STSSB/PCE/TA14/WC007

WELDING CONSUMABLE Rev :1

HANDLING Date : 25/03/04
Page : 1 of 10
AND STORAGE PROCEDURE

WELDING CONSUMABLE
HANDLING AND STORAGE
PROCEDURE

DEFECT RECTIFICATION WORKD

FOR PCESB TA 2014

1 22/3/14 ZULFADLI SHAHARUDDIN

0 25/02/14 ZULFADLI

REV DATE PREPARED BY CHECKED BY REVIEWED BY APPROVED BY

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HANDLING Date : 25/02/04
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TABLE OF CONTENTS

1.0 SCOPE

2.0 APPLICATION

3.0 DEFINITIONS

4.0 RESPONSIBILITY

5.0 GENERAL

6.0 STORAGE AND RELEASE

7.0 BAKING AND HOLDING

8.0 USE OF PORTABLE QUIVERS

9.0 REBAKING OF ELECTRODES

10.0 ATTACHMENTS
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1.0 SCOPE
1.1 This procedure details the administrative and technical controls for storage, issuing
and return of welding consumable.

2.0 APPLICATION
2.1 This procedure applies to all STSSB operations and STSSB Subcontractor’s
operations during work performed on the PETRONAS CHEMICAL ETHYLENE (M)
SDN BHD for shop fabrication and site installation.

3.0 DEFINITIONS
 STSSB - SCIENCE TECH SOLUTIONS Sdn Bhd.
 Subcontractor - All companies and their employees acting under subcontract to STS.
 WPS - Welding Procedure Specification.
 AWS - American Welding Society

4.0 RESPONSIBILITY
4.1 A designated Consumable Controller shall be responsible for the storage and issue
of all welding consumable.
4.2 Relevant supervision in conjunction with the welding, QC Inspector shall be
responsible for determining the size and type of consumables used in accordance
with approved WPS.
4.3 QC Inspector shall check the consumable issue log on a regular basis.

5.0 GENERAL
5.1 Only consumable as specified in WPS shall be purchased for use. Change of
consumable type or brand shall require approval by PCESB and STSSB QA/QC
Department. Such approval will be given verbally after confirmation that Third
Party Approval body approves the consumable brand in question.
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5.2 Any consumable which is unmarked, be it electrode, wire, gas or flux or showing
signs of damage or deterioration shall be discarded.
5.3 All covered electrodes shall be identifiable up to the time of issue by means of AWS
classification end stamping or manufacturer end colour coding. If marking is
destroyed by baking or handling, the electrode shall be discarded.
5.4 Consumable Controller shall ensure that all deliveries of consumable are
accompanied by relevant test certificates. On receipt of material the batch number
on the packaging shall be checked against the batch number on the test certificate. If
everything is in order, the test cert. shall be passed to QC Dept. for filling.

6.0 STORAGE AND RELEASE

6.1 All welding consumables shall be stored in a clean and dry area in accordance with
the manufacture’s instructions prior to use. Storage of consumables shall in a
controlled access area and unauthorised personal shall be prohibited from entering.
The Consumable Controller shall ensure segregation of different type of welding
consumable in the welding consumable store.
6.2 Covered electrodes are supplied in sealed boxes displaying manufacturer’s
identification markings and shall be stored unopened until use.
6.3 For low hydrogen electrodes, the Consumables Controller shall issue only
consumables intended for immediate use. Date, welder number, type, size, quantity
issued and quantity returned in a consumable issue log and sign off by the welding
supervisor, welding foremen or QC Inspector. As a guideline, approximately 40 to
60 electrodes will be issued at one time.
6.4 Consumable issue log shall be available at electrode baking for review by inspector
and auditor.

7.0 ELECTROD BAKING AND HOLDING

7.1 All low hydrogen covered electrodes shall be baked prior to issue in accordance
with manufacturer’s recommendations as detailed in Table 1. The Consumable
Controller shall record the electrode batch number in the baking record log. After
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baking, electrodes shall be held at manufacturer recommended temperature in the

holding oven as detailed in Table 1.

7.2 Differed electrode can be bake on same oven but need to segregate into level inside
baking oven.

8.0 USE OF WELDING CONSUMABLE

8.1 Covered electrodes shall be placed in welder’s heated quivers immediately after
issue for use in the field. Quivers shall be in good working order and shall be able to
maintain a temperature approximately 75 C while welding is in progress.
8.2 Quivers permitted only 1 type of electrode only same requirement for filler metal
handling.
8.3 Filler metal used for fit0up and welding shall be free from contaminate and rush or
otherwise shall be discharges.

9.0 REBAKING OF ELECTRODES

9.1 Electrodes not used for the day shall be returned to the Consumable Controller for
rebaking as per Table 1. Electrodes shall only be rebaked twice with marking to
indicate numbers of return. Electrodes returned the third time should be discarded
immediately.
9.2 Heat resistant paint shall be used to mark electrodes with one circle for each
returned for rebaking as close as possible to the end without obscuring
manufacturers colour coding. Heat resistant paint shall not contaminate the electrode
covering. Any electrodes returned for a third time to the Consumable Controller (i.e.
with the rebaking mark present) shall be discarded.

10.0 ATTACHMENTS
 Table 1
 Flow Chart – Baking and Holding of Low Hydrogen Electrode and Control
 Consumable Issue Log
 Baking Log
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Table 1

Electrode Baking and Holding Temperature

Baking Oven Holding oven

Electrode AWS Baking Duration Holding

Type Class. Temp. C Time (Hr) Temp. C

Kobe LB52 E7016 290 – 350 1 to 2 110 – 150

Kobe LB52 NS

Kobe CMA-96MB E8016-B2 290 - 350 1 to 2 110 – 150

Kobe CMA-106N E9016-B3

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Flow Chart

Baking and Holding of Low Hydrogen Electrode & Control

Electrode Store

Baking Oven  
290oC – 350oC for 1 hour


Holding Oven
110oC to 150oC


Approximately 40-60
electrodes per issue to 
welder with heated quiver

Unused electrode to be returned

Electrode used at job site for the day (paint marked at stud
 end for identification)

Electrode to be discarded
after returned the third time
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Consumable Issue Log (Typical)

Iss Welder Trade Size Qty Signature Qty Date Remarks

ue No Name (mm) Issued of Returned Return or QC
Dat Supervisor Verification
e
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Baking Log

Date Electrode Batch No Qty Temp. Time In Time Out

Type (boxes) (C)
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