction with the applicable project specification, and relevant codes of
Welding.

2. SCOPE
This method statement is applicable only for receiving, storage as per AWS classification and specification,
handling, identification, conditioning and issue of welding consumable used for the welding of

Carbon steel/Carbon steel (nace)


Low temperature carbon steel
Low alloy steels
1.1/4 Cr 1 Mo
2.1/4 Cr 1Mo
5 Cr 1 Mo
9 Cr 1 Mo
Austenitic stainless steel,
SA312 TP 304 L
SA 312 TP 316 L
SA 312 TP 321
Nickel-Copper alloy.
UNS N04400(ASTM B 165)
Nickel-Iron-Chromium-Molybdenum-Copper alloy.
UNS N08825(ASTM B 423)
on package number (2 and 6) work for SOHAR REFINERY IMPROVEMENT PROJECT (SRIP).

3. ABBREVIATIONS
AWS
WPS
PQR
WQT
ASME

:AmericanWeldingSociety
:Weldingprocedurespecification
:Procedurequalificationrecord
:Welderqualificationtest
:AmericansocietyofMechanicalengineers
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Sohar Refinery Improvement Project SRIP

Method statement for


Welding consumable control

Doc Ref : OFD0137-MS-005 Rev-0

Project No: OFD0137

ANSI :AmericanNationalStandardsInstitution
Company :SoharRefineryImprovementProject(SRIP)
Contractor
:DaelimPetrofacJointVenture
SubContractor
:BahwanEngineeringCo.LLC(BEC)
ISO :InternationalStandardsOrganization
ITP :Inspection&testplan
NCR :Nonconformancereport
PPE :PersonnelProtectiveEquipment
RA :RiskAssessment

4. CODES&STANDARDS
:GeneralrepairprocedureforPiping

ASME Sec IIC


ASME Sec IX
ASMEB31.3
AWSD1.1
ASMESect.V
S-000-5220-008-Rev 0
Welding control procedure

: Specification for Welding Electrodes & Filler Metals


: Welding and brazing Qualification
:ProcessPiping
:StructuralWeldingCodesteel
:NonDestructiveExamination
: Specification for welding of pressure piping SW.611

5. ROLES&RESPONSIBILITIES
ConstructionManager

ShallreporttoSiteManager.

He shall be responsible for the implementation of this Method Statement of welding consumable
control.
He shall also be responsible for communicating all element of this Method Statement and
reference documents to down the level and arranging all resources to perform welding
with proper welding Consumable control.

Shall be responsible for the execution of work in accordance with project HSE and
Qualityrequirements.

QA/QCManager

ReporttoSiteManager.

Responsibilities for quality control of the welding consumable controlling , welding,


installation&testing

He shall liaise with Customer and contractor for Quality related matter.

ShallreviewInspectionreports,testcertificates&prepareTQfortechnicalinformation.

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Method statement for


Welding consumable control

Sohar Refinery Improvement Project SRIP


Doc Ref : OFD0137-MS-005 Rev-0

Project No: OFD0137

Shallensurethattherequirements&specificationsstipulatedinthismethodstatementare
appliedandmaintainedthroughouttheprojectconstructionperiod

QA/QCEngineer

ShallreporttoQA/QCManager

He shall be responsible for the quality of welding consumable control method


statement with strict adherence.
He shall ensure that welding consumable is used after proper authorization of welding inspector.
He shall also monitor the compliance of storage and issue of electrodes.

QCInspector

ShallreporttoQCEngineerWelding/Piping.

He shall be
certificate.

responsible

for

reviewing

and

endorsement

of welding

consumable

He shall be responsible for carries out daily inspection of the consumable storage, baking
holding of electrodes and as per manufacturer recommendations and approved WPS of each
consumable (AWS class and SFA) shall be maintained.
He shall also be verifying the issue of welding consumable at store
He shall be verifying the Calibration of Baking, Holding ovens and portable quivers

WeldingForeman

ShallbereportingtoQC/Pipingengineer

He shall
statement.

He shall be responsible for preparing the welding consumable request as per WPS
requirement.
He shall ensure that all unused electrodes have been returned to the baking oven at the end of the
shift every day.

be monitor handling of welding

consumables on site with this method

Shallconducttoolboxtalkpriortostartofwork&ensurecompliancewithWPS

Materialcontroller

ShallreporttoMaterialManager

Shallensurethatallmaterialsarestored&segregatedaspermaterialspecification&size
schedulewise.
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Sohar Refinery Improvement Project SRIP

Method statement for


Welding consumable control

Doc Ref : OFD0137-MS-005 Rev-0

Project No: OFD0137

Shallensurethatallboughtoutprojectmaterialsareinspected&certifiedbyconcern
authority.

Shallensurethatallmaterials/spoolsareissuedforinstallationinaccordancewithMIR.

SafetyOfficer

ShallreporttoHSEManager

Ensure valid work permit for all activities performed during installation and permit
conditionarecomplied.

EnsurethatproperPPEsarebeingusedbyemployeesduringwork.

Conduct tool boxtalkin ordertoexplain possible hazards,associatedrisks&control


measures

IdentifyspecifichazardsandassistconstructionSupervisiontoensuresafeprogressof
workactivity.

Control unauthorizedentry toworkarea byproperbarricading& displaying warning


signboardsandindicators.

CoordinatewithcontractorsiteHSEstaffforeffectivecontrolofactivityatsite.

6. MANPOWER

SiteManager

ConstructionManager

QA/QCManager

QA/QCEngineer

QCInspector

WeldingSupervisor/Foreman

Welders

Materialcontroller

HSEOfficer

Storekeeper
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Sohar Refinery Improvement Project SRIP

Method statement for


Welding consumable control

Doc Ref : OFD0137-MS-005 Rev-0

Project No: OFD0137

7. EQUIPMENT&TOOLS

BakingOven

HoldingOven

PortableOven /Heated quivers

WeldingMachines

Argoncylinder

Weldingconsumables

8. SEQUENCEOFACTIVITIES

Consumable Certification.
Equipment Calibration.

Receipt from Supplier and Storage at sub-contract Stores.


Baking.
Re Baking of Electrodes.
Shielding/Baking Gases ( Argon, Hydrogen & Nitrogen )
Issue of Welding Consumables to Welders.
Vacuum Pack Electrodes.
Disposal of Electrodes.

9. SCOPEOFWORK
9.1.1

Consumable Certification

All welding consumable shall have clear legible copies of manufacturers test certificate and
to be reviewed by sub-contractor QA/QC Engineer / Inspector

The copy of Consumable test certificate and material approval request shall be submitted to DPJV for
approval
The consumable shall be delivered according to the manufacturers data sheet and certified
in accordance with EN10204 3.1

9.1.2.

Equipment Calibration
Electrode baking ovens, holding ovens and heated quivers shall be calibrated primary or
secondary, the calibration records shall be maintained and the calibration certificates shall be
identifiable and available in the subcontract QA/QC Department.

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Sohar Refinery Improvement Project SRIP

Method statement for


Welding consumable control

Doc Ref : OFD0137-MS-005 Rev-0

9.1.3.

Project No: OFD0137

In case of Secondary calibration it shall be done with the equipment, which is primary calibrated
from approved third party calibration lab and having valid calibrationCertificateandshallbe
traceable to international or national standards
The frequency of calibration shall be one year and calibration certificates shall be fil edat
storefor sub-contract QA/QC review

Receipt from Supplier and Storage at Sub-contractor Stores.


All welding consumables to be received at site shall have a valid manufacturers test certificates.

The Manufacturers recommendation pages shall be explained to store keeper andshallbedisplayedin


Container.

Store keeper shall receive the consumables with valid test certificates and store them in dry storage
room as per Manufacturers recommendation/project specification.

Consumables containers shall be identified with the manufacturers name, date, trade name, AWS Class,
specification (example: SFA 5.1, 5.4 etc.) and the Batch number and Size etc

Consumable Packing Shall be examined for damage, if found any damage which shall be reported to the
QCInspector to determine the effect of damage and advise disposition,

Stainless steel Electrodes andfiller wires shallbe separately stored from any other items to prevent
Contamination. A specific area of inside container will be designated for stainless steel electrodes

All low alloy Electrodes and filler wires shall be separately stored from any other items to prevent
Contamination. A specific area of inside container will be designated for low alloy electrodes/filler wire.

Inconel/Monel electrodes and filler wires shall be separately stored from any other items to prevent
Contamination. A specific area of inside container will be designated for Inconel/Monel electrodes

Consumable that are not identifiable and traceable shall be removed from the store.

9.1.4

Baking
Carbon Steel, Alloy Steel and Stainless Steel electrodes shall be baked separately in different
baking ovens and then placed in different holding ovens.
The baking log shall be maintained for each type of electrode in Electrode Baking Log
Sheet.
The baking and holding ovens shall have serial numbers. All ovens with type of electrodes to
be Kept inside, each shelf have with each size of electrodes to be kept.
All low hydrogen Electrodes shall be baked as per the recommendations of the
manufacturer or project specification and transferred to the holding oven maintained at 120150C. CS and Alloy Low hydrogen Electrodes will be baked for minimum 2 hours at 300C
and Stainless steel Electrodes at 200C or as per the manufacturers recommendations.
The electrodes shall be issued into heated quivers which shall be maintain a temperature of 70C
Minimum and shall be used within 4 hours and those electrodes not used within 4 hours shall be returned
for re-baking.

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Sohar Refinery Improvement Project SRIP

Method statement for


Welding consumable control

Doc Ref : OFD0137-MS-005 Rev-0

Project No: OFD0137

9.1.5 Re Baking of Electrodes.

The electrodes which are not consumed within 4 hours shall be re-baked subject to maximum of
one time re-baking and re-baking only permitted for electrodes kept in heated quivers at 70C. Those rebaked Electrodes shall be stored in the baking & holding oven in a specific area to identify
them that they have been re-baked.

9.1.4

9.1.7.

9.1.8.

For identification purpose these electrode tips are dipped in heat resistant silver aluminum
paint before re-baking. Electrodes shall be issued first at the beginning of each shift or
alternately used for welder qualification tests or training purposes.

Shielding/Backing Gases (Argon, Hydrogen & Nitrogen)

Gases shall be used for shielding/baking purposes shall be of the welding grade composition having a
purity, as defined in the WPSs, and this gas will be stored separate gas storage area, the argon cylinder
are in blue color bottle which can be easily Identifiable .

Issue of Welding Consumables to Welders.


Welding supervisor / foreman shall make the issue request on Electrode Request / Issue Note
for welding consumable considering the type and quantum of welding. He shall specify
No and type of electrode, size and filler wire as per applicable WPS, welder name, or
number on issue note
All welding Electrodes and filler wires shall be issued from BEC stores only to
qualified welders as per authorized Electrode Request / Issue Note.
Low hydrogen Electrodes shall be transported from consumable store to place of work in
electrode holding quivers and shall be kept energized at the working place, until their
consumption or return to the stores. If electrodes found damaged, cracked, left open to
atmospheric conditions, flaked and rusted or dirty filler wires shall be scrapped and removed from
site. The scraped and rejected consumables are to be stored separately allocated area.
Consumables in container that are not identifiable / traceable or in damaged condition
shall be disposed of the site.
GTAW filler rod issued to the welder shall be kept clean by the welder at site until
consumption. Any balance filler rod shall be returned to the store at the end of the shift every
day. Storekeeper shall check the same for cleanliness and damage. If any contaminated or damaged
rods are found they shall be scrapped and removed from site.
Vacuum Pack Electrodes

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Sohar Refinery Improvement Project SRIP


Doc Ref : OFD0137-MS-005 Rev-0

9.1.9

Method statement for


Welding consumable control
Project No: OFD0137

Vacuum-packed Electrodes do not require baking (subject to manufacturer recommendations or


project specification) before use provided they are stored correctly before issue. The store man
shall check each individual packet to ensure that it still contains a vacuum.
When issuing vacuum packed electrodes the store man shall be open the plastic capsule and
remove the electrodes and issued into a heated quivers immediately, which shall be maintain a
temperature of 70C minimum
Disposal of Electrodes
Scrap of used Electrodes from each welder will be collected in one container, after
the container is full of scrap Electrodes it will be disposed to metal scrap bin provided
at shop or site working area. Re-baked Electrodes that are returned will be disposed to
metal scrap bin by store keeper.

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